ASQ Auto Webinar Core Tools Slides 101203

Automotive Core Tools Fundamentals Webinar
Dec 2, 2010
Thank You for Joining
ASQ Automotive Division
Ha Dao
Agenda
Polls Housekeeping Items About ASQ Automotive Division Webinar Series Automotive Core Tools Questions & Answers
Ha Dao
Housekeeping Items
Everyone is muted Session is being recorded Session will last about 90 minutes Participate thru polls, chat & questions Will answer questions at the end
Last 10 minutes Please type your questions in panel box Go to www.asq-auto.org for presentation slides
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Special Recognition
Ken Coll - Continental Automotive Jennifer Schneider - Continental Automotive Kevin Wu - ASQ China Dick Shainin - Shainin LLC
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Your Moderator
About Me
Ha Dao, Chair
ASQ Automotive Division ASQ Fellow MBB & Red X Master 15+ Yrs of Experience in Automotive Industry Troy, Ohio hadao@woh.rr.com
Ha Dao
ASQ Automotive Division is a Division of ASQ, the Global Voice for Quality.
ASQ Automotive Division has more than 3200 members globally, who share a common interest in the automotive industry. Members include professionals from almost every discipline in the vehicle manufacturing and supplier business in the automotive, heavy-truck, off-highway, agricultural, industrial and construction equipment industries.
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ASQ Auto Webinars Series 2010-2011

The ASQ Automotive Division is pleased to present a regular series of webinars featuring leading international experts, practitioners, academics, and consultants. The goal is to provide a forum for the continuing education of automotive professionals.
The presentation slides are posted on our website www.asq-auto.org. Recorded webinars are also available for viewing after the events. To register for a webinar, see the listings at our website www.asq-auto.org.
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Call for Speakers & Volunteers
ASQ Automotive Division is seeking Topics and Speakers for our Webinar Series and for our 2011 Symposium.
ASQ Automotive Division is seeking volunteers for leadership positions to serve on the Division Council.
Contact Ha Dao, Chair ASQ Automotive Division hadao@woh.rr.com
Ha Dao
ASQ Automotive Division Webinar Series
Automotive Core Tools Fundamentals Webinar

December 2, 2010
7:00 pm 8:30 pm EST Ken Coll, Quality Manager Continental Automotive
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ASQ Automotive Division Webinar Series

Speaker: Ken Coll, Quality Manager, Continental Automotive Topic: Automotive Core Tools Fundamentals Webinar Date: December 2, 2010 7:00 pm 8:30 pm Eastern Contact Info:
1 Continental Drive, Auburn Hills, MI 48326 kencoll@ameritech.net - 248-393-5868 www.asq-auto.org
Abstract:
The six Automotive Core Tools (APQP, FMEA, Control Plan, PPAP, SPC, and MSA) are core requirements for any supplier in the automotive industry. Proper use and application of the tools is essential to an effective quality system and satisfied customers. This webinar gives an overview of the Core Tools, reviews the basic requirements and purposes of each, and looks at barriers to effectiveness. Ken Coll is a Quality Manager for Continental Automotive, and has over 35 years of experience in the automotive industry as a Tier 1 supplier. His responsibilities include continual improvement, Lean Six Sigma, quality management systems, and quality auditor training and development in North America. Ken has developed and taught a variety of quality and problem solving courses and has worked extensively with QS 9000 and TS16949 quality standards. His career has spanned production and corporate facilities, and he has worked as a production worker, material handler, inspector, quality systems auditor, and quality engineer. He holds a B. A. degree in Management and Organizational Development from Spring Arbor University, an MBA from Northwood University, ASQ Quality Engineer Certification, is a Lean Six Sigma Black Belt, TS16949 lead auditor and is certified as a Master Trainer for TS16949 by Plexus International.
Biography
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Training Goals and Objectives
What This Training Will Do For You:

Provide an understanding of the basic requirements of each Core Tool
Review the purpose and intent of each Core Tool

Look at pitfalls (barriers to effectiveness) of each Core Tool Help you improve customer satisfaction
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Automotive Core Tools

