" Systems As The Way We Work

Innovation in QMS Implementation "

R Vasu (Vice President & Corp. MR)

K N Sudharsan (Manager)

Brakes India Private Limited

Chennai , India
 Contents

Company Profile

Challenges in QMS and Need for Innovation

Innovative Ideas in Audit Planning, Execution &

Continual Improvement

Integration of Six Sigma with QMS

2
 Executive summary

QMS internal audits in large diversified organization becomes a challenge. To

meet the challenge, innovation is the key for efficient and effective QMS
implementation. The following five (5) innovative approaches have been
adopted using Dr. Demings PDCA approach and will be discussed.

1. Innovation in system audit plan Planetary System

2. Innovation in audit scoring Color Coding Rating System

3. Innovation in New Products audit APQP Stages

4. Innovations in PFMEA - GYR Coding

5. Innovative approach in integrating Six Sigma Deployment with other

Management systems

3
 Brakes India Private Limited

Our Joint Venture 51% 49%

Established 1962, Joint Venture with Lucas PLC UK

Net Sales (31/03/15) Rs 3296 Crores (526 Million U.S $)

Employees 7646
Products Braking Systems, Castings, Machine Building, Polymer Compounding
Engineering Capability Design, Develop, Test and Validate

Average Line PPM 11 (Brake Division)

R&D Spend 2.15% of Sales (Brake Division )

Certifications TS16949, ISO 14001, TPM, Ford Q1, Deming (Foundry),

OHSAS 18001, EnMS 50001
Segments Light Vehicle, Commercial, Off Highway, Specialty
Manufacturing Sites Brake Division 15 Foundry - 1
Global Infrastructure Office in US

4
 Manufacturing Locations

Total Productivity Management

Gurgaon (2) Sittarganj

Reduction of Losses

Jhagadia Elimination of Waste

Total Employee Involvement

Sanand

Jamshedpur

Customer Centricity
Waki (Pune) Proximity to Customers

Chennai (Padi,Avadi & SEZ)

Flexible Delivery
Nanjangud

Sholinghur (3)
Flexible Packing
Sholinghur(foundry)

Quick Response
Satellite Plant Polambakkam
Mother Plant Support Plant
5
 Light Vehicle Product Portfolio

Clutch Hydraulics Plastic Master Cylinder Hose Assemblies

3 million p.a.
12 million p.a.
Master Cylinder Booster
.
Drum Brakes

2.63 million Master Cyl

1.40 million Boosters
4.80 million p.a. +
0.6 million p.a.
Slip Control (DIH)
Valves

Lining
Calipers
0.05 million p.a. Pads 1.7 million p.a.
4.5 million p.a.

15.84 million p.a. 6.9 million p.a.

* Also leading Manufacturer of Brake Systems for Commercial, Tractor

& Off Highway Vehicles
6
 Our TPM Journey

TPM Advance
TPM Milestones Special Award
TPM Special
Award
Goal
TPM Excellence in :

Consistent Award

TPM Excellence 2007

Award

2005

2003
TPM Awards by JIPm, Japan.

7
 Our Vision

From Systems for Certification

To

Systems as the Way We Work

(The Way We Do Business)

8
 Need for Innovation in QMS

9
 Why Innovation ?

Multi Sites , Languages , Location

Multi Process

Multi Product group

Increasing Internal & External Customer Requirements

10
 What are the Innovative approaches ?

Innovations in
4) PFMEA GYR coding
5) Integration of Six Sigma with 1) Innovation in
other Management Systems System Audit plan
- Planetary system
Act Plan
How to improve What to do?
next time ? How to do it ?

Check Do
Did things happen Do what was
according to plan? planned ?

3) Innovation in 2) Innovation in Audit

New Products audit Scoring - Color Coding
- APQP stages System

11
 1. Innovative Approach in QMS Audit plan

1) Innovation in
System Audit plan
- Planetary system
Act Plan
How to improve What to do?

next time ? How to do it ?

Check Do
Did things happen Do what was
according to plan? planned ?

