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Driving Towards A Zero Defects Culture (PDFDrive)

This document discusses driving towards a zero defects culture at GM. It emphasizes the importance of having a zero defects mentality and connecting quality tools, functions, and organizations across the supply chain. This includes taking a systems engineering approach to link vehicle hazards to component requirements, enhancing collaboration between departments using a quality chain, and holding multi-functional check-ins at key milestones using Component Readiness Valves. The goal is to address the root causes of defects by improving connectivity and learning across silos.

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eldhoisaac
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
0% found this document useful (0 votes)
48 views59 pages

Driving Towards A Zero Defects Culture (PDFDrive)

This document discusses driving towards a zero defects culture at GM. It emphasizes the importance of having a zero defects mentality and connecting quality tools, functions, and organizations across the supply chain. This includes taking a systems engineering approach to link vehicle hazards to component requirements, enhancing collaboration between departments using a quality chain, and holding multi-functional check-ins at key milestones using Component Readiness Valves. The goal is to address the root causes of defects by improving connectivity and learning across silos.

Uploaded by

eldhoisaac
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 59

Driving Towards a Zero Defects Culture

Gary L. West
Executive Director
Global Supplier Quality & Development
Gary West Introduction

Director of Manufacturing & Product Vice President of Quality GM Korea


Engineering GM Egypt Detroit Michigan
Director of Manufacturing SGMW/GM ChinaTruck Group
Pontiac
Pittsburgh Pennsylvania
Indianapolis – Metal Fab
Plant Manager Detroit Hamtramck
Brownstown Battery
Janesville Assembly
Assembly Plant Plant
Wisconsin

Vehicle Plant Manager GM Mexico Ramos Arizpe

Executive Director Managing Director GM Uzbekistan


Global Supplier Quality & Development
Agenda

• Defect Free Vision – Implications


of not achieving 100%
• GM’s Defect Free Strategy
• Systems Engineering
• Quality Chain
• Component Readiness Valves (CRVs)
• Closing – Where to from here?
Water Heaters?

Pressure Relief
Valve
Many Similarities to Automotive Industry

No Tolerance for
Downtime
Many Similarities to Automotive Industry

Almost any part of a vehicle is either directly or indirectly


affected by Product Safety
Today’s Environment – Requirements Rich

Global Regulations are more & more complex and challenging…

CCC
Today’s Environment – Vehicle Sophistication

Vehicles are more connected, more technically


sophisticated and more complex, driven by higher degrees
of system integration and interdependence.
Complexity

F-22 Fighter Jet Cadillac CT6

2 Million 120 Million


How Many Lines of Software
Code Do These Products Have?
Zero Defect Mentality

A Zero Defect Mentality is not a quest for perfection,


but a new way of thinking about defects that allows
organizations to move from Treating Symptoms to
Solving Systemic Issues.
Zero Defect Mentality

When your Goal is Zero Defects it sets a standard


against which all your processes can be assessed.
It’s about continually striving to work better and not
being satisfied with the status quo.
Success Through Quality

In the book "Success through Quality", the author


estimates that Cost Of Poor Quality for an
average company is about 20% of sales

Number of Good Parts Per Sigma Level 1% - 5% for


companies who
6 have achieved
"six sigma"

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

A 20% Cost Of Poor


Quality (COPQ) implied
that during one day of
each five-day workweek,
the entire company
spent its time and effort
making scrap

GM Confidential
The Billion Dollar Question

Many Mature Engineering & Quality Tools & Processes…

Yet defects still get through ?

Why ?
Systems Engineering
A Significant Part of the Answer…

Silos - Insufficient Connectivity & Collaboration


Silo Mentality
A mind-set present in some companies when certain departments or sectors do
not wish to share information with others in the same company.
A Significant Part of the Answer…
The Many Dimensions of Silos

DFMEA PFMEA Processes Mechanical Body Electrical


Engineering Engineering

Across Tools Across Functions


Across Systems

Vehicle System Subsystem Component OEM Tier-1 Tier-2

Across Vehicle Features/Functions to Systems to Components Across Supply Chain & Orgs

Defect Elimination relies on Deep Understanding and Collaboration at the Connections;


across Tools, Functions, Systems, & Organizations
Commitment to Learning

Continuous improvement requires a


commitment to learning.
In the absence of learning, companies -
and individuals - simply repeat old
practices.
Change remains cosmetic, and
improvements are either accidental or
short-lived.
The Billion Dollar Question

Many Mature Engineering & Quality Tools & Processes…

Yet defects still get through ?

