Maruti Suzuki India Limited (MSIL) follows a robust supplier evaluation system to ensure consistent quality, cost, delivery, and compliance from its vendor base. One of the most important supplier evaluation tools used by MSIL is the Vendor System Audit (VSA).
For Tier-1 and Tier-2 automotive suppliers, understanding the VSA audit clauses, critical clauses, and checklist requirements is essential to qualify, maintain approval, and improve audit scores. This article provides a complete, practical, and audit-ready guide to the Maruti Vendor System Audit checklist, aligned with real audit expectations.
What is the VSA Audit in Maruti Suzuki
VSA full form is Vendor System Audit.
It is a structured audit conducted by Maruti Suzuki/ MACE to evaluate the management systems, manufacturing processes, quality controls, and compliance level of its suppliers.
Unlike ISO 9001 or IATF 16949 certification audits, VSA is a customer-specific audit, focused on how effectively a supplier can meet MSIL requirements on a day-to-day basis.
VSA audit applies to
- Tier-1 suppliers supplying parts directly to MSIL
- Tier-2 suppliers supplying to MSIL Tier-1 vendors
- New suppliers under development
- Existing suppliers with performance issues
Objective of Maruti Vendor System Audit
The key objectives of the VSA audit are
- To ensure suppliers have robust quality systems
- To verify the NPD & Initial Flow Control process
- To verify process capability and control
- To assess risk management and preventive actions
- To improve delivery, cost, and quality performance
- To reduce customer complaints and line stoppages
VSA Audit vs IATF 16949 Audit
Many suppliers assume the VSA audit is similar to IATF 16949, but there are key differences.
| Aspect | VSA Audit | IATF 16949 |
|---|---|---|
| Audit Type | Customer-specific | Standard certification |
| Focus | Practical implementation | System compliance |
| Scoring | Score-based | Pass/Fail |
| Customer Expectation | MSIL requirements | Automotive standard |
| Frequency | As per the MSIL decision | Certification cycle |
Important:
A supplier can be IATF certified and still fail in VSA if implementation is weak.
VSA Audit Clauses – Overview
The VSA audit checklist is divided into multiple sections, covering NPD, 4M Change, Document Control, Training, Internal Audit, Complaints Handling, Maintenance, Safety, and Legal Compliance.
- Production Preparation (NPD)
- Initial Production Control
- Change Management
- Standard Management
- Education & Training
- Quality audit and Process verification
- Supplier Control
- Handling abnormality in quality
- 5S Management
- Equipment and Inspection Equipment Management
- Implementation of Standards
- Product Management
- Handling Management
- Critical Parts Management
- Adequate Testing Facility
- Process Audit
- Financial Data of the company
- Safety (Working Condition, Human & Machine Safety, Fire Safety)
- Legal Compliance and Environment
Critical Clause in VSA Audit
- Change Management
- Education & Training
- Handling Abnormality in Quality
- Equipment & Inspection Equipment Management
- Safety
- Supplier Control ( For Tier 1)
MSIL VSA Audit – Scoring System
VSA audit is score-based, not pass/fail.
General interpretation
Above 60% – Green supplier
40–60% – Yellow Supplier
Below 40% – Red Supplier
Required Min 60% in the Critical clause for green supplier
MACE Audit Check Sheet PDF
“MACE audit check sheet PDF.”
Common VSA Audit Non-Conformities
Typical observations raised by MSIL auditors
- PFMEA is not linked with the control plan
- Corrective actions without root cause
- No effectiveness verification
- Traceability gaps
- Training records incomplete
- Risk is not updated after issues
How to Prepare for Maruti VSA Audit
Step-by-Step Preparation
- Review the previous VSA audit report
- Identify weak clauses
- Update PFMEA and control plan
- Conduct internal VSA mock audit
- Train the shopfloor team
- Close gaps with evidence
Documents to Keep Ready
- APQP/ NPD files as per Enquiry Register
- Initial Supply Files
- 4M Change Records monthwise
- Procedures File
- Process Documents (PFD, PFMEA, Control Plan, Inspection Standard, Operation Standard) of all parts
- Training Records ( Operators, Staff)
- Internal Audit Records
- Maintenance Records
- Calibration Records
- Production Records
- Inspection records
- Calibration records
- Customer complaint file
- Red Bin Analysis file
Difference Between VSA Audit and Process Audit
| Aspect | VSA Audit | Process Audit |
|---|---|---|
| Scope | System + process | Process-specific |
| Conducted by | Customer | Internal / customer |
| Focus | Overall capability | Process discipline |
Importance of VSA Audit for MSIL Suppliers
VSA audit performance directly impacts
- Supplier rating
- New business allocation
- Supplier development decisions
- Long-term relationship with MSIL
Strong VSA performance indicates mature systems and stable processes.