12
 What is the Innovation in QMS Audit plan ?

Earlier Methodology
Assembly
Stand alone system Plants
Warehouse

Dedicated
Sub Assy
Satellite
Plants
Plants

Corporate Mother
Depts plants

QMS audit carried out independently

Not considering the interdependency
Unable to capture Internal Customer voice

13
 Innovation in QMS Audit plan is ..

Planetary system Assembly plants

closer to OEM

Warehouse
Sub assy plants

Dedicated
Satellite plants

Mother
c Corp
plants Departments

Better QMS coordination between plants

Internal Customer voice captured
14
 Benefits

Effectively Captures all the Internal & External customer voices

Internal Customer voices are effectively Reviewed by Senior Management

Team

Interdependent processes are reviewed for Continual improvement

Lead time for CA initiation has reduced

Better QMS coordination between the plants

15
 2. Innovative approach in QMS audit scoring

Act Plan
How to improve What to do?
next time ?
How to do it ?

Check Do
Did things happen Do what was
according to plan? planned ?
2. QMS Audit scoring
- Color coded Dashboards

16
 What is the Innovation in Audit scoring ?

QMS Audit - Objective Score card system

17
 What is the Innovation in Audit scoring ?

Various
Self Domain QMSA
ISO / TS VDA6.3 Brakes Customer/
Audit Function Score
ISO / TS 16949 Standard India QMS ZF TRW
Check Wise GYR
Standard Scoring Procedure Audit
16949 List checklist Status
Forms

VDA6.3
BI
QMS
Procedure

Integration of TS , VDA & BI QMS Audit requirements

From Subjective report to Objective score card

Visual Dashboard for quick look

18
 How ?

ISO/TS
VDA 6.3 Earlier BI
16949 New Methodology
Methodology
Methodology Methodology
Evaluation Criteria
Final
Element Element Final
Final Report Scor Report
Score Score Score
e

Full compliance with

Conformance 10 A Conformance 5 90 100
requirements

Opportunity 80 89
for
Requirements mainly satisfied;
8 B Improvement 4
Minor deviation 70 79
(OFI)/
Observations
Requirements partially satisfied; 60 69
6 3
significant deviation Non 50 59
Conformance Minor NCR
Requirements Inadequately 40 49
4 2
satisfied; major deviation 30 39
C
20 29
Requirement not satisfied 0 Major NCR 1
10 19
NA-Not Applicable /NV-Not
NA/NV NA / NV NA / NV 09
Valuated
19
 Sample scoring sheet

20
 Sample scoring sheet

Final Score results

TS Element

Element
Score Details
Look for
TS Clause Brakes India Objective
Procedure evidence

Element
Score
21
 Elemental Scoring Methodology

Proposed Brakes India

Methodology
Evaluation Criteria
Element Score

Full compliance with

5 90 100
requirements

Requirements mainly 80 89
satisfied; 4
Minor deviation 70 79

Requirements partially 60 69
satisfied; significant 3
deviation 50 59

Requirements 40 49
Inadequately satisfied; 2
major deviation 30 39

Requirement not 20 29
1
satisfied 10 19

NA-Not Applicable /NV-

NA / NV 09
Not Valuated

22
Final Scoring Methodology

Proposed Brakes
India
Evaluation Criteria Methodology

Final Score

Full compliance with

90 100
requirements

Requirements mainly satisfied; 80 89

Minor deviation
70 79

Requirements partially 60 69
satisfied; significant
deviation 50 59

Requirements Inadequately 40 49
satisfied; major deviation 30 39

20 29
Requirement not satisfied
10 19

NA-Not Applicable /NV-Not

09
Valuated
 Benefits

Objective based Score cards

Color coded Visual Dashboard gives direction to stake holders

(Unit/Dept /Site Heads & Top Mgmt ) on focus areas

Easy to Monitor/Review on going performance

Function wise/Unit or Dept wise /Clause wise

Prioritization much easier

No ambiguity in NCR finalization

User friendly

24
 3. Innovative approach in New Product audits ..

Act Plan
How to improve What to do?
next time ? How to do it ?

Check Do
Did things happen Do what was
according to plan? planned ?

