End-to-End Quality for Automotive Suppliers and Industrial ...€¦ · Synopsis Executive Summary...

siemens.comRestricted © Siemens 2016

End-to-End Quality for Automotive

Suppliers and Industrial Machinery (IM) /

Heavy Equipment (HE)

25th Wednesday, 08:00 – 09:00

Giulio FolgaraitRoom: Estrel Hall C1

Restricted © Siemens AG 2017

SynopsisExecutive Summary

Growing global demand for top quality

products is coupled with increased

regulatory requirements to create intense

pressure on manufacturers and their supply

chains.

In the automotive and industrial equipment

industries, external and internal suppliers

feel the pressure to reduce costs, deliver

faster, and improve quality. The needs

apply whether the process is repetitive or

engineer-to-order.

http://blog.lnsresearch.com/bid/176069/3-reasons-why-closed-loop-quality-management-strategies-fail-data

Achievement of zero defect production with the use

of a single quality system from design to execution

(closed loop) and retrofit (lessons learned)

http://blog.lnsresearch.com/bid/176069/3-reasons-why-closed-loop-quality-management-strategies-fail-data


The cost of poor QualityYour business has two things to worry about …

Costs incurred internally and externally are caused not only by defects in

products, but also by inefficiencies in production and processes

External Failure

Costs (EFC)

Internal Failure

Costs (IFC)

=

CoPQ Formula

CoPQ = IFC + EXC

where:

IFC = Scrap Costs + Rework Costs

EFC = Returned Product Costs +

Warranty Costs + Product Recall

Costs

… and difficult to discover


What do we need for a better market position?Targeted Business Benefits

Holistic quality system and centralized data

Early trend analysis, continuous improvement

Compliance with regulations

Complaint resolution within the global network

Manage overall cost of Quality

Anticipating Disruptions, Not Reacting to Them


DFMEA

Customer Complaint

/ Internal Concern

Review & Update

Generic FMEA

Part Specific

Control Plansupdated globally

Complaint

FMEA

Control Plan

Control Plan

Control Plan

Controls in place

Q

Global QE

Plants

Plant

Business Challenges

Align control and

monitoring

procedures from

corporate to

premises

Holistic quality system and centralized data

Federal Mogul is global producer of Power Train and Automobile parts

“An integrated quality management

system, reinforced by a cross-

company software solution, is

indispensable in the planning, control

and monitoring of process and

corporate quality, especially among

global enterprises. Individual,

standalone solutions can be replaced

with a single homogeneous system”.

Dr. Roland Jochem

Professor and Head, Quality

Science Department Berlin

Technical University"

IDEATION


Business Challenges

High costs of stock

surplus parts to

reduce the effect of

defects from

supplier

Anticipating Disruptions, Not Reacting to Them

USA worldwide automotive industry components and parts supplier

“Implementing Supplier Performance

Monitor, which first rolled out in

Germany and Ireland three years

ago, has played a crucial role in the

company's efforts to reduce parts

defects and thereby stock fewer

surplus parts. According to the

company, suppliers have reduced

their parts per million (PPM) by 33%,

meaning more of the parts delivered

from suppliers are passing quality

inspections."

REALIZATION


Business Challenges

Improve process

transparency and

positions for future

growth

Early trend analysis, continuous improvement

Components division adopted QMS Professional

The ability to continually monitor

each

component throughout

manufacturing helps Liebherr

identify trends early in the process. If

needed, the company can make

realignment decisions before

tolerance limits are reached.

(Juergen Stuhlmueller ,

Quality Assurance Manager Liebherr-Components

Biberach GmbH)

UTILIZATION


Trends in Automotive FTSConfigure to Order (CTO)


Trends in Industrial Machinery / Heavy EquipmentEngineer to Order (ETO)


TR

EN

D 1

Impact on Product Quality

Suppliers must deliver 0

defect products and manage

quality according to

automotive standards

(TS16949) and governmental

rules

Possibilities

OEMs are on the move to increased outsourcing of a proportion of their value added business to

suppliers – with the biggest growth in the (electric) powertrain and combustion engine segments

Profit from harmonized and

standardized quality

processes throughout the

product life cycle, with a zero

defect strategy

OEMs with a focus on

design, innovation and

marketing that are

outsourcing to FTS,

continue to ask for

shorter time to market

while complexity

drastically increases

End-to-End solution to

manage all aspects of

quality throughout the entire

product lifecycle, with a

closed loop process to

continuously improve

product quality and

proactively learn from past

errors

SOLUTION

OEM and FTS relationships are changingHolistic quality approach is becoming more critical


OEM and FTS relationships are changing Holistic quality approach is becoming more critical

▪ Chronic underinvestment in quality

▪ Lack of technology and lack of formal processes

▪ Quality is considered to be a department, not a global responsibility.

Much of industry has low quality maturity due to:

Source : LNS Research 2016 Quality Management in the Board Room: Building the Executive Business Case for EQMS


OEM and FTS relationships are changing Holistic quality approach is becoming more critical

▪ Chronic underinvestment in quality

▪ Lack of technology and lack of formal processes

▪ Quality is considered to be a department, not a global responsibility.

