Driving Towards A Zero Defects Culture (PDFDrive)
Driving Towards A Zero Defects Culture (PDFDrive)
Gary L. West
Executive Director
Global Supplier Quality & Development
Gary West Introduction
Pressure Relief
Valve
Many Similarities to Automotive Industry
No Tolerance for
Downtime
Many Similarities to Automotive Industry
CCC
Today’s Environment – Vehicle Sophistication
4 15%-25%
3 25% to 40%
Cost of Poor Quality
4
15%-25%
Average Cost Factors
$2,000.00 $1,860.00
$1,800.00
$1,600.00
$1,400.00
$1,200.00
$1,000.00
$780.00
$800.00
$600.00
Average Cost Factors $400.00
$200.00
$160.00
Requirements 1X
$0.00
$10.00 $40.00
Design 3X- 4X
Development 13X — 16X Requirements Design Development Test Operations
Test 61X — 78X
Operations 157X — 186X
Cost of Poor Quality
GM Confidential
The Billion Dollar Question
Why ?
Systems Engineering
A Significant Part of the Answer…
Across Vehicle Features/Functions to Systems to Components Across Supply Chain & Orgs
GM Confiden
Our Approach to Enhance Connections/Collaboration
Vehicle Program
Vehicle Level Hazards Systems Engineering Component & Subsystems
Occupant Protection Features:
• Inadequate/delayed or loss of vehicle deceleration including Sub-System Components
malfunctions within the regenerative braking feature Front Impact
Seat Structure Frame
•
•
Unintended acceleration
Unintended longitudinal motion; unintended vehicle motion
Side Impact
Side Impact
Adjusters
Rear Impact SIAB
(rollaway) Tracks
• Loss of airbag deployment, unintended airbag deployment or Rollover Safety Belts Recliner
occupant crash protection degradation
• Unintended release of thermal energy causing burns or fire Fasteners
• Unintended travel In the wrong direction, unintended Wiring
propulsion flow etc...
• Unintended or loss of lateralLoss
motionof airbag
(includes deployment, unintended
locked Controls
steering)
airbag deployment or occupant crash Cushion
• Unintended deceleration Fasteners
protection degradation Inflator
• Access to rotating components
• Unintended opening of vehicle doors Cables Rip Seam
• Loss or degradation of vehicle conspicuity or roadway etc…
illumination
• Unintended exposure to high voltage energy system (shock) Safety Systems: Retractor
• Unintended exposure to toxic / flammable chemicals
(gas/liquid) Seat/Side Airbag System Load Limiter
•
•
Unintended access to sharp objects
Windshield visibility loss or degradation
Seat/Side Airbag System
Passive Restraint System Buckle
• Loss of acceleration; loss of propulsion Sensing System etc…
• Loss or degradation of steering or steering assist Vehicle Structure System
• Unintended activation of vehicle closures or windows
• Impeding driver operability of the vehicle etc . . . Critically Linked through
The Quality Chain
Our Approach to Enhance Connections/Collaboration
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Baseline Quality Chain Documents Process / Tool Validation
FREE
Design Solution Development
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline Component & Subsystem Physical Lessons Learned
Failure Mode & Effects Analysis Validation (Proto Tooled)
Interface Control Definition
KCDS Baseline Manufacturing Process Control
Production Validation: Component,
Key Characteristic Designation System System & Vehicle Level; Production
Designators Tooled.
Process FMEA Baseline Mfg Process & Tool Validation
Failure Mode & Effects Analysis
Supplier Part Certification, PPAP
Process Control Plan Capture Lessons Learned
Lessons Learned
Quality Chain Framework
Start of Production
PFI
Program Initiation DSI Design Initiation Product & Process Validation SORP
PPV
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Baseline Quality Chain Documents Process / Tool Validation
FREE
Design Solution Development
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline Component & Subsystem Physical Lessons Learned
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated • Developing the Design
through requirement definition and roll down. Process Control Designators • Confirming
Process the
/ Tool Design Design
& Control Plan DEFECT
• Analysis FREE
Baseline Quality Chain Documents Process / Tool Validation
Design Solution Development • Testing
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline Component & Subsystem Physical Lessons Learned
Failure Mode & Effects Analysis Validation (Proto Tooled)
Interface Control Definition
KCDS Baseline Manufacturing Process Control
Production Validation: Component,
Key Characteristic Designation System System & Vehicle Level; Production
Designators Tooled.
Process FMEA Baseline Mfg Process & Tool Validation
Failure Mode & Effects Analysis
Supplier Part Certification, PPAP
Process Control Plan Capture Lessons Learned
Lessons Learned
Quality
What Chain
is Quality Framework
Chain?