3. New Product System audit

- at various APQP stages

25
 What is the Innovation ?

Introduced System Audit at different APQP phases

Phase 1 : After Design Verification

Phases of APQP
Approval to Develop
Phase 2 : After Product & Process
Quote Approval
validation
Proposal Acceptance
Concept Verification
Phase 3 : After PPAP & Before
Design Verification Phase 1
one month of SOP
Product & Process validation
Phase 2

Product Launch
Phase 3

Program Close out

26
 How New Product audit being Done ?

Focus Elements:

Readiness to meet Customer Requirements

Product / Process Design Readiness Review

Supplier Readiness

Plant /People Readiness

APQP Process Compliance

27
 How New Product audit being Done ?

Check Points

Supplier Readiness
Readiness to meet Customer requirements
New supplier evaluation
Customer special Requirement
BOM Readiness
Response to customer concern
PCM (Product Characteristics Matrix) & SLP
(Safe Launch Plan) Readiness and / or
Product / Process Design Readiness Review implementation

Design documentation readiness Supplier launch readiness

Product / Process Design Change management Supplier PPAP readiness (including Supplier
packaging readiness)
Review of CV / DV / PV testing results
Supplier Run @ rate results
Process design / application readiness
Incoming control readiness
Packaging readiness

28
 How New Product audit being Done ?

Plant Readiness
Mistake Proofing
Line walk audit
Plant PPAP Readiness
Safe Launch Plan

People Readiness
Engineer / supervisor skill / training levels
Line operator skill / training levels

APQP Process compliance

APQP Review reports
New launch program management
Lessons learned
Customer approval status
Plant Run @ Rate status

Reference: ZF TRWs AQP (Advanced Quality Planning) Audit

29
What is to be checked ? (Phase I, Phase II, Phase III)
Customer Requirements Readiness: Audit Sample Sheet

31
Plant Readiness: Audit Sample Sheet

32
Over all Readiness : Audit Sample Sheet

33
 Improvement & Review Process

NPRAA Result Caution status

Phase I < 70% Related actions are
Phase II < 70% required to be completed
Phase III < 75% within one month

Pending as off
proposed target
Verification of High Risk, Escalate
Proposed Action Team member and review
status Action for completion with
revised target

Completed as per
target date

Successful action
by Program Manager Graduation
Phase I / II > or equal to 70 % Phase III > Or equal to 90%
Phase III > or equal to 75%

34
Sample NP Audit score - Dashboard

SYSTEMS READINESS AUDIT SCORE

CUSTOMER PROGRAM DESCRIPTION CATEGORY
RB Caliper HCV PG0029
SlNo Project Project Description Mfg Unit Site
RB 60 Caliper withh xxxxx Pad , RB 68 Caliper with
I PJ0029 T,V,D,E Xxxxx Pad ) Unit 64 Plbk
Feb 2015 April 2015 July 2015
AQP Audit - Phase I Score Score Score
Remarks

1 Design readiness 33 67 67 .
Friction TD to be released
3 Supplier readiness 50 60 75
TOTAL 43 57 71

TOTAL

July 2015
Supplier readiness April 2015
Feb 2015

Design readiness

0 10 20 30 40 50 60 70 80 90 100
 Sample NP Audit score - Dashboard

Feb 2015 April 2015 July 2015

AQP Audit - Phase Il Score Score Score
Remarks

1 Design readiness 33 56 78
3 Supplier readiness 50 50 75
4 Plant Readiness - 211- Mistake Proofing 17 17 83
5 Plant Readiness - E212 - Documents 25 25 100
6 Plant Readiness - G54 - Line Sign Off 0 0 75
8 Plant Readiness - E213 - Safe Launch 33 33 100
TOTAL 27 33 83

TOTAL
Plant Readiness - E213 - Safe Launch
Plant Readiness - G54 - Line Sign Off July 2015
Plant Readiness - E212 - Documents April 2015
Plant Readiness - 211- Mistake Proofing Feb 2015
Supplier readiness
Design readiness

