Stuttgart. • Audit preparation for OEMs & Tier 1 + Tier N according to VDA 6.3 ...
Support with preventive/advanced quality planning (APQP, PPAP, VDA Band 2).
your partner for process audits, audit preparation & consulting
© foQusQM 2012
Company Presentation Revision III (2012)
Overview of foQusQM Services Supports you with… Stuttgart • • • • • • • • • • • • •
Audit preparation for OEMs & Tier 1 + Tier N according to VDA 6.3 P1 potential analysis according to VDA 6.3 PPAP – Production Part Approval Process Process audits according to VDA6.3 [(P2-P4) (P5-P7)] Technical Revision Supplier (TRS) Supplier classification according to A-B-C criteria within an individual commodity Supplier development in 5 phases (5-Phases-model) Support with preventive/advanced quality planning (APQP, PPAP, VDA Band 2) Implementation of a professional supplier & project management, incl. development and training of project management tools Environmental management ISO 14001, energy management EN ISO 50001 LEAN-Management and CIP-projects (Continuous Improvement Process) 5 S implementation and auditing Risk management
© foQusQM 2012
Hamburg • • • •
Sales partnership (customer acquisition, internationalization) Customer interface Forward Sourcing Supply-Chain-Management foQusQM Company Presentation
2
foQusQM Business Areas
Complete Best-Practice-Program from one partner
Business Activities of foQusQM GmbH
Audits & Processes
Supplier qualification
Purchasing & Sales
Trainings & Coaching
Market 46 4 7
31 5
22 4 5
4 35 22
13
2007
2008
2009
Process
People
= Stuttgart Methods … … . . … .
© foQusQM 2012
= Istanbul = Hamburg
foQusQM Company Presentation
3
Audit & Process Market 46 4
• •
OEM Automotive Tier 1 + Tier N supplier automotive (certification level ISO/TS 16949)
• •
OEM wind energy industry Tier N supplier wind industry (certification level ISO 9001)
• • • • • • •
Management & development of a quality / process management system Process improvement to achieve robust process designs to increase the degree maturity Decrease of waste, increase in efficiency within the value chain Support in executing process capability and machine capability analysis Execution of external audits to improve the quality of incoming goods (zero error strategy) Execution of internal audits to evaluate the quality as well as the process management Support of suppliers with new projects & prototype release procedures (Production ramp-up management)
• • • • • •
Process audits according to VDA 6.3 PPAP (Production Part Approval Process) VDA Band 2 5S, 8D, A3 problem solving sheet, PDCA circle, Ishikawa-Diagram, Resident Report System APQP, FMEA, capability analysis Cpk‘s, DoE (Design of Experiments), QFD (Quality Function Deployment) CIP (Continuous Improvement Process) / Six Sigma Environment management ISO 14001, energy management EN ISO 50001
• • • • • •
Experienced OEM LEAD-Auditors according VDA 6.3 Experienced internal auditors according DGQ Experienced system auditors according ISO/TS 16949 Certified PPAP experts Certified FMEA experts Experts in LEAN-Management
7
31 5
22 4 5
4 35 22
13
2007
2008
2009
Process
… … . . … .
