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Valmet Automotive

Quality Management
March 2015

INTERNAL

Valmet Automotive

March 2015

INTERNAL

Management system approvals

Based on the company policies

Process-oriented

Fulfill the relevant quality,


environmental and safety standards as
well as the specific requirements of
customer
Core processes

Serial production

The quality system fulfils the following


standards

Product launch

ISO/TS 16949:2009 (Quality)


ISO 14001:2004 (Environment)
OHSAS 18001:2007 (Safety)

The quality, environmental and safety


systems are certified by a third party

Valmet Automotive

March 2015

INTERNAL

Management system approvals

Quality:
1995
1999
2003

ISO 9001
QS-9000
ISO/TS 16949

Valmet Automotive

March 2015

Environment:
2001
ISO 14001

Safety:
2012

OHSAS 18001

INTERNAL

Quality objectives
The key targets are set and reviewed together
with customer

Internal targets are set by the management based on


the key targets

Action plans to achieve the targets


Management monitors the achievement of the
targets and improvement plans

Company management sets and reviews companylevel improvement projects

Process owners set and review process-related


improvement projects

Valmet Automotive

March 2015

INTERNAL

Main process KPIs


FTOK (first time OK rate-%)
Product audit (index, defect/car)
Delivery accuracy (%)
Productivity (h/car)
These main KPIs are base for our bonus-system.

Valmet Automotive

March 2015

INTERNAL

Quality audits

System audits (internal)

Effectiveness of the management system is


systematically reviewed

Management sets the plan and reviews the results


and corrective actions

Process audits

To evaluate the effectiveness of the production process


and sub-processes

Based on an audit plan and done by experts from the


production departments

Reviews of audit findings and preventive and corrective


actions are managed by the production departments

Product audits

Performed by the quality department according to the


procedure of customer.

Performance of the product audit is secured with


monitoring audit.

COP audits

Done by authorities from different markets (China, Japan, ...)

Valmet Automotive

March 2015

INTERNAL

Management reviews Quality issues

Management team

- Target setting (goals and


objectives)

Production management
team

- Customer satisfaction
- Follow-up of the target fulfillment
- Steering of development projects
- Steering and reviewing the
business line's/plant's operations
- Steering of the management
system

Local department meetings

- Steering of the plant operations


- Steering of continuous
improvement projects
- Customer service
- Follow-up of the target fulfillment

Production meetings

- Steering of the plant operations


- Production conditions
- Customer service
- Short term action

VA Management reviews

Valmet Automotive

March 2015

Quality assurance in
production

INTERNAL

Quality management
Serial production control

10

Quality control plan is the basis for the process control


supported by work and inspection instructions

Team members on the line are responsible for


the assembly and the quality of their work

Separate inspection stations after major production steps

Quality reporting system provides immediate


feedback of the quality for corrective actions

Final approval of the cars is performed according to the


standards and procedures

Valmet Automotive

March 2015

Quality assurance during serial production


Management reviews
Process audits
System audits
Quality cost report
Quality-committee
Quality improvement meetings

Customer quality targets


Product specifications
Supplier part specifications
The standards / Regulations

Quality
management

Customer
requirements

Continuous
improvement
Action plans
Problem solving process
Improvement projects (8D, Six sigma)
Change management
Market feedback process
Control of non-conforming products

Process
definitions

Quality control
&
measurements

Product audit
Quality control points
End of line tests
Material laboratory analysis
Online/offline (3D) mesurings
Control of process parameters
11

Valmet Automotive

March 2015

INTERNAL

Quality assurance plan


Quality control plans
FMEA
Internal quality targets
Operational & work instructions
Preventive maintenance
Production and material planning

INTERNAL

Quality control stations


The purpose of the control activities is to prevent defects from
advancing in the process and to ensure that the quality of the
product is acceptable for the next process phase.
The inspections and tests which are carried out during the
manufacturing process are documented in the quality control
plans. With these inspections and tests the compliance of the
product with customer requirements is verified.
After every main process phase agreed product characteristics
are inspected in separate internal quality control stations to
ensure that these conform to stated specifications
Feedback to production line according to the feedback process