0 10 20 30 40 50 60 70 80 90 100

36
 Sample NP Audit score - Dashboard

Feb 2015 April 2015 July 2015

AQP Audit - Phase Ill Score Score Score
Remarks

1 Design readiness 30 50 70 Packing Approval from TML

2 Customer Readiness 60 70 90
3 Supplier Readiness 50 60 70 PPAP / Re-PPAP Point.
4 Plant Readiness - 211- Mistake Proofing 30 30 80
5 Plant Readiness - E212 - Documents 30 30 80
6 Plant Readiness - G54 - Line Sign Off 10 10 70 Line Sign off to be done.
7 Plant Readiness - PPAP 10 10 70
8 Plant Readiness - E213 - Safe Launch 20 20 30 Implementation of SLP
9 People Readiness 20 20 100
10 GDPIM Process Compliance 50 50 80
TOTAL 31 35 74

TOTAL
GDPIM Process Compliance
People Readiness
Plant Readiness - E213 - Safe Launch
Plant Readiness - PPAP July 2015
Plant Readiness - G54 - Line Sign Off April 2015
Plant Readiness - E212 - Documents Feb 2015
Plant Readiness - 211- Mistake Proofing
Supplier Readiness
Customer Readiness
Design readiness

37 0 10 20 30 40 50 60 70 80 90 100
 Benefits

Ensure flawless New product launch by timely audit & review

Able to Identify , Monitor & Review effectively on New product Systemic gaps
Function wise / APQP gate wise

Systemic issues are reduced after Product launch phase

Customer specific requirements are captured and implemented prior to product

launch

Helps to sustain and continually improve QMS

38
4. Innovative approach in PFMEA

4. PFMEA - GYR approach

Act Plan
How to improve What to do?
next time ?
How to do it ?

Check Do
Do what was
Did things happen
according to plan? planned ?

39
 What is the Innovation ?

PFMEA GYR codification

(Process Failure Mode Effective Analysis)

40
 What is the Innovation ?

Earlier Method Current Guidelines

PFMEA

PFMEA
Final /Sub
Other Mfg .Process
Assembly
All Types of Assemblies &
Other Mfg Process
Category-1 Category-2 Category-3 Category-4
SC / CC Non SC/CC SC / CC Non SC/CC

S x O x D = RPN
S vs O S vs D S vs O S vs D S vs O S vs D S vs O S vs D

Action for High RPN R R R R R R R R

Y Y Y Y Y Y Y Y
G G G G G G G G

ZONE SEVERITY OCCURRENCE DETECTION Recommendations Actions

High High - PPM Low DETECTION LEVELS Error Proofing, Poka Yoke, 100% Testing Investments are
RED
prioritized

YELLOW Medium Medium - PPM Medium DETECTION LEVELS Controls are medium like First off, Last off

GREEN Low Low - PPM High DETECTION LEVELS Controls are relaxed

41
 How ?

PFMEA Table Matrix

Assembly / Machining / Machining /

Assembly /
Pressing / Pressing /
Sub assy Sub assy Moulding etc Moulding etc
( SC / CC) ( Non SC / CC) ( SC / CC ) Non ( SC / CC )

Severity &
Table 1 Table 3 Table 5 Table 7
Occurrence

Severity &
Table 2 Table 4 Table 6 Table 8
Detection
 How ?

PFMEA Tables

Severity x Occurrence Severity x Detection

Table 8
Table 7

Table 6
Table 5

Table 3 Table 4

Table 1 Table 2
43
 Benefits

Addresses FMEA 4th Edition in an effective manner

Covers various BI Processes under single SO & SD color coding

To prioritize actions based on color coding

To use PFMEA as an enabler and user friendly

44
 5. Innovative approach in Integration
of Six Sigma

5. Six Sigma integration with other

Management Systems

Act Plan
How to improve What to do?
next time ? How to do it ?

Check Do
Did things happen Do what was
according to plan? planned ?