Methods
© foQusQM 2012
People
foQusQM Company Presentation
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Auditing
Analyze and audit the manufacturing and indirect processes at supplier Auditorder Targets of customer • Customer’s order • Audit covering letter • Time scheduling
Require documents Claim & PPAP Specification & Drawings
Auditexecution • Execute Audit with VDA Tool • Visualization of findings
Auditfollow-up • Report out • Ranking according to VDA 6.3 • Handover of audit documentation
© foQusQM 2012
• • • •
Auditpreparation
foQusQM Company Presentation
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Levels of qualification according to P³-model process-orientated resident engineering according to VDA 6.3 reduction of warranty costs professional
• APQP
• VDA 6.3
• FMEA
• problem solving methods
• regular audits • QAA • specification
pragmatic • resident engineering
• processoriented QM-system ISO TS 16949
5
P³ pattern
5
• facts & figures in production
• visual management
P³ pattern Commodity 6
5
Commodity 4
P³ pattern
5
P³ pattern
Commodity 3
P³ pattern
5
Commodity 5
Commodity 2
P³ pattern
risk classification
P³ - model
preventive
Commodity 1
external quality costs
• Poka Yoke 2012
2013
2014
2015
2016
2017
• Reduce Quality Costs
€
• Eliminate Quality Risks • Reduce Maintenance Costs
© foQusQM 2012
• Increase Competitiveness
foQusQM Company Presentation
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Path of development Qualification by foQusQM through „client emphasis“ and VDA 6.3 systematic Actions
Audit P7
Innovation
Audit P6
Innovation
Actions
Audit P5
© foQusQM 2012
Productivity
Actions
Potential
self-initiative (Paradigm)
Time foQusQM Company Presentation
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Customer benefits costs / profit
product quality assurance vs. process quality assurance
Savings due to decreasing quality costs
Savings
Hard Savings due to reduction of:
Quality costs
cost-benefit ratio Project costs
End of project
X
• External quality-control / static quality testing e.g. inspectors • Re-working costs • Supplier's error rate • Maintenance costs • Unplanned standstill periods
X
time
• Claim costs • Burden costs
Break-Even-Point
© foQusQM 2012
Zero-defect program Reduction of process risks Lessons learned foQusQM Company Presentation
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foQusQM Business Areas
complete Best-Practice-Program from one partner
Business Activities of foQusQM GmbH
Audits & Processes
Supplier qualification
Purchasing & Sales
Training & Coaching
= Stuttgart © foQusQM 2012
= Istanbul = Hamburg
foQusQM Company Presentation
9
Supplier qualification Market 46 4 7
31 5
22 4 5
4 35 22
13
2007
2008
2009
Process
… … . . … .
Methods
© foQusQM 2012
People
• • • • •
Suppliers with quality problems (claims, insolvencies, relocations) Suppliers that failed in a customer audit Potential suppliers willing to supply OEMs OEMs targeting to improve their supplier management OEMs targeting to integrate their escalation process
• • • •
Inspector-Resident engineer (static quality assurance) Process-Resident engineer (process-orientated quality assurance) Design engineer (constructive approach) Project change management
• • • • • • •
SMART-cell (implementation of a multi supplier best-practice-loop within a commodity) RRS Resident Report System (tool based action tracking) A3 problem solving sheet and systematic, PDCA, T-Card-method Six Sigma, PFMEA, DFMEA Supplier development according to 5 phases model (process-orientated approach) OEM portal such as Mercedes-Benz: Dialog, NCM, Zeus, SQMS, Start, Smaragd CAD Tools: CATIA V5, SolidWorks; SolidCam, AutoCAD,
• • • •
Development engineer with more than 30 years of OEM experience Production engineer with premium OEM experience of many years technicians and foreman with longtime experience and knowledge of production International engineers from the co-operation partner: FAP³RIC: 3 industrial engineers, 3 mechatronics engineers, 4 mechanical engineers, 2 electrical engineers, 3 chemistry engineers (Focusing synthetics ,GRP and lacquer) foQusQM Company Presentation
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Resident program SMART-Cell VDA 6.3-Tool
PreAudit
00
PostAudit
Action Control
01
02
03
04
05
06
REAudit
ActionControl
07
timeline in months
08
09
10
11
Resident
12 Resident
A
foQusQM-Resident
Best practice loop
• • • • •
Audits with supplier classification Risk identification Problem detection Supplier qualification Initializing capacities
Competence center Stuttgart C
B
© foQusQM 2012
foQusQM-Resident
foQusQM-Resident
• Conference call with customers • Weekly RRS-Tool • Review with customer
foQusQM Company Presentation
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foQusQM 5-phases-model Achieving A-Supplier status by Supplier-Development-Tool within 12 months
timeline in Months
01
Process steps
© foQusQM 2012
Phases
1
02
03
04
05
06
07
08
09
10
5.1 - 5.7
6.1
6.2
6.3
6.4
6.5
6.6
7.1 - 7.6
2
3
PHASE 1
Initial audit (current state analysis & weak point analysis) Definition of project team at the supplier
PHASE 2
Preparation for P5 (Supplier Management) Interim audit for P5
PHASE 3
Preparation for P6 (process analysis/production) Interim audit for P6
PHASE 4
Preparation for P7 (customer care/customer satisfaction/service) Interim audit for P7
PHASE 5
Affirmation audit with foQusQM certificate
foQusQM Company Presentation
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4
12
5
12
Resident-Engineers – RRS
© foQusQM 2012
Implementation of a resident •
Resident engineer is constantly present at the customers factory
•
Implementation of measures according to VDA 6.3 through the resident engineer
•
Tool based tracking of measures and following actions
•
Constant measuring and evaluating the progress of the qualification through the resident engineer
•
Regular reporting to the customer with the tool based RRS
RRS – Resident Report System
foQusQM Company Presentation
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Example of practical method: T-Card
© foQusQM 2012
Implementation of the TCard-method by foQusQM for ensuring additional process validation. With this method also component variants can be covered. (creating component specific cards) development phase
1. At the beginning of each shift all T-Cards turned red by the foreman. Afterwards the T-Cards are released for the employees to handle them.
