Layout Inspection and Functional Testing in Compliance with IATF 8.6.2 Requirements and CSRs

Product validation in the pre-launch phase is a critical supplier activity that also continues during ongoing production.

This process includes re-qualification, which is required under IATF 8.6.2 Layout Inspection and Functional Testing and Customer Specific Requirements (CSR). Understanding the principles of this process is essential for effective project management and compliance.

IATF 8.6.2 Layout Inspection and Functional Testing – CSR Overview

The IATF 8.6.2 requirement mandates that each product (or product family) undergoes proper dimensional control and functional testing. However, it does not specify the frequency of these checks. The required frequency is detailed in the respective Customer Specific Requirements (CSR).

Below is a summary of the requirements for major OEMs:

  • Stellantis xFCAΒ 
    • Revalidation must be carried out annually (similar to North American OEMs).
    • Relevant details are established during the Advance Quality Planning meeting with the customer’s engineering team.
    • Key document: Supplier Product Validation (SPV), which specifies whether individual tests are required. If the SPV column is not filled, all tests must be repeated.
    • Test results should be documented in the Control Plan, as verified in question 7.2 of the Process Audit.
  • Ford
    • Revalidation is required every 12 months.
    • CSRs specify that 5 samples should be tested, or, in the case of multi-cavity molds, only one cavity needs to be tested.
  • Volkswagen (VW)
    • Revalidation frequency is every 36 months, less stringent than other OEMs.
    • Additional details are in the VDA documents RPP – Robust Production Processes and the 2020 edition of VDA 2.
  • BMW
    • Re-qualification is required annually, per Group Standards 90018-1 and 90018-2.
  • Mercedes
    • Annual checks must confirm compliance with Daimler specifications, as outlined in MBST 14/06, Section 5, Clause 9.
  • Other OEMs (e.g., Stellantis-PSA, GM, Renault)
    • These OEMs do not have explicit CSR requirements for revalidation. Suppliers must adhere to IATF 8.6.2 and define periodic re-qualification based on risk assessments.
Layout Inspection and Functional Testing according to OEM CSR"s
Table 1. Customer-specific requirements list in relation to the 8.6.2 IATF requirement

Defining Layout Inspection and Functional Testing

A successful re-qualification process requires the active involvement of the supplier’s engineering team.

Key Components of a Successful Layout Inspection and Functional Testing Process
Fig. 1. Key Components of a Successful Layout Inspection and Functional Testing Process.

This ensures:

  • Test Scope Definition
    • The scope of re-qualification tests can be aligned with the availability of appropriate validation equipment.
  • Budget Consideration
    • When using external companies for re-qualification tests, these costs should be included in the project quotation and planned expenses for current production.
  • Part Storage Agreement
    • Agree with the customer on the storage period for tested parts. This ensures that in case of warranty claims, the tested parts can be presented for verification.

Dariusz Kowalczyk