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Automotive Core Tools Advanced Product Quality Planning (APQP) Failure Mode and Effects Analysis (FMEA) Control Plan Production Part Approval Process (PPAP)
Statistical Process Control (SPC)

Measurement System Analysis (MSA)
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Examples: AIAG Blue Book Manuals
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Examples: Other Manuals
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Core Tools in ISO/TS 16949:2009
APQP: 7.1 (Note)
FMEA: 7.3.3.1, 7.3.3.2

Control Plan: 7.5.1.1, Annex A Product Approval Process (PPAP): 7.3.6.3
SPC: 8.1.2, 8.5.1.2

MSA: 7.6.1
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APQP
Advanced Product Quality Planning
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APQP
What is it?
Management of product development
Why do we use it?

To understand what our customer wants and fulfill those wants
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ADVANCED PRODUCT QUALITY PLANNING

CONCEPT INITIATION/ APPROVAL
PROGRAM APPROVAL
PROTOTYPE
PILOT
LAUNCH
PLANNING
PRODUCT DESIGN AND DEV. PROCESS DESIGN AND DEVELOPMENT PRODUCT & PROCESS VALIDATION
PLANNING
PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION
Planning INPUTS | Planning OUTPUTS
Product Design & Dev. INPUTS | Product Design & Dev. OUTPUTS
Process Design & Dev. INPUTS | Process Design & Dev. OUTPUTS
Product & Process Validation INPUTS | Product & Process Validation OUTPUTS
Feedback, Assessment & Corrective Action INPUTS | F, A & CA OUTPUTS
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APQP Plan and Define Phase
Concept Initiation/Approval
Inputs:
Voice of the Customer Market Research (Including OEM Vehicle Timing and Volume Expectations Historical Warranty and Quality Information
Team Experience
Business Plan/Marketing Strategy Product/Process Benchmark Data Product/Process Assumptions Product Reliability Studies Customer Inputs
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APQP Plan and Define Phase
Concept Initiation/Approval
Outputs:
Design Goals
Reliability and Quality Goals Preliminary Bill of Materials Preliminary Process Flow Chart Preliminary Listing of Special Product and Process Characteristics Product Assurance Plan
Management Support
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APQP Product Design and Development Phase
Program Approval
Design Outputs:
Design Failure Mode and Effects Analysis (DFMEA) Design for Manufacturability and Assembly Design Verification
APQP Outputs:
New Equipment, Tooling and Facilities Requirements Special Product and Process Characteristics Gages / Testing Equipment Requirements Team Feasibility Commitment & Management Support
Design Reviews
Prototype Build -- Control Plan Engineering Drawings (Including Math Data)
Engineering Specifications
Material Specifications Drawing and Specification Changes
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APQP Process Design and Development Phase
Prototype
Outputs:
Packaging Standards and Specifications
Product/Process Quality System Review

Process Flow Chart Floor Plan Layout
Process Failure Mode and Effects Analysis (PFMEA)

Characteristics Matrix Pre-Launch Control Plan Process Instructions Measurement System Analysis Plan Management Support Preliminary Process Capability Study Plan
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APQP Product and Process Validation Phase
Pilot
Outputs:
Significant Production Run
Measurement Systems Evaluation Preliminary Process Capability Study
Production Part Approval

Production Validation Testing Packaging Evaluation Production Control Plan Quality Planning Sign-Off and Management Support
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APQP Feedback, Assessment and Corrective Action Phase
Launch
Outputs:
Reduced Variation Improved Customer Satisfaction Improved Delivery and Service Effective Use of Lessons Learned/Best Practice
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ADVANCED PRODUCT QUALITY PLANNING
Pitfalls
APQP treated as a Quality Department Responsibility
APQP a separate process, not integrated into product development Key stakeholders brought in late (quality, production, suppliers) Milestones and deliverables ignored No top management involvement/support
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FMEA
Failure Mode and Effects Analysis
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FMEA
What is it? A risk analysis of a part or process Why do we use it?
To find and fix a problem before something breaks or someone gets hurt
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Types of FMEAs
Design FMEA Process FMEA
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Types of FMEAs
Others:
System FMEA
Concept FMEA Environmental FMEA Machinery FMEA Software FMEA
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FMEA Process
Subsystem Potential Failure Mode Potential Effect(s) of Failure S e v Function Requirements C Potential O l Cause(s)/ c a Mechanism(s) c s of Failure u s r Current Controls Prevention Detection D e t e c R. Recommended Responsibility P. Action(s) & Target N. Completion Date Action Results Actions S O D Taken e c e v c t R. P. N.
What are the Effects?

