Personnel Development

and Continuous Improvement –

Utilizing AIAG Core Tool Products

David Kneisler

VP, Global Quality

Dana Holding Corporation

Dana Overview

Dana Snapshot

• Founded in 1904

• Based in Maumee, Ohio, USA

• 2014 sales: $6.6 billion – Fortune ranking: 385

• Global operations and customers – 90 major facilities

– 25 countries on six continents

– 4,000 customers in more than 125 countries

• 15 R&D centers

• Approx. 23,000 people

2

Dana Global Markets

Sales by Market and Region

50% Light

Vehicles

30% Heavy

Vehicles

2014 Sales by Market 2014 Sales by Region

20% Asia Pacific*

43% North America

25% Europe

20% Off-Highway

Markets

47% North America

30% Europe

12% South

America

11% Asia Pacific

Dana Core Technology Expertise

Sealing – Oil Consumption and Emissions

Gaskets and seals, molded cover and pan

modules, fuel-cell plates

Brand: Victor Reinz® (since 1909)

Thermal Management – Manage the Heat

Heat shields, transmission and engine oil

cooling, battery cooling, charge air cooling,

active warm-up, fuel-cell products

Brand: Long® (since 1903)

Driveline – Torque Management

Axles, driveshafts, off-highway transmissions,

tire management systems

Brand: Spicer® (since 1904)

Dana Products

Light Vehicle Products

• Cylinder Head Gaskets

• Thermal Acoustical Protective

Shielding

• Active Warm-up Units

• Engine Oil Coolers

Axles

Driveshafts

Sealing

Thermal

• Water-Cooled Charge Air Coolers

• Thermoplastic Oil Pans

• Cylinder Head Cover Modules

• Secondary Gaskets

• High-Temperature Gaskets

• Valve Stem Seals

• Transmission Oil Coolers

• Fuel Coolers

• Battery Cooling

Transmissions • VariGlide™ CVP Variator

• Transmission Valve Body

Separator Plates

Quality in Today’s Automotive

Environment

• Quality doesn’t “sell”!

• Expectations:

– Safety

– Reliability

– No Issues / Hassle Free

• To achieve expectations, automotive people need to know the “rules” and “tools”

– OEM’s, Tier 1 – Tier “N”

AIAG Quality Core Tools

• The AIAG Core Tools are the “building blocks” for Quality knowledge and performance expectations in the automotive industry

• Utilized / required by many OEM’s and Tier 1 supplier in the automotive industry

– Third party auditors required to be certified so they can effectively audit these Core Tools

AIAG Quality Core Tools

APQP / Control Plan

Automotive Quality

Core Tools

FMEA PPAP

SPC MSA

AIAG Quality Core Tools

• Advanced Product Quality Planning/Control Plan (APQP/CP)

– Guideline for quality planning for new product development

• Failure Modes & Effects Analysis (FMEA)

– Reference manual for product and process risk assessment

• Production Part Approval Process (PPAP)

– Requirements for confirmation of supplier product/process capability prior to serial production launch

• Measurement Systems Analysis (MSA)

– Guideline to evaluate capability of inspection/test equipment

• Statistical Process Control (SPC)

– Guideline for application of statistical methods in production

AIAG Core Tool Self-Assessment

• FREE, on-line Self-Assessment

– Available in English, Spanish, Korean, Chinese, Russian

• Purpose:

– Measure basic understanding of the core tools

– Identify where more education / training may be useful

– Feedback on effectiveness of prior training investments

• Timed, open book assessment

– Questions based on Body of Knowledge from the Core Tool certification courses

– Seasoned quality professionals should be able to score 90+ in their prime competencies, 80+ in all areas

AIAG Core Tool eLearning

• Two Overview Courses

– Core Tools Overview

– Quality Core Tools - Connect the Dots

• Four Detailed Courses

– Implementing APQP, Control Plan and PPAP

– Implementing Failure Mode Effects Analysis

– Implementing Statistical Process Control

– Measurement System Analysis with Applications

Dana’s Core Tool Scope and Vision

• Dana has an excellent, professional Quality staff.

– Varied industry backgrounds

– Business specific training focus

– Quality Career Path knowledge base differences

• Recognized that we had an opportunity to leverage AIAG’s core tool products to benefit all Dana employees.

– “Level up” to common knowledge set

Initial Desired Outcomes

• Deploy AIAG Core Tool Products across Dana globally.

• Develop a Dana Core Tools Certification based on AIAG Core Tools.

• Focus on Quality professionals: e.g. Managers and Engineers

• Link demonstrated Core Tool knowledge to the Dana Quality Career Path

Dana Core Tools Certification

• Utilize AIAG’s Core Tool Self-Assessment as the basis for Dana’s Core Tool Certification.

• “Passing” scores set at >= 80% on all four scoring categories in a single test session.

• Initiated the program late Q1 2015.

Knowledge Deployment supporting

Certification Efforts

• Goals:

– Global access with local language support

– E-Training focus

– Access to Technical Experts as needed

Knowledge Deployment supporting

Certification Efforts (continued)

• AIAG Core Tool and CQI Documents available to Dana employees via Dana Intranet

• AIAG Core Tool E-Training communicated globally

• Dana “expert” access established

Initial Core Tool Self Assessment

Framework

• Requested Quality professionals to take the self-assessment without preparation or study.

• Emphasized that scores do not need to be shared with anyone unless applying for the Dana Certification.

• Communicated expectations:

– Take the self-assessment within 90 days from roll-out.

– If needed, study and re-take the self-assessment as needed to achieve the Dana Certification.

First Round Results

• No one “passed” on the first attempt!

– Do not be surprised if this happens to you!

• Initial Score Results (averages):

– APQP/PPAP: 73

– FMEA: 74

– MSA: 72

– SPC: 69

– Overall: 72

First Round Results

• Dana scores were consistent with AIAG’s baseline industry results.

• No significant differences noted between populations:

– Business Unit

– Region

– Corporate / Tech Center / Plants

First Round Results

• Key feedback from Dana personnel:

– Universally positive! (worth the time)

– In many cases a single category or two required additional study.

– Great appreciation for online access to AIAG documents (via Dana Intranet) and AIAG e-learning (via AIAG website)

– Desire for certification and associated recognition

Learning Progression

• Clear positive trend in scores on subsequent self-assessments

• In many cases only self-study of AIAG material was needed to achieve desired score targets

• Although a few certifications were achieved fairly quickly, significant progress was not seen for six months

– Study time vs. workload

Current Certification Status

• 63 Quality Professionals Certified

– Average score = 86%

• 14 points above the initial baseline scores

– Largest improvements seen in MSA and SPC

• Certifications now happening weekly

• Significant support from Operational leaders

2016 Deployment Expectations and

Plans

• Most Quality Professionals are expected to be certified in 2016

• Expanding certification efforts to Applications Engineering, and some Process Engineering positions

• Adding the Dana Core Tools Certification to our Quality Career Path requirements for Quality Manager and Quality Engineer positions

Deployment Lessons Learned

• Key success factors:

– Initial communication

• Employee and customer benefits

• Desired outcomes

• Score anonymity

– Access to documents and e-learning

– Access to subject matter experts

– Leadership support (all levels)

• Especially Plant Managers

– Employee Recognition

Questions?

Thank you!