12

Valmet Automotive

March 2015

INTERNAL

Process follow-up / analysis


Q-targets for each process (body, paint, assembly, material, design)
Q-costs are reported at management meetings
Problem analysis are done acc. 8D-method
Weekly Q-improvement meetings, reporting with 8D
Continuous improvement process
SixSigma method in use (3 BB at Valmet)
Q-Committee monthly meetings
3D measurements (off-line)
- 3 measuring units (DEA and Johansson)
- 2 portable measuring units (Faro-arm)
On-line measurements at production line (body)

13

Valmet Automotive

March 2015

INTERNAL

Production quality assurance


Preventive & corrective actions in production phase
Flow chart
- New product
- Process change

PFMEA
- New product
- Process change

Control plan
- New product
- Process change
- New control methods

Reaction priority
1. Design change
2. Process change
3. Control
14

Valmet Automotive

March 2015

Operator instructions
- New product
- Process change
- New control methods

Results/feedback
- Production
- Final audit
- Customers

Failure ranking list

INTERNAL

Production quality assurance


Online
Measuring
Station

Metal & Body


appearance
Inspection

Quality Audit
Body

EC
Inspection

Primer
Inspection

Top coat
Inspection

Final Insp.
Paint

LM 2
Inspection

ECOS

LM 1
Inspection

Diagnosis

Delivery
check

Cpk-Values / Offline Measuring Station

Body shop

Roller test

Wheel &
Light
alignment

Paint shop

Water
test

offline

Diagnosis

Paint
Inspection

Underbody
check

LM 3
Inspection

ECOS

Assembly shop

Test drive

ECOS

Product Audit

15

Valmet Automotive

March 2015

INTERNAL

Body shop / Quality concept


OVILINJA

Mercedes A-class manufacturing


ALUSTALINJA
InLine Mittaaminen
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm

KESKILATTIALINJA
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Ksnhitsaus visuaalinen
tarkastus
Ksnhitsaus momenttitarkastus

OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus
Laserhitsaus - VISIR

VIIMEISTELYLINJA
Visuaalinen pintalaatutarkastus
Ovien pulttien momenttitarkastus
Luukkujen sovitemittaus
Hitsaamon laadunmittaus (LM)

KORILINJA
InLine Mittaaminen
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm

16

ETUPLINJA

TAKAPLINJA

OffLine mittaus
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Liimauksen visuaalinen tarkastus

OffLine mittaus
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Liimauksen visuaalinen tarkastus
Lyhytkaarihitsaus visuaalinen
tarkastus
Lyhytkaarihitsaus
momenttitarkastus

Valmet Automotive

March 2015

SIS- JA ULKOSIVULINJAT
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus

LUUKKULINJA
Valssauksen visuaalinen
tarkastus
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus
Laserjuottamisen visuaalinen
tarkastus