2. When the tasks are accomplished, the cards have be turned on green. Then there is to be set a check at ‘OK’ in the quality control sheet.
3. If the work has been controlled but it is not satisfying, the card still can be turned green though the check has to be set at N.OK. Furthermore the foreman has to be noticed. Then the foreman generates an action with responsibilities at the quality control sheet.
4. When the quality control sheet is filled out completely, it is discarded in the problem storage to detect repeating problems. At least the foreman and the management are responsible for the smooth flow of this system.
foQusQM Company Presentation
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Problem-Solving-Tools Variety of Problem-Solving-Tools Erfordernisse
S
Erfordernisse
I
Lieferanten
P
O
Prozess
Eingaben
Standardized methods
C
Ausgaben
Kunden
Prozessgrenzen Factor
Ranking
Ranking % Cumulative %
Delta diameter 104 Transition angle (steep/smooth) 91 Material grain (Walzrichtung) 83 Nominal case diameter 81 Type of material 73 Calibration mode (one step, stepwise) 62 Nominal Gap 58 Length of case calibrated area 48 Forming speed 48 Jaw surface finish 43 Use of lubricant on jaws/case 43 Material thickness 41 Length of cone interface (uncalibrated area) 40 Temperature (machine, case, ambient…) 38 Number of case calibration jaws (8; 12; 15…) 33 Type of weld seam 33 Cross-section / shape 0
Grundgesamtheit
Stichprobe
11,3%
11,3%
9,9%
21,2%
9,0%
30,3%
8,8%
39,1%
7,9%
47,0%
6,7%
53,8%
6,3%
60,1%
5,2%
65,3%
5,2%
70,5%
4,7%
75,2%
4,7%
79,9%
4,5% 4,4% 4,1%
84,3% 88,7% 92,8%
3,6%
96,4%
3,6%
100,0%
0,0%
100,0%
Todays situation
Show Stopper!
High Reduce Risk or Stop!
C
T
Improvement Step 1
Improvement Step 2
O
Probability of Occurence
PPAP
Minimize Risk / Keep an eye on!
P-Diagram A B C D E F G H
Be Cautious! Continue!