45
 How we integrate ?

Integrating Six Sigma with Other Systems

Customer Company ISO /TS 16949 TPM Objective ISO 14001 OHSAS Energy
Set Medium Term Process Measurable & Targets Objectives & Objectives Objectives
Objectives Objectives Objectives & Targets of Each Pillar Targets & Targets & Targets

New
Regular Monitor the Trends against the
Products/
Products Targets & Benchmarks
Process

Yes Trends with No

in Targets

Process Problem New Process

Optimization / Re Solving Validation
validation / VA VE
Identify the team
Identify the team
Scope of project (preferably members from
(Not Resolved nearly for Unit Tech Module / QC)
(preferably members from more than 6 months)
Unit Tech Module / QC)

Nature of project Take the Initial

Take the Current Process Parameters
(Really do not know the
Process Parameters Root Cause of variation)

46
 How we integrate ?

47
 Six Sigma Deployment

Site Heads
Leader/
Champion

Master Black Belt Corp QMS

(MBB)
Functional Heads /
Black Belts (BB) Module leaders

Green Belts (GB) Module leaders / Engineers

Project Team Members

( Yellow Belt YB ) First line supervisors

48
 Result : Six Sigma Skill set ( Plant wise )

Black Green Yellow GB & BB

Location MBB
Belt Belt Belt Projects

BI - Padi - 10 22 53 46

BD- Sholingur - 6 9 29 21

BI- Polambakkam - 9 15 18 18

BI Foundry - 6 28 - 34

BI Nanjangud &
- 6 12 14 18
Sundaram Polymer

BI SEZ, Rolltec,Waki,
Sitarganj, MRC1, MRC2 - - 15 27 21
Gurgaon Plants
Corporate
Departments (ER&D,
Marketing, Corp QA, 3 8 33 48 47
SDI, Corp MSE, QHSE,
Padi Finance)
TOTAL 3 45 107 189 205

49
 Six Sigma Project focus

Project Themes Project Themes

OEE Improvement Quality Improvement

Throughput Improvement Lead time reduction
Reliability Improvement Responsiveness
Supply Chain Optimization Cost Customer Experience
Customer
Waste Elimination Focus Focus

Project Themes

Energy Recovery
Effluent Reduction
Water/fuel conservation
Safety Improvement

SHE Focus
50
 Over All Summary

Benefits
Innovative Approaches
Qualitative Quantitative

1. QMS Audit Planning Audit plan and execution Reduced mandays CAR
Planetary audits easier reply time less

2. QMS Audit Report - Audit is objective & colour Audit is Quantified with
Score card / dashboard coded Score - GYR Status

3. New Product audits - @ Able to address system Reduction in Safe

diff. APQP stages gaps prior to product launch launch PPM

4. PFMEA Color coding Trigger actions based on

GYR status

5. Six sigma integration with - Improving analytical skill Cost benefits, No. of
Management systems of employees GB, BB, YB
- Production / Product
variation reduction

51
 Conclusion :

With these Innovative Approaches we could realize our Vision of

Systems as the way we work

(Do Business)

by Efficient & Effective Implementation of QMS and gain Customer Confidence

52
 BI Plants - Location Matrix

Locations across India

Top
Core
Management

Mother Plants Polambakkam Sholinghur Nanjangud Jhagadia

Padi (0 Kms)
Location ( 100 kms) ( 102 Kms) ( 490 kms) ( 1654 Kms )

Rolltec Avadi SEZ

Export Plants
( 22 kms) ( 65 kms)

Waki Gurgaon 1 Gurgaon 2 Sitarganj Rolltec DTA

Assembly Plants
( 1148 Kms ) ( 2292 Kms) ( 2312 kms) ( 2245 Kms) ( 25 kms)
Aztec
Freins Engg Wichitra 1 Aztec Aztec JSR
Sub assy Plants Chakan
( 55 Kms) ( 8 kms) ( 7 kms) (1581 Kms)
( 1225 Kms)
Modular Auto
Dedicated Satellite Wichitra 2 &3 Friens Metals Trans Energy Task Press
1&2
plants ( 12 Kms) ( 10 Kms) ( 12 kms) ( 12 kms )
( 8 kms)

54
 Processes in Brakes India

55
 Brakes India Customer / Product scope

6 Vehicle Segments requirements

52 OEM expectations

28 Product catalogs
CUSTOMER
Higher product Mix

New Technological Products

New multiple JVs

BMW Group General Motor Corporation

Daimler AG PSA Peugeot Citroen

IATF Subscribers
Fiat Chrysler Automotive Renault

Ford Motor Company Volkswagen AG

56
 Red Zone
area is more

57
 Red Zone
area is less

58