Without well understood


connection, collaboration
Systems Engineering and joint ownership.
What are we going to do different?

GM Confiden
Our Approach to Enhance Connections/Collaboration

• Systems Engineering – Connecting vehicle functions to


subsystems and components

• Quality Chain – Connecting Functional Departments, Quality


Tools & Organizations, along the Vehicle Development Process

• Component Readiness Valves (CRVs) – Multi-Functional


check-in to assess rigor and status at key milestones

CONNECTIVITY ACROSS THE QUALITY TOOLS


& FUNCTIONS (Including Suppliers) IS KEY
FORWARD LOOKING VISION FOR GM SYSTEMS ENGINEERING

Systems Engineering is a method, not an organization


The Systems Engineering perspective is based on
systems thinking — focused on an awareness of wholes
and how the parts within those wholes interrelate, when
a system is considered as a combination of system
elements.

It is an enterprise process – through the Vehicle


Development Process

Expect that activities and deliverables must change


across Product Development – Systems thinking for all!
SYSTEM AND COMPONENT REQUIREMENTS LINKED
TO VEHICLE LEVEL HAZARDS

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

• Systems Engineering – Connecting vehicle functions to


subsystems and components

• Quality Chain – Connecting Functional Departments, Quality


Tools & Organizations, along the Vehicle Development Process

• Component Readiness Valves (CRVs) – Multi-Functional


check-in to assess rigor and status at key milestones

CONNECTIVITY ACROSS THE QUALITY TOOLS


& FUNCTIONS (Including Suppliers) IS KEY
Quality
What Chain
is Quality Framework
Chain?
Start of Production
PFI
Program Initiation DSI Design Initiation Product & Process Validation SORP
PPV

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Feature Level Establish Requirements
Design Solution Development

System Level Standardized


• Virtual Analysis WorkTesting
Physical (Spec. Templates)
Sub-System • Definition
DFMEA forProcess
Actual Program or Part
Failure Mode & Effects Analysis
Design Failure Mode & Effects

Component • Rolldown Analysis

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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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

Baseline Quality Chain Elements


Failure Mode & Effects Analysis Validation (Proto Tooled)
 Interface Control Definition
KCDS Baseline  Production Validation: Component,
Key Characteristic Designation System • Standardized Work for our
 Manufacturing Process Control
Designators
ProactiveSystem
Quality Work Level;
& Vehicle in Engineering
Production
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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

Sub-System DFMEA Design of Product and Process for the


Process Failure Mode & Effects Analysis
Vehicle Program
Design Failure Mode & Effects
Analysis

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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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

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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Not justVirtual
what has Physical
Analysis to happen,
Testing but also
Sub-System WHEN DFMEA it has to happen!
Process Failure Mode & Effects Analysis
Design Failure Mode & Effects
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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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

Interface Control Baseline



Analysis work, preventing errors
Design & Process Failure Mode Effect
andPPAP
Part Certification,
Production Part Approval Process

Component & Subsystem Physicalsaving work next time


 Design Confirmation: Virtual Analysis,
Design FMEA Baseline 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

Requirements Flowdown and Production Design Development Validation of Product and


Balancing, and Standard Work and Assessment Manufacturing Process Designs
Vehicle Level Hazards & System (Product & Process) for Production
Safety Assessment
Design Solution Development
Feature Level
System Level Virtual Analysis Physical Testing

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 FMEA Baseline  Mfg Process & Tool Validation


Failure Mode & Effects Analysis
 Supplier Part Certification, PPAP
Process Control Plan  Capture Lessons Learned
Lessons Learned
Water Heater Quality Chain Connectivity Example

System Level Hazard: Uncontrolled Release of


Pressure (Explosion)