Low
Control Factors Delta Diameter (min, max) MaterialThickness Material Grain
Role (what does it do)
Levels 2 2 2
Level 1 Level 2 min 1,2 0
max 1,5 90
Level 3
spec. mm °
Low
High Impact on Project Success
Input Signal Nominal Diameter
System
Calibration of Case
Output Response
Springback [mm]
© foQusQM 2012
Noise Factors Ambient Temperature friction material parameter (e-modul) toleranz of form and position
Failure Modes Measurement failure beetween LLM and Faroarm
Optimierter Prozess
foQusQM Company Presentation
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Benefit of getting a qualified supplier Developing comprehensive for the requirements of audits according to VDA 6.3
Classification as quality-capable supplier (A) at OEMs •
Increased rating in the allocation process of new projects
•
•
higher balance scorecard rating at OEMs
•
Training in handling with audit requirements
•
Lower requirements in future OEM audits and prevention of claim audits
•
Balance between costbenefit-ratio
•
Development and implementation of best practice approaches in the forefront of the audit
•
Cost and capacity reduction for upcoming audits
+
Increased understanding of the audit method for all relevant people
Communication of the questionnaire
© foQusQM 2012
•
Quality issues are preventively solved
foQusQM Company Presentation
•
PPM-Rate reduction
•
Sustainable product quality
•
Implementation of stable processes
•
Implementation of quality methods beforehand (Poke Yoke)
•
OEM compliant reporting system according to VDA6.3
•
Reduction of rework and recheck
•
Avoiding of Scrap
•
Prevention of OEM focus(QHelp)
•
OEM expectation is communicated to the employees (coaching)
+
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foQusQM Business Areas
complete Best-Practice-Program from one partner
Business Activities of foQusQM GmbH
Audits & Processes
Supplier qualification
Purchasing & Sales
Training & Coaching
= Stuttgart © foQusQM 2012
= Istanbul = Hamburg
foQusQM Company Presentation
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Purchasing & Sales Market 46 4 7
31 5
22 4 5
4 35 22
13
2007
2008
2009
Process
… … . . … .
Methods
© foQusQM 2012
People
• • •
Companies intending to go global Companies which need an optimization in purchasing Companies targeting to expand their client portfolio
• • • • • •
Forward Sourcing (align the supply chain with the future needs of the company) Purchasing partnership Global Supply Chain Management & Development Constituting Customer-Supplier-Interface Support in negotiations Execution of tenders and bidding rounds
• • • • • •
Purchasing market analysis Sales market analysis TCO approach (Total Cost of Ownership) Supplier Assessment & Evaluation Creditworthiness analysis Quotation analyzes (purchasing & sales)
• •
Business engineer with more than 5 years international experience in purchasing Business engineer with international experience of many years in sales and project management M.A. Business Administration and Marketing with experience in marketing & CRM
•
foQusQM Company Presentation
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Forward-Sourcing 1 Customer: Catalog of requirements
Input customer: Market requirements
foQusQM: Forward Sourcing 1
Purchasing market analysis
2
Supplier pre-selection
3
Auditing
4
Qualification according to VDA 6.3
5
Conduct of negotiations
6
Supply-Chain-Management
Product requirements
© foQusQM 2012
Quality requirements
2
Output: Integrated Supply-Chain
3
Development and handover of a quality capable and integrated Supply-Chain in accordance to the customer requirements
Reduction of purchasing efforts – planning reliability – quality assurance – efficiency increase
Sustainable cost reduction foQusQM Company Presentation
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Why Supplier Management? Because of cost-intensity as well as supplier-controlling it makes sense to rank the suppliers according to their importance for the company.
The task is to focus on the main suppliers. At the internal Supplier Management there should be only those suppliers involved which are essential for the success of the company.
Supplier Management enables to get a realistic view of the Status Quo which represent the relation of expenses and earnings.
Supplier management also assists • to separate essential issues from inessentials, • to spot rationalization focuses, • to increase operating efficiency and • to back decision that have been made.