Maruti VSA Audit Checklist:
- Production Preparation/New Product Development
- Regulation of Initial Production Control
- Change Management
- Standard Management
- Education and Training
- Quality Audit and Process Verification
- Supplier Control
- Handling abnormality in quality
- 5S Management
- Equipment and Inspection Equipment Management
- Implementation of Standard
- Product Management
- Handling Management
- Critical Parts Management
- Adequate Testing Facility
- Process audit
- Scale and top management bandwidth (Financial Data of the Company)
- Safety(Safety (Working Conditions, Human & Machine Safety, Fire Safety)
- Top Management Bandwidth and HR Practices (Legal Compliance and Environment)
VSA Audit Check Points Clausewise:
Clause 1: Production Preparation/ New Product Development
| S.No | Check Point |
|---|---|
| 1 | Do you define the procedure for Product development including the following? -scope of parts, responsibility of each department, control contents/items? |
| 2 | Do you implement follow-up to control the schedule and progress of production preparation items? Incl top management |
| 3 | Do you consider the following items and implement corrective and preventive action to the processes and standards before regular production? -Troubles in the past; -Defect items expected; -Defect items unable to capture at the customer; -Defect items difficult to repair. |
| 4 | Do you prevent defects by quality-improving activities of cross-functional teams to evaluate quality performance? |
Procedure for New Product Development (Production Preparation/APQP)
Clause 2: Initial Production Control
| S.No | Check Points |
|---|---|
| 1 | Do you define the following items related to initial production control by standards? -controlled parts; -controlled items; -inspection method, -initial production control period, a person who announces the start/end of initial production control and the finish condition. |
| 2 | How do you define items that require special control during initial production control? Do you set stricter inspection methods than ordinary inspection? |
| 3 | Do you control process capability and defect rate (For visual defects) during initial production control? |
Procedure for Initial Production Control (Initial Flow Control)
Clause 3: Change Management
| S.No | Check Points |
|---|---|
| 1 | Do you define unexpected change (unusual) and planned change clearly? |
| 2 | Do you define the procedure (rules applied from sharing information to result confirmation) at change occurrence? |
| 3 | Do you record product quality check results to ensure traceability? Incl retroactive checks |
| 4 | Do you define and control the initial part? |
| 5 | Do you control initial parts separately and make quality records about them? (Both internal and outsourced processes are included) |
Procedure for Change Management
Clause 4: Standard Management
| S.No | Check Points |
|---|---|
| 1 | Do you make and review process control standards, Inspection specifications and Operation instructions for all products that are shipped to SMC / MSIL / Tier 1? |
| 2 | Do you have the consistency to keep process control standards, inspection specifications, operation inspection and parameter chart? |
Procedure for Standard Management
Clause 5: Education and Training
| S.No | Check Points |
|---|---|
| 1 | Do you clarify the department in charge of promoting quality education and implementing education based on the annual plan? Are records of education kept? |
| 2 | Do you define and implement the skill evaluation of the operator to determine whether the operator can work without surveillance? (e.g. acceptable level/evaluation frequency/evaluation method) |
| 3 | Do you periodically monitor the skills of certified operators and follow up to improve their skills? |
Learn about the Education and Training procedure and Process of the Poison Test
Clause 6: Quality Audit and Process Verification
| S. NO | Check Points |
|---|---|
| 1 | Do you conduct quality audits to identify issues and properly improve them? |
| 2 | Do you confirm consistency between the actual operation and the standard? |
| 3 | Do you confirm if that countermeasures are taken properly to prevent the recurrence of quality failure? |
Procedure for Internal Audit
Clause No. 7: Supplier Control
| S.No | Check Points |
|---|---|
| 1 | Do you define criteria to certify new suppliers and implement them? |
Procedure for the Supplier Selection and Development Process
Clause No. 8: Handling Abnormality in Quality
| S.No | Check Points |
|---|---|
| 1 | Do you clearly define what an abnormal situation and make operators know the definition? |
| 2 | Do you clarify and standardize the handling rules/routes for customer claims, in-process failure and supplier failure? |
| 3 | Do you reflect on corrective action to improve process control and review of standards? |
| 4 | Do you prevent the recurrence of issues by analyzing the cause of occurring defects based on process investigation results, such as 5-why analysis? |
| 5 | Do you reflect corrective action to improve of process control and review of standards? |
| 6 | After corrective action, do you conduct an on-site check-up and evaluate the effectiveness? And horizontal deployment. |
Procedure for Handling Abnormalities in Quality.