Design Failure Analysis


Pressure Relief Valve
Process Failure Analysis

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

Pressure relief valve does


Component not function correctly

CONNECTIVITY ACROSS ALL QUALITY TOOLS & FUNCTIONS IS KEY


Our Approach to Enhance Connections/Collaboration

• Systems Engineering – Connecting vehicle functions to


subsystems and components

• Quality Chain – Connecting Functional Departments, Quality


Tools & Organizations, along the Vehicle Development Process

• Component Readiness Valves (CRVs) – Multi-Functional


check-in to assess rigor and status at key milestones

CONNECTIVITY ACROSS THE QUALITY TOOLS


& FUNCTIONS (Including Suppliers) IS KEY
Component Readiness Valves (CRV’s)

Component Readiness Valves (CRV) are cross-functional Product


Development Team health assessments of deliverables at various program
milestones.

CRV concept was based on two standardized processes: SRVs (Supplier


Readiness Valve) and PQRRs (Program Quality Readiness Review)

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

CRV reviews are not a time for defect discovery!


CRV Leadership Visibility

Red and Yellow issues


from completed CRV
assessments are escalated
by functional owner
through the applicable
forums
Key Takeaways

 Leadership Message: Significant need for a Defect Free Culture


at GM
 GM has implemented 3 new approaches:
 Systems Engineering
 Quality Chain
 Component Readiness Valves
 Engineering Leadership is required to Effect This Change !
o Commit, Own and Drive Defect Free
Driving the Future

• Customers are Demanding Zero Defects.

• Product quality has to be at the highest level ever.


Being “Good enough” is no longer good enough.

• On average in our Automotive industry for every


vehicle sold there was one vehicle recalled for
potential safety defect.
Requirements / Standards

IATF 16949:2016 AS9100


Automotive Quality Requirements for
Management Aviation, Space and
Defense Organizations
Quality Management
Systems
Driving the Future

Some of our tools we are using to help us manage quality (SPC / Control Charts)
depend upon three factors to ensure high quality

1. Long Production Runs


2. Capable Processes – the future can only be predicted if the past is repeatable
consistent
3. Common Cause Variation – Process variation is caused by normal
phenomena and can be statically predicted.

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

Because manufacturing is more complex today we have developed


tools to address this challenge
LEAN SIX SIGMA
• Six Sigma Methodologies • Guiding principles based • Focus on voice of the
operating systems customer
• Lean Manufacturing • Relentless elimination of all • Data and fact based
• Lean Six Sigma waste
• Creation of process flow and
decision making
• Variation reduction to
demand pull near perfection levels
• Resource optimization • Analytical and
Although these tools are successful, • Simple and visual statistical rigor
their use results in even more
complexity. We now require highly
Strength: Efficiency Strength: Effectiveness
skilled people to understand these
EXTREMELY POWERFUL COMBINATION
tools and implement them in our
plants.
A Better Approach….

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.

By understanding the roadmap (Quality Chain) that each part needs to


follow, and where each part is on the roadmap at all time, simplifies
mistake proofing and problem solving.
A Better Approach….

Consider the Analogy of Driving to a Destination.


1. Someone can provide you with directions

2. You could print out a map and follow those directions to the best of your ability
A Better Approach….

… or you can use a GPS.


3. Punch in the destination and the GPS will get you there turn by turn.
A Better Approach….

… or you can use a GPS.


3. Punch in the destination and the GPS will get you there turn by turn.
A Better Approach….

If you make a wrong turn…


A Better Approach….

If you make a wrong turn…


The GPS immediately recalculates the correct route
and gets you back on track.
A Better Approach….

If you make a wrong turn…


The GPS immediately recalculates the correct route
and gets you back on track.

The great thing about GPS is that it


requires very little technical ability
to get to your destination
– EVERY TIME !
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…

The system immediately triggers predefined containment, notifications, and


corrective actions to minimize waste and maximize quality
Impossible Thinking

Just think of a few things that were considered to be


impossible just a few years ago, yet they exist today.
So perhaps the question,
“IF something can be done?”,
should be replaced with,
Impossible Thinking
“WHEN can it be done?”.
In other words, anything is possible, it’s
just a matter of when will the “impossible”
become “possible”.
What Has Our Focus Been?

As we Implement Quality Chain Methodology and Strengthen our Standard work…

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

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