INTERNAL

Body shop / Quality

= OffLine measuring
= InLine measuring
= Fit&flush measuring

Geometry measuring concept


ZB Radeinbau VO RE ZB Lngstrger RE
002L01
001L01

ZB Radeinbau LI

ZB Radeinbau VST RE
005A01L

ZB Radeinbau VO LI ZB Lngstrger LI
002R01
001R01

ZB Stirnwand
010A01

ZB Fahrertr LI
530

ZB Fondtr LI
530

ZB Rckwandtr
570

ZB Radeinbau VST LI
005A01R

560

530

ZB Motorhaube

ZB Fahrertr RE

530

320A
ZB Lngstrger VST HI LI

305A01L
Quertrger LI

Lngstrger IN OB VO RE
003R01

ZB Vorbau Lngstrger IN OB VO LI

025

003L01

ZB Seitenwand IN RE
410L

ZB Seitenwand AU RE

ZB Fondtr RE

ZB Seitenwand AU VST RE

425R

435R
325A
Quertrger RE
ZB Heckboden
340

ZB Z2.1

ZB Unterbau
630

ZB Z2.3
790

745

325A
ZB Lngstrger VST HI RE

305A01R
ZB Radeinbau RE

320A

17

Valmet Automotive

245

ZB Hauptboden

March 2015

410R

425L

ZB Seitenwand IN LI

ZB Seitenwand AU LI

435L

ZB Seitenwand AU VST LI

CONFIDENTIAL

INTERNAL

Paint shop process description and Quality controls


Pre-treatment
From
body
shop

Degreasing Degreasing
spray
dip

Rinse
spray

Activation Phosphate Phosphate


dip
dip
spray

Rinse
dip

Rinse
spray

Sealing
Sealing
touch-up

Robot
sealing

Robot sealing/
SAM

Manual
sealing

Passivation
spray

Rinse
dip

Rinse
spray

EC
BS surface
touch-up

EC
oven

DIW Rinse
spray

UF Rinse
dip

UF Rinse
dip

UF Rinse
spray

Cathodic
immersion

Primer surfacer (WB)


Sealing
oven

EC touch-up
(dry)

Audit
1

Masking
station

Flash-off

Manual
ESTA
Back-up Flash-off
spraying application

Off-line
repair

Back-up

Robot
clear coat

Primer
oven

Audit
2

Clear coat
Top coat
oven

Manual
wiping

Base coat (WB)


Heated
flash-off

Recip.
base coat

ESTA
base coat

Manual
base coat

Primer
touch-up
(Moist)

Manual
wiping

Off-line
repair

Finishing

Rating
OK / NOK

Audit
3

Control

Cavity
treatment

Cavity
treatment
oven

To
general
assembly

Spot repair

NOK line

18

OK line

Valmet Automotive

March 2015

Sanding
rerunners

Audit
4

Quality concept Paint Shop

INTERNAL
TOP COAT

Line check- All vehicles


Top coat surface quality
Top coat appearance

PRETREATMENT

Quality Audit 3

Random sample min 1


body/shift

(Random sample min 1 body/shift)


Primer touch up quality
Top coat surface quality (body &
paint)
Visual color assessment
Colorimetry
Film thickness (EC, primer coat,
base coat and clear coat)

Phosphate surface quality


Phosphate coating weight
EC surface quality
EC layer thickness
EC roughness

KPIs
-FTOK % Top coat
-- Quality Audit 3

SEALING & SAM

Line check - All vehicles

PAINT SHOP FINISH

Robot seams position


Robot seams completeness

Line check - All vehicles

Quality Audit 1

Top coat finishing quality

(Random sample min 1


body/shift )
Body shop surface quality
EC surface quality (body & paint)
Seam sealant positioning
Seam sealant completeness
Seam sealant leak tightness
Seam sealant optical appearance
SAM positioning
SAM completeness
SAM film thickness

Quality Audit 4
(Random sample min 1 body/shift)
PRIMER

Line check - All vehicles


Masking tape completeness
Primer coat surface quality

Quality Audit 2
(Random sample min 1 body/shift )
EC touch up quality
Visible area seam sealant appearance
Primer coat surface quality (body & paint)
Masking tape positioning
Masking tape completeness

19

Valmet Automotive

March 2015

KPIs
-FTOK % Primer
- Quality Audit 2

EC TOUCH-UP

Line check - All vehicles


EC surface quality
SAM completeness
Visible area seam sealant
KPIs
-FTOK % EC
-Quality Audit 1

Orange peel (LW, SW, DOI)


Cavity wax completeness
Optical appearance of the seam
sealant in the visible area
SAM completeness
Paint surface defects
Body shop surface quality
KPIs
-FTOK % Paint Shop Finish
-Quality Audit 4

Audit 1

Quality concept
Assembly shop

INTERNAL

All vehicles

Audit 2

Check:
-Line 1 and IP-preassys most
important and safety-relevant
assemblies

Audit 3

All vehicles
Check:
-Line 2 and Chassispreassys most important
and safety-relevants
assemblies