What are the Functions, Features or Requirements?
How bad is it?
What can be done? Design Changes Process Changes Special Controls
What can go wrong? No function Partial / Over /Degraded Function Intermittent Function Unintended Function
What are the Cause(s)?
How often does it happen?
Changes to Standards, Procedures, or guides
How can this be prevented and detected?
How good is this method at detecting it?
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Risk Action Strategies
1st Priority is Severity. Severity has a direct impact on the customer. 2nd Priority is Criticality (Severity times Occurrence: S x O). Criticality evaluates the risk that an event with a high impact on the customer will occur. 3rd Priority is RPN. RPN evaluates the ability to detect and contain poor quality.
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Failure Mode and Effects Analysis
Pitfalls
FMEA started late in the development process (just in time for PPAP!) FMEA never updated after release FMEA not updated from nonconformity corrective actions Right side (action area) is blank RPN thresholds FMEA written by one person FMEA treated as a Quality Department Responsibility
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Control Plan
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Control Plan
What is it? A summary of controls used to make sure my customer gets good product Why do we use it?
To make sure controls are used and stay in place
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Control Plan
CONTROL PLAN
Prototype Control Plan Number Pre-Launch Production Key Contact/Phone Core Team Supplier/Plant Approval/Date Supplier Code Other Approval/Date (If Req'd.) CHARACTERISTICS NO. Date (Orig.) Date (Rev.)
Part Number/Latest Change Level Part Name/Description Supplier/Plant
Customer Engineering Approval/Date (If Req'd.) Customer Quality Approval/Date (If Req'd.) Other Approval/Date (If Req'd.)
MACHINE, PART/ PROCESS NAME/ DEVICE, PROCESS OPERATION JIG,TOOLS, NUMBER DESCRIPTION FOR MFG.
METHODS SPECIAL CHAR. PRODUCT/PROCESS EVALUATION/ SAMPLE PRODUCT PROCESS CLASS SPECIFICATION/ MEASUREMENT SIZE FREQ. TOLERANCE TECHNIQUE
CONTROL METHOD
REACTION PLAN
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Control Plan Elements

TS 16949 Annex A
A.2 Elements of the control plan The organization shall develop a control plan that includes, as a minimum, the following contents. a) General data control plan number, issue date and revision date, if any, customer information (see customer requirements), organization's name/site designation, part number(s), part name/description, engineering change level, phase covered (prototype, pre-launch, production), key contact, part/process step number, process name/operation description. b) Product control product-related special characteristics, other characteristics for control (number, product or process), specification/tolerance. c) Process control process parameters, process-related special characteristics, machines, jigs, fixtures, tools for manufacturing. d) Methods
evaluation measurement technique,

error-proofing, sample size and frequency, control method. e) Reaction plan and corrective actions reaction plan (include or reference), corrective action.
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Control Plan
Pitfalls
Control plan and PFMEA not aligned
Control plan and operator instructions not aligned Control plan out of date
Control plan not updated from nonconformity corrective actions
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PPAP
Production Part Approval Process
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PPAP
What is it? Requirements for approval of production parts. Why do we use it? To make sure that I understand all my customer requirements, and that I can meet them under actual production conditions.
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PPAP
1 Design Records
2
3 4 5
Authorized Engineering Change Documents

Customer Engineering Approval Design FMEA Process Flow Diagrams
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Initial Process Study
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13 14 15
Qualified Laboratory Documentation