Clause No. 9: 5S Management
| S.No | Check Points |
|---|---|
| 1 | Do you keep store material, work-in-process, finished products, inventory and containers at appropriate storage protected from dust, rust, scratches, deformation and rainwater? |
| 2 | Do you control material, work-in-process and finished products by designated location, volume and standard using visual control? |
| 3 | Do you implement inspection or critical operation under a properly controlled environment luminance /temperature/humidity/vibration/noise/work table etc.)? |
| 4 | Do you keep the condition of production equipment, jigs and tools properly? |
| 5 | Do you keep the condition of inspection equipment properly to ensure accuracy? |
Procedure for 5S Management.
Clause No. 10: Equipment and Inspection Equipment Management
| S.No | Check Points |
|---|---|
| 01 | Do you conduct daily/regular checks of production equipment, dies and jigs? Are records of maintenance kept? |
| 02 | Do you confirm regularly the function of Pokayoke, automated stop and alarm? Are records of maintenance kept? |
| 03 | Do you standardize the frequency of polishing and replacement for consumable tools (blade/electrode/rub stone, etc.)? |
| 04 | Do you regularly calibrate inspection equipment and put the expiration date on them? |
| 05 | Do you control the deterioration (expiration date) of boundary samples for objective judgments, such as appearance inspection? |
Procedure for Machine Maintenance and Calibration
Clause No. 11: Implementation of Standard
| S.No | Check Points |
|---|---|
| 01 | Do you use easy expressions (visualizer, onomatopoeia etc.) for operation instructions? So that the operator can easily understand the process and critical points. |
| 02 | Do you keep operation instructions in an accessible place and post important quality points and critical operation points in a place where operators can see them easily? |
| 03 | Do you regularly monitor that each operator operates according to the operation instructions? |
| 04 | Is it possible to judge OK/NG specifically by each check sheet (of daily equipment check, quality control report, etc.) you use? |
Clause No. 12: Product Management
| S.No | Check Points |
|---|---|
| 01 | Do you keep FIFO (first-in first-out) of finished products and work-in-progress (material, reserve parts? By using an identification tag or lot indication? |
| 02 | Do you control production history by product lot numbers? -production date; -production volume; -shipping date |
| 03 | Do you control the identification of similar parts separately? |
| 04 | Do you control the identification of non-conforming parts and parts on hold? Do you store them separately? |
| 05 | Regarding repaired non-conforming parts and parts on hold to re-use, do you define responsibility to implement? Are repair records kept? |
Clause No. 13: Handling Management
| S.No | Check Points |
|---|---|
| 01 | Do you make arrangements with customers about the packing style & transportation system to prevent damage during the handling of finished products & perform accordingly? |
| 02 | Do you have a system to maintain Bins /Trolleys in Good Condition? |
Clause No. 14: Critical Parts Management
| S. No | Check Points |
|---|---|
| 01 | Do you have Special checks/Inspections for the Maru A parameters of the Maru A part available? |
| 02 | Do you have the Identification of the Maru A Process/Operator on the Shop Floor? |
| 03 | Do you keep the repair history when repairing & using Maru A items? |
Procedure for Product Safety. (Maru A Parts)
Clause No. 15: Adequate Testing Facility
| S. NO | Check Points |
|---|---|
| 01 | Does the supplier have all the testing equipment and rigs required as per the drawing specifications? |
| 02 | Does the Supplier have trained manpower to operate these inspection and testing instruments? |
| 03 | Does the Supplier have trained manpower to operate these inspection and testing instruments? |
Clause No. 16: Process Audit
| S. No | Check Points |
|---|---|
| 01 | Conduct a process audit as per the process control standard (Control Plan) |
| 02 | Closure of all the observations. |
Clause No. 17: Scale and Top Management Bandwidth
| S.No | Check Points |
|---|---|
| 01 | Do you have an adequate organizational structure and defined roles/ responsibilities for key areas such as Plant Head, Quality, Production, Safety and Maintenance? |
| 02 | How frequently does Top management visit the shop floor? How frequently does Top Management monitor key performance KPI (Performance at the customer end, in-house quality, productivity, maintenance, safety etc.)? |
| 03 | Plant Sales Turnover for the auditee plant. Group Turnover |