Much of industry has low quality maturity due to:

Unique standard platform with a centralized database

Standard charts for acquired data evaluation - definable metrics

Continuous Improvement/innovation by consistent/integrated

Lessons Learned loops

D-FMEA and Process FMEA to perform risk analysis

Standard platform for entire Quality Product lifecycle

Supplier portal, Supplier Complaint, Supplier Assessment, PPAP

support

Capability to manage Internal, Customer and Suppliers complaints

Standard module to manage Audit and compliance

Structured feedbacks by means of actions and complaint

management

Several reports available for all stakeholders

Source : LNS Research 2016 Quality Management in the Board Room: Building the Executive Business Case for EQMS


Holistic quality approach is becoming more critical


OEM and FTS relationships are changingIncreased Supply Chain complexity

TR

EN

D 1

OEMs with a focus on

design, innovation and

marketing that are

outsourcing to FTS,

continue to ask for

shorter time to market

while complexity

drastically increases

New complex collaboration

and dependencies with OEM

and Tier-2 suppliers;

regulations and cross-

company tracking & tracing of

modules, parts, and

components

Impact on Processes

Optimize customer and supply

chain management with

standardized processes and

effective assessment metrics

OEMs are on the move to increased outsourcing of a proportion of their value added business to

suppliers – with the biggest growth in the (electric) powertrain and combustion engine segments

Possibilities

Implement an Integrated

system to support and

interact with customers and

suppliers, with standard

processes and reliable

procedures

SOLUTION


OEM and FTS relationships are changing Increased Supply Chain complexity

Central database for supplier complaints management

Supplier assessment cross plant

Collaboration on problem solving from complaints between customer and

suppliers based on portals

Customer complaints - Problem solving with 8D and Ishikawa/5 Whys

Incoming/outgoing goods inspection based on dynamic sampling profiler


Increased Supply Chain ComplexityIncoming Goods control and Supplier Complaints


Change in customer preferences Mass customize via an integrated quality planning and execution

End customer demand for

customized products

TR

EN

D

Impact on Product Quality

▪ Answer customization requests on standard

offerings, reducing opportunity to reuse past

quality designs because of new, specific

demands

▪ Difficult to estimate and keep time to market

engagements

▪ Need to improve the process and the

effectiveness of the equipment to meet goals for

energy consumption and waste production

Which change in approach?

Perform safely quality

processes capturing all

the complexities of global

product variations for all

product configurations

Enable reduction of time to

market via fully integrated

quality solution along the

complete lifecycle (from

planning to execution)

linking ideation, realization

and utilization

SOLUTION


Change in customer preferences Mass customize via an integrated quality planning and execution


Business Challenges

Fragmented system

landscape limits

performance improvement

opportunities

Standard QMS systems do

not integrate Quality

Management with Product

Design

QMS systems must be able

to be integrated with

existing, higher level

systems and shop floor

Align and optimize supply

chain with integrated

processes for complaint

resolution and

collaboration


▪ Extend ERP logistic into

detailed plant quality

providing local flexibility

▪ Interact with supplier via

managed approach (8D,

Portal)

▪ Modify Process

Planning using

complaint sources

▪ Enable change

management

▪ Use lessons learned for

future problem solving

Value PropositionIBS QMS Professional:Quality Management Solutions

Business Goals


Increase transparency

and response to

deadlines via integration

of quality tools

Rationalization of

inspection strategies and

operating procedures

Quality Planning

Comprehensive planning and support of all quality relevant tasks

▪ Advanced Product Quality Planning

(APQP) Project Management, Control

Plan

▪ Failure Mode and Effects Analysis

(FMEA)

▪ Inspection Mgt (IPM) & Gauge Mgt

▪ First Article Inspection (FAI) & Production

Part Approval Process (PPAP)

Standard-based risk

analysis for product and

process design

Businesses are challenged by … then our customers expect from us ...


Real-time tracking and

data exchange enabling

reduction of inspection

and defect costs

Change management

driven by closed loop

between execution and

planning

Quality Execution

Efficient quality data acquisition and defect handling

▪ Incoming Goods Control / Outgoing

Goods Control

▪ In Process Quality Control

▪ Manual and automated quality data

acquisition

▪ Visual support for efficient data

acquisition by Statistical Process Control

(SPC)

▪ Defect Tracking

▪ HACCP procedure enforcement

Integrated complaint

management reducing

defects through reliable

data transmission



Hard facts for supplier

assessment (delivery

quality, date & quantity

reliability)

Collaboration for

problem solving

Quality Analytics

Aggregation of real-time data to relevant KPIs depending on role / level

▪ Supplier Assessment (SAM)▪ Targets for each supplier with and actual ratings

comparison

▪ Overview of the complete supplier history

▪ Evaluation (EVA) & Statistics▪ Comparing actuals to the specifications

▪ Ability to analyze deviations in product

quality

▪ Concern and Complaint Management

Statistics and Process

reliability calculation



Configurable OOTB (Out of the box)

Why Siemens solutions

Summary

Enables “digitalization” Best-Practice for Industry

Holistic Quality approach

Support the entire Product and

Process Life Cycle

Best-Practices manufacturing:

Automotive Suppliers, Industrial

Machinery and Heavy Equipment

Replacing the heterogeneous system

landscape in a single platform

Problem solving Process driven by

standardized method


As such, presentations help

define the company’s reputation

and provide both internal

and external orientation.

Questions

Q&A

Answers

Restricted © Siemens AG 2017Realize innovation.

Giulio Folgarait

Manufacturing Operations Management Business Enablement

Senior Director - MOM Industry Management Automotive

Email: [email protected]

mailto:[email protected]

Date post:	28-Jun-2018
Category:	Documents
Upload:	tranque
View:	219 times
Download:	0 times

End-to-End Quality for Automotive Suppliers and Industrial ...€¦ · Synopsis Executive Summary...

Documents