The scope of production in the automotive industry covers various areas, where the requirements for manufacturing vehicle components are often driven by high customer expectations, particularly regarding top-tier quality. This is especially true when the clients ordering automotive parts are industry giants such as Ferrari, Aston Martin, Bentley, or BMW. Companies of this caliber have incredibly complex demands—not only due to their long-standing tradition of ensuring high-quality products but also in terms of safety.

Experts in the automotive industry understand that the quality of vehicle components directly impacts road safety. The production of these components follows equally rigorous certification and audit methods as vehicle homologation, the final process of verifying technical standards before a new vehicle is approved for use. Automotive parts manufacturers must comply with numerous requirements and are obligated to continuously test and audit their performance.

SAPA Polska Sp. z o.o. – A Key Player in the Automotive Industry

SAPA Polska Sp. z o.o. is part of the Italian SAPA Group, a manufacturing company specializing in automotive components and supplying some of the world’s largest car brands. In addition to the aforementioned companies, SAPA also serves Porsche, Audi, DAF, Jeep, and Rolls-Royce. These prestigious names leave no doubt about the high-quality standards expected from suppliers.

SAPA Polska, one of SAPA Group’s divisions, operates in Sosnowiec, Poland. The company has been using the auditomat® system for an extended period to conduct regular audits and quality control. Implementing an auditing system enables the company to meet the highest customer standards and requirements.

Challenges in Automotive

To better understand the complexity of factors influencing the quality of automotive component manufacturing, it is worth analyzing lean management principles and methodologies pioneered by companies such as Toyota. Toyota is best known for its Toyota Production System (TPS), a comprehensive socio-technical framework.

Manufacturing processes in automotive companies are continuously improved to meet client needs. However, when a company like SAPA Group operates multiple divisions across Europe, maintaining uniform and consistent production standards becomes a significant challenge. Although components can be produced at different locations across the continent, quality must remain consistently high regardless of the manufacturing site. Consequently, the company must conduct frequent quality checks and audits.

Beyond quality control, the industry presents several challenges that necessitate constant auditing:

• Stringent Quality Requirements: Cost reduction efforts cannot come at the expense of quality. Audits help monitor and maintain high product quality even while optimizing production costs.
• Cost Reduction Pressure: The automotive industry is highly competitive, placing constant pressure on manufacturers to reduce production costs while maintaining quality.
• Supply Chain Management: Automotive component production involves multiple suppliers, requiring effective supply chain management. Audits ensure timely deliveries and maintain product quality at every stage of the supply chain.
• Adapting to Technological Changes: The industry is undergoing rapid transformations, such as the rise of electric and autonomous vehicles. Frequent audits assess whether production processes align with emerging technologies and market demands.
• Production Flexibility: Demand for automotive parts fluctuates based on economic conditions and consumer preferences. Manufacturers must be agile and capable of adjusting their production strategies accordingly. Audits help evaluate whether production processes meet this criterion.

Streamlining Audits in the Automotive Industry: SAPA and auditomat®

The automotive industry is characterized by stringent quality standards and continuous pressure to optimize processes. This requires effective auditing tools.

Companies like SAPA are committed to continuous improvement in their quality control procedures. The introduction of innovative solutions, such as the auditomat® system, has become a crucial part of their strategy to enhance audit processes.

How SAPA Uses auditomat®

SAPA Polska leverages auditomat® in several key areas:

• Optimized Audit Planning and Scheduling: auditomat® simplifies complex audit scheduling by digitizing the entire process. Users can effortlessly plan audits in compliance with VDA 6.3 standards or conduct immediate, unplanned audits to address non-conformities.
• Centralized Document Management for Audit Readiness: auditomat® serves as a secure, centralized repository for essential audit documentation, including ISO 9000 guidelines, organizational structures, process manuals, customer requirements, and analytical data (e.g., FMEA and PPM reports). Version control and secure access ensure document integrity, while the system facilitates the sharing and distribution of critical materials such as question catalogs.

“As a user of the application, I can confidently say that auditomat® is an exceptionally functional and reliable tool for conducting audits. It stands out for its intuitive and user-friendly interface, allowing even less experienced users to quickly master its features. Automating audit processes saves valuable time by eliminating unnecessary manual tasks, significantly improving efficiency.” — Tomasz Wolny, Industrial Engineering Manager

• Proactive Defect Prevention Through Predictive Audits: auditomat® supports proactive defect prevention by facilitating predictive audits (P1). By identifying potential issues early, organizations can implement preventive measures, reducing costly errors and ensuring product quality.
• Enhanced Corrective Actions for Quick Problem Resolution: auditomat® streamlines the entire process of identifying, implementing, and verifying corrective actions. This ensures swift and effective issue resolution, preventing recurrence and driving continuous improvement.
• Continuous Improvement (KVP) Through Data Insights: The auditomat® system provides data and analytical tools essential for process optimization and continuous improvement (KVP). By analyzing audit results, users can identify areas for enhancement and implement effective improvement strategies.

“The advanced reporting capabilities of auditomat® are another significant advantage. With its extensive reporting features, I can easily generate detailed summaries that support key decision-making. Additionally, team collaboration within the app is seamless and efficient, facilitating the sharing of audit results and accelerating decision-making processes.” — Tomasz Wolny, Industrial Engineering Manager

Benefits of Implementing auditomat®

The deployment of auditomat® at SAPA Polska has yielded numerous benefits, particularly by enhancing audit efficiency through automation of repetitive tasks. Additionally, digital data recording has improved accuracy and consistency. Other key benefits include:

• Significant Increase in Audit Efficiency: auditomat® drastically reduces the time and effort required to conduct audits by automating repetitive tasks and streamlining workflows.
• Improved Audit Accuracy and Consistency: By minimizing human error through digital data capture, auditomat® ensures consistent application of audit standards, leading to more precise and reliable results.
• Enhanced Compliance with Industry Standards: The system simplifies compliance verification with VDA and other quality standards, helping SAPA maintain regulatory compliance and build customer trust.
• Data-Driven Decision-Making: auditomat® provides management with actionable insights from audit data, enabling informed decision-making and continuous process improvement.

“The technical support team is always available, further enhancing the user experience. In summary, auditomat® is a highly reliable and modern tool tailored to the needs of professionals. I recommend this application to anyone seeking an efficient audit solution.” — Tomasz Wolny, Industrial Engineering Manager

Conclusion

The implementation of auditomat® at SAPA Polska has streamlined audit processes, increased efficiency, improved data accuracy and consistency, and enhanced document management and defect prevention.

Does your automotive company face audit challenges? Contact us today to learn more about the benefits of implementing auditomat®. Schedule a free demo—visit our website or call us for details.