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Case StudyCase Study
Large Automotive OEM – FMEA Managed Service
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Failure Mode & Effects Methodology
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Block Diagram
Block Diagram
Customer Requirements
Customer Requirements
SystemFMEA
Design InputsDesign Inputs
Process FlowProcess Flow
ProcessFMEA
ProcessFMEA
Control PlansControl Plans
Shop Floor Checklists
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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
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Initial Quality of U.S. and Import Brands 1999-2010
Note: Import Brands Include Europe and Asia
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Case StudyCase Study
Large Aerospace Engine Manufacturer
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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
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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
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Case StudyCase Study
Truck – System Supplier
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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
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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
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Semiconductor Semiconductor Industry TransitionIndustry Transition
Semiconductor Assembly Council – Representing 95% of Chip Industry
Outside Japan
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Semiconductor Industry Methodology
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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
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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