© foQusQM 2012
foQusQM Company Presentation
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Supplier Management Do Auditing
Plan Classification
© foQusQM 2012
Supplier classification according to A-B-C ranking systematic Identification of risky suppliers Supplier assessment Component-Risk-Classification
Process audit according to VDA 6.3 Audit by order of customers for Tier-NSuppliers
Act
Check
Development of new suppliers
Development of existing suppliers
Identification of potential suppliers Relocation management (planning, execution & process approval) Approval of new suppliers “by order” with Source-Evaluation Auditing-tool
Audit preparation for a quality capable ASupplier according to foQusQM‘s 5Phases-Model Action Planning & Tracking according to the results of audits analogical to Best Practice TRS (Technical Revision Supplier)
foQusQM Company Presentation
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Sales partnership
Sales partnership
Increase of efficiency •
Lean communication due to customer interface: foQusQM
• •
Usage of the broad foQusQM network in multiple industries Valuable contacts within different industry fields by reason of former foQusQM projects
•
Experience with international business dealings
•
International sales managers
Increase of competitiveness •
Professionals CRM
•
Increase of customer satisfaction
•
Increase in sales due to new business
© foQusQM 2012
•
Customer service via KeyAccount-Manager
Expansion & globalization
foQusQM Company Presentation
22
foQusQM Business Areas
complete Best-Practice-Program from one partner
Business Activities of foQusQM GmbH
Audits & Processes
Supplier qualification
Purchasing & Sales
Training & Coaching
= Stuttgart © foQusQM 2012
= Istanbul = Hamburg
foQusQM Company Presentation
23
Training & Coaching Market 46 4 7
31 5
22 4 5
4 35 22
• Companies with the target to develop their own experts with external specialists
13
2007
2008
2009
Process
… … . . … .
Methods
© foQusQM 2012
People
• • • • •
VDA 6.3 Awareness through training in VDA questionnaire with examples Junior staff development through employee qualification towards auditor and claim manager Executive coaching in cooperation with OEMs and conflict talks Supplier individual product coaching according to commodity (internal as well as external) Training in product liability issues according standards of automotive sector with practical examples for executives and employees • Training in human resources management : From employment to assessment • Misalignment management: Implementation of return-to-work interviews and integration of long-term-sick employees • • • • • •
APQP, PPAP, FMEA, Six Sigma VDA 6.3, ISO/TS 16949, ISO 14001, ISO 50001 Kanban, FIFO KAIZEN, KVP, Poka Yoke Lean Management, 5S Problem-solving-methods, 8D
• Senior quality manager with 33 years experience as director of quality management in the automotive industry • Senior Graduate Engineer with 35 years work experience in R&D dep. at a premium OEM • VDA 6.3 LEAD-Auditor with 20 years work experience at a premium OEM and specialization in supplier auditing, claim editing & sampling • Senior human resources manager with 30 years work experience at a Premium OEM with focus at misalignment management • Young experts specialized in customer specific areas foQusQM Company Presentation
24
Training of Lead-Auditors Theoretical Part
Practical Part
New Auditors Participation in module 1 - 10
New Auditors min. 2 attendant Audits and one Audit in lead function An audit plan is going to be created . foQusQM is monitoring the creation process only as Co-auditor and will intervene as less as possible and as much as necessary.
Witness Audit
© foQusQM 2012
= Theoretical Content = Practical Content
foQusQM guarantees to qualify auditors who will be technically as well as methodically on top level.
= Practical Closing foQusQM Company Presentation
Release and nomination to a LEADAuditor according to VDA 6.3 including foQusQM evaluation and release certification. 25
Customer Portfolio …. Projects at:
Audits at:
© foQusQM 2012
Customer:
foQusQM Company Presentation
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© foQusQM 2012
Thank You!
foQusQM Company Presentation
27
© foQusQM 2012
BACK-UP
foQusQM Company Presentation
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Training of Lead-Auditors Module 1
Module 2
Quality management basics
DIN/ISO 9001
Quality statistics
ISO TS 16949
Cpk/Cmk
Module 10 Closing theory VDA 6.3 coaching for external auditors
Module 3
Module 9 FMEA for Auditors
Module 5
Module 4 VDA Auditor to intern Auditor
Module 8 Training in product liability
Module 7 Product management training
Practical training of LEAD-Auditors
Module 6 Environmental and work security training 18001
Modul 11
© foQusQM 2012
= theoretical content = closing theory = practical content
1. Attendance
2. Attendance
3. Attendance
of a LEAD-Auditor
of a LEAD-Auditors
In LEAD-Function
- Preparation - attending internal preliminarytalk - conducting of the introductory talk at the supplier
- preparation - Conducting an internal preliminary-talk - Conducting of the introductory and closing talk at the supplier - Generating of the evaluation and closing report
foQusQM Company Presentation
- Completely self-consistent Execution of the audit - adequacy of the auditor According to assessment criteria “audit quality” - professional competence available 29