Start of Production
PFI
Program Initiation DSI Design Initiation Product & Process Validation SORP
PPV
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Product and Process
Baseline Quality Chain Documents Validation Process / Tool Validation
FREE
Design Solution Development
• Confirmation That Production Methods,
Design & Tools
Processand Systems
Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Meet Requirements Design Confirmation: Virtual Analysis,
Production Part Approval Process
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Baseline Quality Chain Documents Process / Tool Validation
FREE
Design Solution Development
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline Component & Subsystem Physical Lessons Learned
Failure Mode & Effects Analysis Validation (Proto Tooled)
Interface Control Definition
KCDS Baseline Manufacturing Process Control
Production Validation: Component,
Key Characteristic Designation System System & Vehicle Level; Production
Designators Tooled.
Process FMEA Baseline Mfg Process & Tool Validation
Failure Mode & Effects Analysis
Supplier Part Certification, PPAP
Process Control Plan Capture Lessons Learned
Lessons Learned
Quality
What Chain
is Quality Framework
Chain?
Start of Production
PFI
Program Initiation DSI Design Initiation Product & Process Validation SORP
PPV
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Baseline Quality Chain Documents Process / Tool Validation
FREE
Design Solution Development
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline Component & Subsystem Physical Lessons Learned
Failure Mode & Effects Analysis Validation (Proto Tooled)
Interface Control Definition
KCDS Baseline Manufacturing Process Control
Production Validation: Component,
Key Characteristic Designation System System & Vehicle Level; Production
Designators Tooled.
Process FMEA Baseline Mfg Process & Tool Validation
Failure Mode & Effects Analysis
Supplier Part Certification, PPAP
Process Control Plan Capture Lessons Learned
Lessons Learned
Quality
What Chain
is Quality Framework
Chain?
Start of Production
PFI
Program Initiation DSI Design Initiation Product & Process Validation SORP
PPV
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators
Lessons Learned
Process / Tool Design & Control Plan DEFECT
FREE
Baseline Quality Chain Documents Design Solution Developmentused to improve standard
Process / Tool Validation
Sub-System DFMEA
Design Failure Mode & Effects Process Failure Mode & Effects Analysis
Analysis
Component
Interface Controls Product Validation Testing
Vehicle level hazards assessed and mitigated
through requirement definition and roll down. Process Control Designators Process / Tool Design & Control Plan DEFECT
Baseline Quality Chain Documents Process / Tool Validation
FREE
Design Solution Development
Design & Process Failure Mode Effect
Interface Control Baseline Analysis
Part Certification, PPAP
Production Part Approval Process
Design Confirmation: Virtual Analysis,
Design FMEA Baseline
Failure Mode & Effects Analysis
Component & Subsystem Physical
Validation (Proto Tooled)
MORE Lessonstime
Learned and
KCDS Baseline
Interface Control Definition
Manufacturing Process Control
money
Production Validation:saved -
Component,
Key Characteristic Designation System
Designators Tooled. PAY POINT
System & Vehicle Level; Production
Process Control
System Subsystem &
Component Fixture alignment and
functional check prior
to part release from Process Confirmation
station
Sub System Process Control Plan
established Operator work
instructions
o SRV is a cross-functional event led by Supplier Quality Engineer during launch assessing risk in
component design, validation, and production
o PQRR is a cross-functional event led by the Program Quality Manager spanning the vehicle
development cycle to assess risk in vehicle design, validation, production
o CRV combines the component assessment from SRV with spanning the Vehicle Development Process
from the PQRR
Some of our tools we are using to help us manage quality (SPC / Control Charts)
depend upon three factors to ensure high quality
Times have changed; Todays customers want their products unique and
personalized which results in a seemingly endless combination of
component and options
Driving the Future
A Better Approach….
Having quality built in every step that is required to build each part, and
then put controls in place to ensure all process are completed
successfully.
2. You could print out a map and follow those directions to the best of your ability
A Better Approach….
By managing every individual part through the entire value stream, you can
build in quality at every step.
A Better Approach….
By managing every individual part through the entire value stream, you can
build in quality at every step.
Like the GPS, a built in quality system knows the required manufacturing
roadmap and will immediately see a special cause when it occurs and when a
wrong turn is made…
A Better Approach….
By managing every individual part through the entire value stream, you can
build in quality at every step.
Like the GPS, a built in quality system knows the required manufacturing
roadmap and will immediately see a special cause when it occurs and when a
wrong turn is made…
CONNECTIVITY
ACROSS THE
Fixing QUALITY TOOLS
Defects & FUNCTIONS
Preventing (Including Suppliers)
Defects IS KEY
Which side
PFI of the Defect Free scale are you & your team focused
SORP on?
Wrap-up / Q&A