interactive quality on the shop floor
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DESCRIPTION
View the latest webinar from IBS America about managing quality on the shop floor. Visit IBS America to learn more about quality management software systems: www.ibs-us.com Don't forget to sign up for the next webinar in July, 2011: check out our blog for details! http://info.ibs-us.comTRANSCRIPT
IBS: Interactive Quality Management June 2011
IBS AmericaT H E P R O D U C T I V I T Y A D V A N T A G E
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Qsys and IBS Overview
PDCA Process Walk-Through
Q&A
The Case for Interactive Quality
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Quality
© IBS AG Slide 3
Solve Quality Issues Early in the Cycle
Warranty and Recall costs $$$$
Scrap and Rework $$$
Non Conforming Purchased Items $$
Interruptions in Production $$$
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Shop Floor Quality
© IBS AG Slide 4
Solve Quality Issues Early in the Cycle: How?Design and Plan for reliability, quality $$$$Verify Supplier QualityMonitor Production QualityUse Proven Improvement Processes Continuously:
SPCCAPAFMEAPDCA
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Shop Floor Quality
© IBS AG Slide 5
Examples of Savings From This Approach
TRW Warranty Cost Savings $3 Mill
BP Increased Production Rates ROI < 1 Year
Delphi ROI < 12 Months plus reduced materials cost and increased production
BMW Reduced Assembly Costs by $30 Mill
Ceramtec ROI < 12 Months + reduced liability
THE PRODUCTIVITY ADVANTAGEIBS Overview
Reduce Costs
© IBS AG Slide 6
Design Quality Issues Out
Increase Production
Ship 100% Quality
Stop Adding Value to Non-Conformities
Efficiently Handle Complaints
Use SPC
Identify Non-Conforming Purchases
Root Cause Analysis
Corrective actions
Maintain Control
THE PRODUCTIVITY ADVANTAGEIBS Overview
Reduce Costs
Design Quality Issues Out Increase Production Ship 100% QualityStop Adding Value to
Non-ConformitiesEfficiently Handle
Complaints Use SPC Identify Non-Conforming
PurchasesRoot Cause AnalysisCorrective actionsMaintain Control
© IBS AG Slide 7
APQP/FEMA
Inspection Planning/First Article
Outgoing Goods Inspection
In Process Inspection
Complaint Management Process
SPC Analysis
Incoming Goods Inspection
CAPA
CAPA
Audits/Alerts
Strategy Implement:
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Discussion / Goals
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
•
Act Plan
DoChec
k
FMEAControl Plan
Flowchart
Inspection Planning
Project Management
Production
Incoming Goods
Outgoing GoodsQuality Control
Panel Supplier Assessment
SPC
Problem Solving Process
Action Management
Audit Management
IBS Quality Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
Act Plan
DoChec
k
Fine planning
Process Overview /Online-Visualization
KPI (OEE, FPY)Analysing (PAA, CPK)
ODA
Resource Planning
PRISMA
DB
Admin/Konfig. Koppel-PC
ACC
Koppel-SPSAndon Board
Diagnose-Touch Panel
Info-Point
Masch.-SPSMobil-Scanner
Docking-Station
Handy
Auswertung
...
LiTab
Prozess-Netz (Ethernet)
MDA
Problem Solving Process
ActionManagement
Audit Management
Order Management
PaperlessRepair
© IBS AG Slide 10
IBS Quality Execution Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Traceability solutions for product and process traceability
Customer
Supplier
Plant 1Plant n
Transport
Purchased Parts
Standard Assembly Groups
Standard Components
TraceabilityKPI‘s
Cockpit
© IBS AG Slide 11
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Discussion / Goals
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS America, Inc.
Group with 5 companies Germany, USA, Lithuania plus
Support office in in China
Publicly traded since 2000 Revenue 2008: ~ $30 million
Founded in 1982 Today about 180 employees
Supporting over 4000 customer installations globally (spanning over 50 countries and 5 continents)
THE PRODUCTIVITY ADVANTAGEIBS Overview
Key Competences & Positioning
Industry independent Process consulting
Implementation
Training
Project Management
ServicesInnovativeSoftwareSolutions
Integration withcorporate
IT-Systems
MIS
MaintenanceOperationImplementation
Machinecontrol
ERP
Process control
MESCompany mgmt.
Production
Directors
Dat
a flo
w
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Customers Save Money
The Cost of Quality as % of RevenueSource: Aberdeen Group 2009
IBS customers achieve substantial cost reductions
with better than average performance (e.g. first pass yields, on time shipments).
0%
50%
100%
IBS Average Average Laggard
18% 24% 29%
THE PRODUCTIVITY ADVANTAGEIBS Presentation
•
Act Plan
DoChec
k
FMEAControl Plan
Flowchart
Inspection Planning
Project Management
Production
Incoming Goods
Outgoing GoodsQuality Control
Panel Supplier Assessment
SPC
Problem Solving Process
Action Management
Audit Management
© IBS AG Slide 16
IBS Quality Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Presentation
CustomerRequirements
One Knowledge Database for Engineering
APQP/First Article Inspection Project plan and
Checklists
Design Engineering
Customer DrawingPart Master
Process Engineering
Design FMEA
OperationsProcess Flow ChartProcess FMEAControl Plan
Spend time on the “floor” = Identify and gather data
First SampleInspection
THE PRODUCTIVITY ADVANTAGEIBS Presentation
1
2
3
APQP - Data flow between Process Flow Chart, FMEA, Control Plan
THE PRODUCTIVITY ADVANTAGEIBS Presentation
THE PRODUCTIVITY ADVANTAGEIBS Presentation
SPC Evaluation
Statistical Process Control - Analytics
Single Value Chart
Control Chart
Shopfloor data is immediately availablefor evaluation
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Supplier Assessment
Suppliers are assessed on four main criteria:
Supplier Assessment
Product Quality
Accuratedelivery dates
Accuratedelivery quantities
Softcriteria
Data collected for each deliveryData valid for apre-defined period.
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Supplier Portal
Error analysis and corrective actions
Supplier Complaint passed to the Supplier Portal
Supplier completes analysis and actions
Optional: Display keyquality indicators from the Supplier Assessment module
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Action items
Insert documents or photos of any type
Create actions with a due date, escalation profile and responsible person
Concern and Complaint Management
Email integration
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Concern and Complaint Management - Reporting
Define reporting periods and get immediate visual results
Drill-Down and Drill-Up functionality
Export into Excel
THE PRODUCTIVITY ADVANTAGEIBS Presentation
QSYS Modules - Overview