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Case Study

Case Study. Large Automotive OEM – FMEA Managed Service. Failure Mode & Effects Methodology. Process Flow. Block Diagram. Customer Requirements. Design Inputs. Process FMEA. System FMEA. Control Plans. Shop Floor Checklists. Automotive OEM – FMEA Managed Service.

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Case Study

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  1. Case Study Large Automotive OEM – FMEA Managed Service

  2. Failure Mode & Effects Methodology Process Flow Block Diagram Customer Requirements Design Inputs Process FMEA System FMEA Control Plans Shop Floor Checklists

  3. Automotive OEM – FMEA Managed Service Design Failure Mode and Effects Analysis -- Distribution of Recommended Actions After AQP Before AQP

  4. Initial Quality of U.S. and Import Brands 1999-2010 Note: Import Brands Include Europe and Asia

  5. Case Study Large Aerospace Engine Manufacturer

  6. New Product Introduction & PPV Program Start Experimental Production Product & Process Planning PPV Activities Consolidation Planning Product Design and Dev. Ongoing Part & Process Control Process Design and Development Product and Process Validation Industrialization Production Corrective Action Board activity Plan & Define Program Product Design & Development Verification Process Design & Development Verification Product & Process Validation CAB Activity

  7. 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

  8. Case Study Truck – System Supplier

  9. Operations Excellence MANUFACTURING Materials Purchasing FUNCTIONAL EXCELLENCE Quality 6S/VISUAL WORKPLACE Team Skills Global 8D FOUNDATIONAL EXCELLENCE QOS TS16949/APQP/PPAP

  10. Truck Industry Large Sub System Provider 187 DPM

  11. Semiconductor Industry Transition Semiconductor Assembly Council – Representing 95% of Chip Industry Outside Japan

  12. Semiconductor Industry Methodology 8-D Customer Involvement Similar to Aerospace Industry MSA, SPC, and Process Control ISO TS 16949 plus APQP and PPAP

  13. 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

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