turtles

FAURECIA EXHAUST SYSTEMS,

NORTH AMERICA, INC

Title: Process Turtle Diagram Form No.:

QP-CRP-T4-003-01

Issued by: K. Kimmet, C. Miller, S. Rich ‹#› of 15

Approved By: P. Bethune Issue Date: 22-5-07

Revision: 01

Note: Printed copies are uncontrolled unless that have an original approval signature in the title block


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

Support Division Production Facilities by: •Providing product definitions which may be Manufactured, are Profitable and Service Compatible

1)Process –Product Design, Testing & Development; Service Engineering

4) With What ?(Materials, equipment, etc)

�CAD and CAE Software�Other Predictive and Analytical Software�Acoustic and Structural Testing Equipment (Bench and Vehicle)�Prototype Fabrication Equipment�Metallurgical Analysis Lab�Engine Dynamometer Lab

5) With Who ?(Comp, Skills, Training, etc)

�CAD Designers�FEA/CAE Specialists�Product Engineers�Materials Specialists�Integration Engineers�Testing Technicians

2) Outputs

•Product Definition•Prints and GDT

3) Inputs

•Customer Requirements•Vehicle Performance Targets


Service Compatible•Providing the necessary testing and engineering to support normal production.

Support the customer by providing a product Definition that:•Meets the vehicle performance targets•Installs easily in vehicle assembly•Meets the cost targets of the program team•Meets program timing requirements

6) How(Methods, procedures, techniques, etc)

�Product Development Process�Standard Test Procedures�Design Guides & Standards�Product Failure Mode Knowledge Base (lessons learned)

•Prints and GDT•CAD Models•Materials Specifications

•Development Prototypes•DV Testing Results•PV testing results

7) How Effective ?

(Measurable objectives)

•Vehicle Performance Targets•Materials Requirements•Packaging Space Available•Durability Targets•NVH Requirements

•Manufacturing Constraints•Program Cost Constraints

•QOS Measurables•Annual Engineering Budget•Customer Satisfaction with Product/Vehicle Requirements met•Program Timing Met

Process Owner: ESPG-NAO

VP Engineering


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –

Supplier Partnership


�JDE• APQP monitoring•DMR process•Scorecard process•PPV tracking by supplier


�Finance�SQA/ �ASQ�Divison Buyers�Plant Buyers

2) Outputs3) Inputs

•Program tracking sheets•DMR alerts


Establish, manage and maintain a best panel of suppliers for series production and program launch.

Partnership


�Monthly reviews for cost and quality�Faurecia Core procedures�Weekly reviews on LCC

Monthly reporting to Product Group and Division staff in LIG.

7) How Effective ?


•DMR alerts•Spend by supplier for cost and panel status

-PPM-PPV-LCC-Number of suppliers Process Owner:

ESPG-NAO VP-Purchasing and

Supply Chain Management


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

• Process Architecture• PMT and Footprint strategy development• Capacity/Capital

1) Process - Process Design & Manufacturing Development

4) With What?(Materials, equipment, etc)

• 7 Quality Basics• Procurement System• Managing The Change• PSE for ME Principles

5) With Who?(Comp, Skills, Training, etc)

• Advanced Manufacturing engineers• Internal and external training• Lessons learned• Expert Networks

2) Outputs

Manufacturing processes meet all customer & organizational requirements with respect to: • Plant Readiness• Validated Process• Capable Processes

3) Inputs

-Product Design• DFMEA• Supplier PPAP’s• Process Flow• Capital Requirements


• Capacity/Capital Management


• Management review• Customer specific documents• Faurecia engineering documents

• Capable Processes• Efficient Processes• Customer PPAP approval• PFMEA

7) How Effective?(Measurable objectives)

• 3 PR• Run @ Rate• PPAP• TRS• R3

Process Owner:Manufacturing Engineering Director


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –

Program

Management


�Work Packages�Program Dashboards�Business Plans�Checklists (GR, FM, other…)�OPX2 System & Master timeline


2) Outputs3) Inputs

Program Core Team & WPO extended teams

Function Departments (Mfg, Purc, Eng, Quality)

PSC (Division Management)

PRC (PG Management)


Manage Programs from acquisition phase through series production to deliver Quality, Cost, Delivery and Performance (remove and Customer) targets.

