Post on 23-Dec-2015
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Case StudyCase Study
Large Automotive OEM – FMEA Managed Service
Failure Mode & Effects Methodology
© 2010 Omnex Inc 2
Block Diagram
Block Diagram
Customer Requirements
Customer Requirements
SystemFMEA
Design InputsDesign Inputs
Process FlowProcess Flow
ProcessFMEA
ProcessFMEA
Control PlansControl Plans
Shop Floor Checklists
Review, Investigate, Evaluate
48%
Monitor2%
Supplier6%
Design Change7%
Analytical9%
Physical Test10%
Process Issue13%
Other5%
Benchmark20%
Design Improvements
40%Escalation
1%
Process Review
3%
SSR11%
Verification / Testing
13%
Analytical / Math12%
Before AQP After AQP
Design Failure Mode and Effects Analysis-- Distribution of Recommended Actions
Automotive OEM – FMEA Managed Service
© 2010 Omnex Inc 3
Initial Quality of U.S. and Import Brands 1999-2010
Note: Import Brands Include Europe and Asia
Case StudyCase Study
Large Aerospace Engine Manufacturer
New Product Introduction & PPV
6
CAB Activity
Planning
Program Start
Experimental Production
Product Design and Dev.
Process Design and Development
Product and Process Validation
Production
Corrective Action Board activity
Plan & Define
Program
Product Design &
Development Verification
Process Design &
Development Verification
Product & Process
Validation
Ongoing Part & Process Control
Product & Process Planning
PPV Activities Consolidation
Industrialization
© 2010 Omnex Inc
Large Aerospace Engine Manufacturer
• Conducting PPV (Product and Process Validation including FAI) training and facilitation for internal resources and 200 suppliers
• Rollout PPV to ensure product and process conformance for all new products
• Currently in initial stages – 10% to 30% improvement expected in RCNs
Case StudyCase Study
Truck – System Supplier
Purchasing
FUNCTIONALEXCELLENCE
FOUNDATIONALEXCELLENCE
QOSQOS TS16949/APQP/PPAPTS16949/APQP/PPAP
Team SkillsTeam Skills Global 8DGlobal 8D
6S/VISUAL WORKPLACE6S/VISUAL WORKPLACE
Quality
Materials
MANUFACTURING
Operations Excellence
© 2010 Omnex Inc 9
Truck Industry Large Sub System Provider
Improvement Before After Comments
Quality Rejects measured in percentages
3 Years – 187 PPM Implementation of APQP and PPAP internally and with Supply Base
187 DPM
Semiconductor Semiconductor Industry TransitionIndustry Transition
Semiconductor Assembly Council – Representing 95% of Chip Industry
Outside Japan
Semiconductor Industry Methodology
© 2010 Omnex Inc 12
8-D 8-D
MSA, SPC, and Process Control
ISO TS 16949 plus APQP and PPAPISO TS 16949 plus APQP and PPAP
Customer Involvement Similar
to Aerospace Industry
Customer Involvement Similar
to Aerospace Industry
Customer Driven Changes: 1998 to 2004
• Productivity improvements: 10% – 30%– Equipment– People
• Yield improvement– Subcontractor yields improved to 99.6%
• Performance to schedule improvement– Consistently sustaining 100%
• Number of customer complaints decreased– Up to 15x reduction
• PPM improved by over 100 times to under 30 PPM
© 2010 Omnex Inc 13