KPIs
FTOK % & QC

All vehicles
Check:
-Line 3 and doorspreassys most important
and safety-relevants
assemblies

R C
. .
U
N T
I 1

L E
E
C T
R IC C
A B IN
E T
S

R
. C
.
U N
I T
1
E
L E
C R
T C
I C B
A IN
E T
S

R .C
U N IT 2

O S T
E N
S
S O
R
C A
B IN E
T

Process flow

HUOLT O

Process flow

KPIs
FTOK % & QC

KPIs
FTOK % & QC

Rework

Process flow
Water test

All vehicles
Check:
--Leaks- optical
and manually

Process flow
All vehicles

Test Drive

KPIs
FTOK %

5% test track
100%
cobblestone
drive
Check:
-drivability,
functions, noises
KPIs
FTOK %

High pressure
All vehicles
water test
5 % of cars

Roller test

All vehicles
line 7 Q-check

Paint surface

All vehicles

All vehicles

Check:
- All cars
- CPA-focus
points, feedback
from previous
days/weeks

Check:
-damages,
scratches,
assembly marks

defect/car

KPIs
FTOK %

defect/car

20

Valmet Automotive

March 2015

Line 8

Quality
audit
All vehicles

All vehicles

Check:
-drivability,
functions, noises

5 cars a day

Final inspection
Check:
-deliverable
-chassis card OK
-vehicle corresponds the
order
-delivery condition and
cleanliness
-final diagnose
KPIs
FTOK %

defect/car

KPIs
FTOK %

Quality Assurance Plan Assembly shop

INTERNAL

Line 1 Quality Check 100%


Line 2 Quality Check 100%
Line 3 Quality Check 100%
Water Test 100%
Wheel alignment & Roller Test 100%
Extra Quality Check 5 cars
Paint surface inspection 100%
Line 7Q-check defined points (CPA etc.)100%
Test Drive (test track 5%, cobblestone 100%)
High pressure water test 5%
Line 8 100%
21

Valmet Automotive

March 2015

Product Audit
2 cars/day

INTERNAL

Measuring center

22

Valmet Automotive

March 2015

INTERNAL

Measuring center equipment


Coordinate measuring machines (CMM)
-

Dual arm machine with four movable measuring pallets

Measuring range X=6000 mm, Y=2797 mm, Z=2400 mm

Portal machines

Measuring range X=1500 mm, Y=1500 mm, Z=800 mm


Measuring range X=700 mm, Y=450 mm, Z=350 mm

Other equipment
-

23

Spring testing gauges


Dial indicator gauge
Block gauges
Pressure calibrators
Length measuring machines

Valmet Automotive

March 2015

INTERNAL

Material laboratory
Provides services to all VAs departments. It gives support for monitoring processes of the
paint shop and it helps introducing new materials into production. The laboratory also
provides its expertise to different VAs projects as required. The main activities of the
material laboratories can be divided following categories

Surface treatment laboratory

Alignment test programs for the new materials


Acceptance tests for all base coats and clear coat batches (including e.g. color, mechanical properties)
Climate and corrosion tests (e.g. according to VDA-standards)

Chemical laboratory
Process baths and sewage water analysis / monitoring
Chemical managements (e.g. VAs MSDS register)

Metal laboratory / Rubber and plastic laboratory


Tensile strength tests, compression stress test (including textiles and plastics)
Hardness measurements (Vickers, Brinell, Rockwell, Shore A, Shore D)

Cooperation together
Authorities
Material suppliers - SQ activities, analysis / testing services
Universities and research centers - e.g.
o Outotec , Research Center material technology and analytical laboratory
o VTT Technical Research Center analytical service (e.g. metal analysis and other problem solving)

24

Valmet Automotive

March 2015

Product quality

INTERNAL

Product quality improvement meetings


Product audit
- Review of each car daily
Weekly product quality improvement meetings with management
- Prio-issues from product audit
- Task force teams for selected issues
- Problem analysis are done acc. to 8D-method
- Reporting with 8D-form
Weekly QM-meeting with all quality managers
- Review of the results vs. internal targets and corrective actions

26

Valmet Automotive

March 2015

INTERNAL

Customers
audit process

Product audit process


Monitoring
A
R&D

Prod.