Management


�FCP FAU-P-DSC-2240 and related procedures mentioned therein, Gate Review Procedure�All FCPs in Development leg of FES triangle and more�ESPG PMS Manual�Lola, Best Practices, BIKE, LEGO, Program Portal

2) Outputs

Monthly Programs status G/Y/R, Gate results G/Y/R.Program Delivered Quality, Cost, Delivery, and Performance targets on time, within budget, at target.

7) How Effective ?


Program AwardProgram Kick-off MtgWork Package Owners status reportsInitial Business PlansProgram DashboardsFM milestones, QVRs

-FES indicators-PMS Key Indicators for Time To Pass Gates, First Pass Yield, First Time Through, Confidence Index, Programs Status. All measured monthly.-Sop Status report-Customer systems-PLRs


Director of Program Management (with support from PMS Network and PG Functional Managers)

Created by J.Oliver Director-NAO Division PMS

Approved by M. Dewitt ESPG PMS Manager


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –CONTROL

PROGRAM

PROFITABILITY


�JDE�Cost models�Faurecia’s Business plans


�Manufacturing functions�Plant controllers�R&D functions

2) Outputs

• P&L per program

3) Inputs

-Costing information-Actual costs


Support Division and CBU in achieving program targeted profitabilitySupport initiatives to improve program profitability


�Plant visits and audits�Comparison Cost model versus Actual costs�Managing R&O lists

• P&L per program •Updated Business plan per program

7) How Effective ?


-Objectives of VCM/ OI & IRR-Achieving targeted results

Process Owner:•VP Finance•Program Controller


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –Employee Empowerment


� FES System� FCP Manual� 7 Core Values


Divisional StaffDivisional HR Support & StaffDivision EE Mgr.Plant HR Mgrs.

2) Outputs

Product & plant processes meet all customer & organizational requirements with respect to:

3) Inputs

• Faurecia Strategy• Faurecia PMT


Application of Business Management System to ensure:Verification of Employee Empowerment (EE) system implementation and effectiveness


� Internal and external audits� Management review� OHP validation� Administrative processes� Management development� Compensation and Benefits� Training and succession plans� OAR/APDR processes� Effective communication

requirements with respect to: • Trained competent workforce• Career opportunities• Employee motivation & productivity• Mature industrial relations

7) How Effective ?(Measurable objectives)

• Faurecia PMT• HR Strategy• Employee Expectations• Local Regulations

- Absenteeism Rate- Employee Turnover- Improvement Ideas- Internal Mobility- R3 Efficiency

Process Owner: VP – Human Resources


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

Support ESPG-NAO Division and Plant IT functions and tools through system

1)Process –IT


�PCs�Email�Phone Calls�Faurecia Intranet�Local IT


�Users�Power Users�Managers�Local IT

2) Outputs

•Help Desk FAQs

3) Inputs

•Help Desk System•Project Requests


IT functions and tools through system maintenance, uptime, and continuous improvement activities. These “functions and tools” consist of:•Applications (J D Edwards, ‘Future3’, Covisint, etc.)•Network/Infrastructure/Security•Engineering Systems•User Support


�Plant visits�Management Meetings�Training Sessions

•Help Desk FAQs•Help Desk Statistics•Documentation on Intranet

7) How Effective ?


•Project Requests•System monitoring•Interaction with sites

-Meeting Objectives-Achieving Budgeted Targets-Part of OAR

Process Owner: IT Director


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –PC&L


�JDE�Microsoft Office�E-mail�Faurecia Intranet


�Finance�VP Operations�Manager PCL ESPG�PCL Managers

2) Outputs

•Monthly LIG Metrics

3) Inputs

•Regular Plant visits•Weekly PCL Scorecard


Support Division and Plants in defining and achieving PCL Objectives:•Inventory $ and %•MPM•Customer Delivery Scores•FES Initiatives per FCP’s


�Plant visits�Weekly Conference Calls�Plant Audits�JDE�Action Plans

•Monthly LIG Metrics•PCL Intranet site•Weekly PCL Conference calls•Quarterly PCL Mgr meeting

7) How Effective ?