| 04 | PAT/Sales ( Profit After Tax / Sale) |
| 05 | D/E ratio ( Debt / Equity Ratio) |
| 06 | ROCE ( Return on Capital Employed) |
Note: Clause No. 17 has been revised to the New EHS requirement
Clause No. 18: Safety
| S.No | Check Points |
|---|---|
| 01 | Is the shop floor temperature, noise level and air quality (fumes) ok? Is the layout and escape route on the shop floor OK? Are Rest areas/ Toilets Available? Is the area/machine sufficient enough to allow easy movement of machines and tools? |
| 02 | Are Safety Standards made (as per process requirement) and taught to all operators? Are PPEs available as per the standards or not? |
| 03 | Machine Safety system (Door sensors etc.) available or not? Is Safety in material movement and tools ensured or not? |
| 04 | Are safety standards followed on the shop floor as per the procedure? Are usage of PPES adhered and monitored (by a supervisor/senior) on the shop floor? Accident reporting mechanism is defined? Countermeasures against accidents taken and periodic verification being done? |
| 05 | Audit conducted by a reputed 3rd party on MSIL defined check sheet? |
Note: Clause No. 18 has been revised to the New EHS Requirement
Clause No. 19: Legal Compliance and Environment
| S.No | Check Points |
|---|---|
| 01 | Consent to operate (Valid as on date) available or not? |
| 02 | Enrolment of all employees for ESI & PF |
| 03 | Are different types of wastes identified on the shop floor and standards/ Procedures made? Is Segregation done at the source for different types of waste? Storage and disposal being done as per consent and periodic confirmation at the disposal stage? |
New EHS Requirements redefined by MSIL / MACE
17. Financial data of the company
18. Safety (Working Conditions, Human & Machine Safety, Fire Safety)
19. Top Management Bandwidth and HR Practices:
EHS requirements for Tier 2 Vendors in detail:
New EHS Requirements by MSIL / MACE
Frequently Asked Questions (FAQs):
What is the Maruti Vendor System Audit (MACE Audit)?
The Maruti Vendor System Audit, also known as MACE Audit or Vendor System Assessment (VSA), is a structured evaluation of supplier systems by Maruti Suzuki India Ltd. It covers 19 key areas as discussed earlier in the post.
Why is the Maruti Vendor Audit important?
This audit ensures that suppliers consistently meet Maruti Suzuki’s quality, safety, and delivery requirements. Passing the audit not only helps suppliers maintain business with Maruti but also improves their internal processes and competitiveness.
How many clauses are there in the MACE Audit checklist?
The audit checklist has 19 clauses that cover all critical aspects like management responsibility, production preparation, calibration, safety, delivery performance, and continual improvement.
Who conducts the Maruti Vendor System Audit?
The audit is typically conducted by Maruti Suzuki’s Supplier Quality Assurance (SQA) team or the Maruti Center for Excellence (MACE) Team.
How can suppliers prepare for the Maruti Vendor Audit?
Suppliers should:
- Implement a strong Quality Management System (QMS) aligned with IATF 16949.
- Ensure documentation and records are up to date.
- Train employees on process and safety requirements.
- Strengthen process controls and traceability systems.
- Focus on continual improvement initiatives.
What happens if a supplier fails the MACE Audit?
If a supplier does not meet the required score, they may receive a Corrective Action Request (CAR). Continuous poor performance may impact future business with Maruti Suzuki.
Is the Maruti Vendor System Audit linked to IATF 16949?
Yes, many requirements of the MACE Audit are aligned with IATF 16949 standards. Suppliers certified to IATF 16949 have a stronger foundation to perform well in this audit.
What is the full form of VSA?
VSA full form is Vendor System Audit.
Is the VSA audit mandatory for Maruti suppliers?
Yes, the VSA audit is mandatory for MSIL suppliers.
How many critical clauses are there in the VSA audit?
Usually, 4 to 6 clauses are treated as critical based on risk.
Is the VSA audit the same as IATF 16949?
No, VSA is a customer-specific audit.
Conclusion
Maruti Vendor System Audit is not just an audit but a system maturity evaluation tool. Suppliers who treat VSA seriously and implement systems effectively consistently perform better in quality, delivery, and customer satisfaction.
Understanding VSA audit clauses, critical clauses, and checklist requirements helps suppliers prepare confidently, avoid major observations, and build a strong partnership with Maruti Suzuki.
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