Appearance Approval Report Sample Production Parts Master Samples
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7 8 9
Process FMEA
Control Plan Measurement System Analysis Studies Dimensional Results
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Checking Aids
Customer-Specific Requirements (Records) Part Submission Warrant Bulk Material Requirements Checklist
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Material / Performance Test Results
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Production Part Approval Process
Pitfalls
PPAP is treated as a separate process, rather than integrated into product development Incomplete PPAP Assuming that submission levels are whats required, rather than whats submitted
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SPC
Statistical Process Control
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SPC
What is it?
A collection of statistical methods, especially control charts, used to analyze and control a process
Why do we use it? To know when processes change and respond accordingly
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Variation
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Distributions can vary in Location

Location (Center): 3 key measures
Mean = Average or
Median = Middle (by count) Mode = Most often
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Distributions can vary in Spread
Spread: 3 key measures Range = R
Standard Deviation =
or s
Variance =
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Distributions can vary in Shape
Normal Distribution
68.25%
95.46%
99.73%
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Control vs. Capability

If only common causes of variation are present, the output of a process forms a distribution that is stable over time and is predictable
Common and Special Causes
If special causes of variation are present, the process output is not stable over time
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Control vs. Capability
Statistical Control
In- Control Out-of-Control
(Common Cause)
Acceptable
(Special Cause)
Variation (Capability)
Case 1
Case 3
Unacceptable
Case 2
Case 4
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Cp, Cpk, Pp & Ppk
Cp / Pp: can the car fit into the garage?
Cpk / Ppk: does the car fit into the garage?
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Measures of Process Capability

(Capability Index)
Within Subgroup Variation
Overall Variation
Within Subgroup Variation
Overall Variation
if stable
Performance
Ppk
Cpk
Capability If centered
Pp
Cp
Overall
Within
Kenneth J Kortge
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Capability Metrics Acceptance Criteria

Typical:
Index 1.67
Acceptable
May Be Acceptable
May require an improvement plan
1.33 Index 1.67

Index 1.33
Not Acceptable
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2 Types of Data
Variable
Attribute
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Variables Charts
Typical:
Chart Type X-Bar & R Median Individual & Moving Range (MR)
Primary Usage
Routine monitoring of manufacturing processes
Usually used as a monitoring tool for product or processes
Used when only one sample is possible
What Is Charted
Plots the average size and the range of the part sizes
Plots the individual sizes of the parts and the median of the part sizes
Plots the sample size and the moving range of the sample size
Sample Subgroup Size
Usually 3 to 6
Should be an odd number: 3, 5, 7, etc.
One
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Attribute Charts
Typical:
Chart Type Primary Usage P Chart Used for analyzing proportion or percent nonconforming or defective parts nP Chart Used for analyzing the number nonconforming or defective parts C Chart Used for analyzing nonconformities or defects U Chart Used for analyzing nonconformities per unit
What is Charted
Plots the proportion or percent of the nonconforming units Variable
Plots the number of nonconforming items
Plots the count of all nonconformities found in the sample Fixed
Plots the average number of nonconformities in each sample Variable
Sample Subgroup Size
Fixed
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X & R Chart
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How Control Charts Work

UCLX

LCLX
UCLX
LCLX
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Special Cause Criteria
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Special Cause Criteria
1. Most measurements cluster around the center (average) line 2. A few measurements approach the edges (control limits) 3. No measurements outside the control limits 4. Same number of measurements on both sides of the center (mirror image) 5. Random (no patterns)
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Statistical Process Control
Pitfalls
Ignoring out of control conditions
Comparing control limits to spec limits Making process adjustments without understanding the source of the special cause variation Putting SPC charts on everything
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MSA
Measurement Systems Analysis
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MSA
What is it?
A collection of statistical methods used to assess how much I can trust the information from a gauge Why do we use it?
Since all my information about a part/process comes from gauges, I need to know when the gauge information is dependable, and do something when its not
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Bias: difference between the measurement and the "true" value
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Stability: change in bias over time
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Linearity: change in bias across expected range of measurements
Note that unacceptable linearity can happen in a variety of ways. Do not assume a constant bias.
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Gage Repeatability and Reproducibility = GRR = R&R