•Weekly PCL Scorecard•FES Indicators

-Meeting Objectives-Achieving Budgeted Targets-Part of OAR

Process Owner: ESPG-NAO Director,

PC&L


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –MANUFACTURING-

Production and

Service



•Plant Managers & plant teams•Internal and external training•Lessons learned•FES Network- Division•FES Network- Prodcut Group

2) Outputs

Product & plant processes meet all

3) Inputs

•Customer Demand•Employee Training

•7 Quality Basics•Breakthrough Quality Plan•Procurement System•Managing The Change•FES Tools•FCPs



•FES audits•Management review•LIG Reviews•PMS Gate Reviews

Product & plant processes meet all customer & organizational requirements with respect to: • Optimized Manufacturing

Quantities• Polyvalence, polycompetence

employees• PM’s attained on time• Quality Product• FES Audit Scores

7) How Effective ?


•Employee Training•Capable Product & Processes•TPM Deployment•Correct Inventory Level•Manufacturing Schedule•PMS Process•CAPex Core Teams

•FR0t, FR1t•Scrap and rework•Delivery Performance•Schedule Attainment•TRS•Productivity•PPOH, PPM, Customer Complaints•FES Indicators


VP-Operations

Application of Business Management System to ensure:•Verification of plant effectiveness•Verification of product conformity to customer requirements (PPAP)•Verification of FES activities effectiveness


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –Prototype Design, Testing & Manufacturing


� Stainless Steel Tubing/ Flat Stock � Purchased Components� Fabrication/ Inspection Equipment� CNC Machining Centers


� Prototype Prod. Engineers� Prototype Group Leaders� Prototype Technicians� Prototype Inspection Techs

2) Outputs3) Inputs

• Blue Prints, Proto Control Plans, EBOM, Check Lists


Fabricate Prototype Samples to support OEM Customers, Internal Testing and Manufacturing Plant requirements for Development, Testing, Fit & Function. Fabricate Tooling, Dies and Fixtures to support Internal Build, Testing and Manufacturing Plants requirements.


� Tool/ Die/ Fixture Building� Tube Bending, Forming� Component Fabrication� Welding (Manual & Automatic)

• Fabricated Hot & Cold End Prototype Exhaust Systems & Components.• Tools, Dies & Fixtures

7) How Effective ?


Plans, EBOM, Check Lists• Engineering Sample OrderSystem (ESO)• Prototype Build Package

Monthly QOS Metrics:- 6mr Defects per 1,000 (D/1000)- Samples Delivered On Time - Labor Hours per Part- Samples Shipped per Month


VP Engineering,

Prototype Manager


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –

LEGAL

FUNCTIONS


�Manager’s Legal background�Legal Treatises�Outside Counsel where appropriate


�Legal Managers

2) Outputs

•Legal Documents approved for

3) Inputs

-Facts gathered internally-Any applicable documents


Support Division-level functions and Plants with:•Draft and review of contracts•Resolution of commercial disputes with Customers and Suppliers


�Comprehensive review and understanding of facts.

•Legal Documents approved for signature�Resolved disputes and/or litigation

7) How Effective ?


-Any applicable documents-Discussions with appropriate Faurecia personnel

-Litigation avoidance due to properly drafted contracts- Delay-avoidance in plant modifications due to legal disputes Process Owner:

•Manager of Tax & Legal ; Asst. Treasurer; Asst. General Counsel


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01

1)Process –

HSE



2) Outputs3) Inputs

• Plant Manager• HSE Designate• Faurecia HSE Requirements

• External Legal Requirements• Best Management Practices

•FR0/FR1 Data•QRQC 8D Data



7) How Effective ?


Process Owner: ESPG-NAO HSE

Director/Manager

Application of HSE ManagementSystem:• Provide Framework for HSE Network

• Implement HSE PMT/Strategy

•QRQC 8D Data•ESPG Requirements

•FR0/FR1 Data•Internal Review•External(3rd Party) Review

Standardized HSE Mgmt. System.•Reduction in FR0/FR1•ISO 14001 Certification

•Facility Review•Gate Reviews•HSE PMT


NORTH AMERICA, INC


QP-CRP-T4-003-01



Revision: 01
