global supply chain quality improvements with...
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Global supply chainquality improvements with certificationand what can be done beyond
Jens Kulenkampff - TÜV Rheinland Industrie Service GmbH
Hannover fair April 2013
TÜV Rheinland: 140 years of tradition and innovation
Your advantage: our experience.
2009World‘s largest photovoltaic lab
1926First material analysis laboratory
1900Vehicle inspection and driving license tests
1957Commitment to environmental protection: dust register in Cologne
2006Joined the
UN Global Compact
1872Entrepreneurs take the initiative and set up the DÜV to ensure the safety of their manufacturing plants
1969International product tests and certifications
1918Activities in the energy and mining sectors
1975Medical work
2007Represented on all continents
2011Establishment of wind department
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
TÜV Rheinland is at home on all continents.
500 locations in 61 countries around the world.
TÜV Rheinland Industrie Service GmbHAm Grauen Stein • 51105 Cologne • Headquarter• Head of certification body• Head of QA/QC services & project managmt.• Material testing (TR laboratories)• Welding technology
TÜV Rheinland Industrie Service GmbHJulius Vosseler Str. 42 • 22527 Hamburg • Component & project certification on- & offshore
• QA/QC services, manufacturing surveillance• Recurrent test items onshore/ offshore• Marine warranty survey
TÜV International GmbHShanghai • China• QA/ QC services (whole project life cycle)• Third party inspections• Material testing (TR laboratories)• Welding technology & welding education
TÜV International GmbHBangalore • India• QA/ QC services (whole project life cycle)• Third party inspections• Material testing (TR laboratories)• Welding technology & welding education
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Wind energy services of TÜV Rheinland
Certification
Supply chain services Wind farm services
Certified as inspection body according to DIN EN ISO / IEC 17020Accredited as certification body for wind energy turbines and components
Services along theWind turbinesLife cycle
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Wind energy facts worldwide
new installed capacity p.a.Worldwide [MW]
Source: Bundesverband Windenergie e.V.http://www.wind-energie.de/
Installed capacitycumulated 238351 MW
Installations are growing on a high level
Installations are performed worldwide
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Implications of the global business
Global installations
Global or local supply?
Boundary conditions for supply chain decisions- Market consolidation- Big cost pressure - Limit of investments
vs. local content requirements- Big component big shipping cost
vs. build up multiple factories- Second source policy
Make or buy?
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Wind in the TCQ triangle
time
cost quality
x
Situation of wind energy supply chain- New and unqualified sub-suppliers
in local market- Minimum quality staff at suppliers- Systematic quality approach not
yet everywhere implemented in supply chain
- Repair and rework on daily basis due to non stable processes
- End user require integrated quality approach in their projects
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Quality is environmentalfriendliness
What do YOU think is quality?
Quality is anice look
Quality is durability
Quality is high performance
Quality is safe operation
Systematic quality approach
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Quality is environmentalfriendliness
Quality is anice look
Quality is durability
Quality is high performance
Quality is safe operation
Systematic quality approach
Quality is fulfillment of all defined requirements
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
An ISO 9001 quality approach is a minimum requirement.
Principles of ISO 9001 quality management system1. Customer focus2. Leadership3. Involvement of people4. Process approach5. System approach to management6. Continual improvement7. Factual approach to decision making8. Mutually beneficial supplier relationships
Formal requirements to component manufacturersand sub-suppliers- ISO9001 quality certified- Certified welding workshop- GL composite workshop approval- Qualified bonding workshop
Workshop evaluationi.e. equipment
Staff evaluationi.e. qualification, numbers
Quality system evaluationi.e. procedures, test plan
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
ISO 9001 certification“just for the certificate”
Certification over quality?
And still it happens.
ISO9001 certification needs a solid foundation of people, equipment and know how
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Certification and what can be done beyond.
workshop approvalISO9001 certificationComposite workshop
certificationWelding workshop
certification
Quality methodsLean manufacturing
Project quality support APQPGap analysis for workshop approval
Risk assessment HSERisk assessment tools & equipment
Design assessment product and production process
Quality system setup
Test & inspectionIn process inspection
Non destructive testingFinished goods approval
Expediting
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Before certification: typical supplier qualification
Qualified supplierSustainable qualitySecurity of supply
Supplier pre-assessment
TechnicalQuality system
Financial
Technical reviewFit for purpose
Quality audit VDA 6.3Manufacturing inspection
Detail risk assessmentManufacturing processes
Quality controlHealth, safety and
environment
Risk mitigationEnabling quality control
Enabling healthy operations
Supplier post audit
Measure control
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Beyond certification: Project quality approach with APQP
Product design phaseProduct implementation
phaseProduct serial production
Identification ofCustomers requirements
Critical to quality items Test and inspection plan
Advanced Product Quality Planningaims for transparency
and continuous monitoring ofcritical product items
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Summary: wind energy global supply chain.Certification and what can be done beyond
• Wind energy’s supply chain is fast growing and global
• Cost and time pressure often compromise quality
• Diligent supplier qualification is first step
• ISO 9001:2000 certification is minimum requirement
• To achieve sustainable quality, various accompanying methods shall be used
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff
Thank You for Your Interest.
Jens Kulenkampff
TÜV Rheinland Industrie Service GmbH
Wind energy
Julius-Vossler-Straße 42
22527 Hamburg
T: +49 (0)40 3787904-65
M: +49 (0)172 458 4422
www.tuv.com
Global supply chain - quality improvements with certification and what can be done beyondHannover fair April 2013Jens Kulenkampff