Variable, replicable measurements
Typical:
10 Parts 3 Appraisers 3 Trials
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GRR / R&R
2 GRR = 2 Reproducibility
2 Repeatability +
% Total Variation vs. % Tolerance Number of Distinct Categories (NDC)
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Repeatability: gage-induced variation
Appraiser A
Repeatability
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Reproducibility: operator-induced variation
Reproducibility
Appraiser
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The Effect of Measurement Error

Observed Actual
Total Variation = Process Variation + Measurement Variation
Total
Process
Measurement
Think of a right triangle Measurement Variation
Process Variation
Kenneth J Kortge
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The Effect of Measurement Error

Total Variation = Process Variation + Measurement Variation
Total
Process
Measurement
Measurement Variation
What You Want to Know

Kenneth J Kortge
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Gage R&R Acceptance Criteria (Typical)

% R&R
Under 10% error Acceptable 10% - 30% error May be acceptable based upon importance of application, cost of measurement device, cost of repair, etc. Over 30% error Not Acceptable. Every effort should be made to improve the measurement system
Number of Distinct Categories (NDC):

Greater than or equal to 5 Acceptable
Less than 5 Generally Not Acceptable
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Measurement Systems Analysis Pitfalls

Using MSA to obtain a number, rather than to understand gage variation Not documenting a conclusion and any actions needed, as part of the study Not conducting MSA for all gages on the control plan (TS 16949 requirement) Not validating Software (TS 16949 requirement) Using wrong analysis method (non-replicable, attribute, etc.)
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Automotive Core Tools Advanced Product Quality Planning (APQP) Failure Mode and Effects Analysis (FMEA) Control Plan Production Part Approval Process (PPAP)
Statistical Process Control (SPC)

Measurement System Analysis (MSA)
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Questions & Answers

Please type your questions in the question box
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Contact Us
ASQ Automotive Division Ha Dao, Chair www.asq-auto.org hadao@woh.rr.com (937) 760-4689 2590 Merrimont Drive Troy, OH 45373
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Thank You for Attending!
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Automotive Core Tools Fundamentals Webinar

Thank You for Joining

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

ASQ Auto Webinars Series 2010-2011

Call for Speakers & Volunteers

Contact Ha Dao, Chair ASQ Automotive Division hadao@woh.rr.com

ASQ Automotive Division Webinar Series

Automotive Core Tools Fundamentals Webinar

ASQ Automotive Division Webinar Series

ASQ Automotive Division

Training Goals and Objectives

What This Training Will Do For You:

Review the purpose and intent of each Core Tool

ASQ Automotive Division

Automotive Core Tools

Statistical Process Control (SPC)

Automotive Core Tools

ASQ Automotive Division

Automotive Core Tools

ASQ Automotive Division

Core Tools in ISO/TS 16949:2009

APQP: 7.1 (Note)

FMEA: 7.3.3.1, 7.3.3.2

SPC: 8.1.2, 8.5.1.2

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

Management of product development

Why do we use it?

ASQ Automotive Division

ADVANCED PRODUCT QUALITY PLANNING

PRODUCTION FEEDBACK ASSESSMENT AND CORRECTIVE ACTION

Planning INPUTS | Planning OUTPUTS

Feedback, Assessment & Corrective Action INPUTS | F, A & CA OUTPUTS

ASQ Automotive Division

APQP Plan and Define Phase

ASQ Automotive Division

APQP Plan and Define Phase

ASQ Automotive Division

APQP Product Design and Development Phase

APQP Process Design and Development Phase

Product/Process Quality System Review

Process Failure Mode and Effects Analysis (PFMEA)

APQP Product and Process Validation Phase

Production Part Approval

ASQ Automotive Division

APQP Feedback, Assessment and Corrective Action Phase

ASQ Automotive Division

ADVANCED PRODUCT QUALITY PLANNING

ASQ Automotive Division

ASQ Automotive Division

ASQ Automotive Division

Design FMEA Process FMEA

ASQ Automotive Division

ASQ Automotive Division

What are the Effects?

How bad is it?

What can be done? Design Changes Process Changes Special Controls