Robust QOS / In-Process

Metrics (IPM) Roll-out

December 2007

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1
 Objectives
• Drive a robust QOS within the supplier site by integrating
the five key Manufacturing Site Assessment (MSA)
elements into supplier's QOS.
• Reinforce the five focus MSA elements with in-process
measurable data.
• The five key MSA elements are:
– FMEA/Control Plan/Reaction Plan
– Sub-Supplier Quality Management
– Process Variability Monitoring
– Problem Solving/Corrective Action
– Manage the Change

Note:
Note: Suppliers
Suppliers are
are still
still responsible
responsible to
to be
be compliant
compliant to
to the
the entire
entire Manufacturing
Manufacturing Site
Site
Assessment, this process outlines a focused deep dive into the five key elements.
Assessment, this process outlines a focused deep dive into the five key elements.

2
Where Do We Need To Focus?

Analysis of Supplier Quality Issues Shows:

Supplier
Design FMEA/ Control
25% Plan

60% Sub-Supplier
40% Supplier Management
Internal

Supplier
Manufacturing Process Control
35%
Manage the (Cpk)
Change
Gage R & R

Opportunity - 5 Systemic Root Causes 3

IPM Results: Pilot Suppliers
Target: 100% Metrics Green
In-Process Metrics -- Overall Status
(24 Suppliers x 5 Metrics = 120 Data Points)
3%
100% 11% 8% 3% 3%
100%

13% 86% Red

20%
26% 31% 91% 24%
80% 24%
Element Ratings

80%

50% 38% 30% 26% Yellow

60% 40% 60%

38% 58% 63% 71% 73% 73% Green

40% 40%

38%
40% 49% % Plan
20% 20%

to Green
13% 37%
0% 0%

* **
6
6

06

06

6
06
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Target Q1 Score: 800 - 1600
Average Q1 Score
(24 Suppliers)
1600

1200 1004 1009 996

974
Q1 Score

942
813 863
740 755 787
800 642

400

0
6

6
06

06

06

6
06

6
-0

-0
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4
Linkage to Manufacturing Site Assessment (MSA)

5 Systemic
Root Causes 5 MSA
Elements
FMEA/ Control
Plan

Sub-Supplier
1. FMEA/ Control Plan/ Reaction Plan
Management 2. Process Variability Monitoring
Process Control
• Process Capability
(Cpk) • Gage R&R
Gage R & R
3. Manage the Change
Manage the
Change
4. Problem Solving/Corrective Action
5. Sub-Supplier Quality Management

5
Robust QOS

• Living process GOVERNANCE

• Closed loop for
effective
implementation of FMEA/ Control
Plan
Sub-Supplier
Management
Process
Variability
corrective actions
• Governed process Sub-
Sub-Tier
Replication
• Continuous
improvement system Manage the
Change
Problem Solving/
Corrective Actions

Closed Loop Process

“Permanently addresses systemic failure modes” 6
 Operational QOS
PROBLEM SOLVING
External Inputs
Warranty
PROBLEM
TGW PROCESS MANAGE THE
SOLVING/ CORRECTIVE
Quality Data VARIABILITY CHANGE
ACTIONS
Internal Inputs Sup. K 8D MTC
(Special Characteristic
Productivity DOCUMENTATION CHECKLIST
Linkage)
Capability
Sup. K1
FTT (Change Management &
Other Problem
Scrap Problem Solving Linkage) solving tools:
e.g.,: 6-Sigma, Shainin
AUDIT Gage R & R

MTC
Log
WORKING LEVEL
Paynter
MTC CHECKLIST CONTROL PM
DFMEA TRACKING
Code MTC # PLAN
Tool Control 12

DFMEA 12

PFMEA 12 WORK SUB-TIER

Control Plan 12 PFMEA INSTRUCTIONS IMPACT
Work Instructions 12

7
Linkage to In-Process Metrics
In-Process Metrics
Supplier Information FMEA/Control Plan
Panel #1 Green
FMEA/Control Plan Peer Group Sign-Off
Supplier Name: ABC Company 100%

Site Code: AB123 80%

FMEA/Control Plan
60%
Month Reported: Mar-06

5 MSA
40%
Comments:
20%

0%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

% Sign-off Planned % Sign-off Actual

Total # of FMEA/CP Reviews = 18
% Audit Planned % Audit Actual

Process Variability Monitoring

Elements
Panel #2 Green Panel #3 Red
Process Capability (Cpk) Gage R&R (ANOVA)
100% 100% 100% 100%
100%
7% 3% 97% 100% 100% 100% 100%
100% 7% 93% 90% 90%
7% 90%
7%
10%
17%
80%
80% 75% 30% 30% 30%
80% 80% 75% 75%
25%
73% 25%
67% 67% 67% 25%

% of SC, CC, HIC

60%
60% 20%

% of Gages
60% 50% 25%
25%
97% 100% 100% 100% 100% 100% 25%
90% 93% 25%
83% 87% 40%
40% 77% 25%
67% 65% 65% 65% 65%
60%
55%
50%
45%
20% 20% 40%
35%
30%
25%

0% 0%
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
% <1.33 and contained % Gages (<10%)
Total # of Characteristics = 30 % >1.33 or error proofed Total # of Gages = 20 % Gages (11% - 30%)
% Plan to >1.33 % Plan to <30%

Manage The Change Problem Solving / Corrective Action

Panel #4 Green Panel #5 Red
Manage The Change Checklist Compliance Problem Solving / Corrective Action Capability
100% 100% 100% 100% 100% 100%
40 100% 96% 96%
1
00%

100% 100% 100%

93% 30 100% 100% 94% 100%
96%
100
%

91% 94% 89% 100% 96%

35 94% 38 38 91%
88% 88% 88%
26
82% 30 86%
8
0%

25 80% 82% 25 80%

30 26 27 75% 23
71%

Total # of 8Ds
25 20 67%
21 21 21 6
0%

60% 60%

18 19
20 17 15 16 17
14 4
0%
40%

15 11 11
10
10 8
2
0%
7 20%

3 5 5
5 3

0 0
%

0 0%

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Repeat Issues
Cum. MTCs Planned % Closed 8Ds
% 8Ds to D3 (Contained)
Total # of Planned MTCs = 38 Cum. 8Ds Opened
% Compliance (QOE)

1. FMEA/Control Plan • Engineering Documents

Linkages
2. Process Variability • Process Capability and
Monitoring Gage R&R
3. Manage The Change • Manage The Change QOE
Compliance
4. Problem Solving/ • Problem Solving / Corrective
Corrective Action Action Capability
5. Sub-Supplier Mgt. • Sub - Tier Replication 8
Summary

Move from REACTIVE to more PREDICTIVE

Quality Management System

Living Lessons Learned

Closed Loop Robust QOS

Move from Compliance Review Mindset

to Data Driven Quality-of-Event!

9
Questions?

10