P
Audit

A
Delivery

P
Audit

Independent activity

Random sample 1 %

Final audit

Legal req.,
functions

Optical
27

Valmet Automotive

March 2015

Results
A/B/C-faults
Improvement
potential

Corrective actions

Customer
Internal operations
Suppliers

INTERNAL

Product audit action plan

Perhaps

Optical
Quality
Improvement
Potential

Statistical

Valmet Automotive

Immediate

Functional
Defects
(Audit, Quality Measuring)

Delivery Block
Defect Analysis / Immediate Actions

Actions

28

Next WS visit

Depends on the repair costs

Type of
defect

Defect
weighting

Walk home failure

Complaint

March 2015

Rework

Safety

Disturbance

Legal
Test drive
interruption

Customer
reaction

INTERNAL

Handling of major and systematic defects

Defect founder

Area where the


defect was caused

Defect

1.

1. Defect added to
body, paint or
chassis card

Defect added to body, paint or


chassis card and issue reported
verbally and in written format to the
defect source.

2.

Defect stopped and inspections &


repair activities started. Sampling
inspection of 25+25 cars. Delivery
stop if defect found from already
approved cars.

3.

Root cause analysis and corrective


actions to prevent the issue
happening again. Analysis and
actions reported to stakeholders.

4.

Solution approval and additional


actions if needed. Defect creator
informed.

2. Defect stopped,
inspection & repair
3. Analysis +
corrective &
preventive actions

Quality Manager

29

Valmet Automotive

4. Approval and
additional actions if
needed

March 2015

INTERNAL

Market feedback
Car owners

Dealers

Receive, summarise
and inform
(contact person)

Define priority
(task force)

Plan and implement


corrective actions
(responsible)

Verify and approve


corrective actions
(task force)

Reporting

30

OEMcustomers

Warranty info
Leasing cars
Test reports
Dealer reports
JD Power
Suppliers
Audits

Valmet Automotive

Reporting

March 2015

Research
companies

Press

Define root cause


and responsibility
(task force)

Customer satisfaction

INTERNAL

Delivery stop process


This process is used, if there would
be found a critical defect in the
product audit, in the production or
in case the legal requirement is not
met.

Cars are blocked and deliveries to


the harbour and further will be
stopped until the corrective actions
are done.

The decision for a delivery stop is


done by QM / product quality.

By using this process it will be


secured that all the possibly
affected cars will be checked and
reworked before delivery to the
customer.
31

Valmet Automotive

March 2015

Communication

INTERNAL

Reporting/Escalation

Information/Support

Daily Information Flow


at VA Production Depts

Production
management
morning round

SV+ PRD-D, LOG, SQ, M, QS, ENG: 08:20 - 08:50

Valmet Automotive

TL+ SV, ENG:

07:40 - 08:10

TL+ OPS:

07:10 - 07:40

OPS:

07:00 - 07:05

March 2015

PRD-VP
PRD-D
QS
LOG
SQ
FIN
ENG
PRD-C
M
SV
TL
OPS

Director of Production
Department Director
Quality representant
Logistics
Representant of Supplier Quality
Representant of Finance
Representant of Process Engrg
Representant of Prodn Control
Representant of maintenance
Supervisor of a Prodn area
Teamleader
Operator on a station

Daily at:
09:20-10:00
Participants: PRD-VP, PRD-D, QS, LOG,
FIN, PRD-C, M
Themes:
Volume, Quality, Productivity,
Availability of parts/materials,
Escalation

Production morning walk

32

Abbreviations

Daily at: 07:00-08:50


Themes: Volume, Quality,
Productivity,
Availability of parts/
materials, Escalation

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