" 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. Deming’s 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
51%
Our Joint Venture
Established
Net Sales (31/03/15)
49%
1962, Joint Venture with Lucas PLC UK
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
Manufacturing Sites
Global Infrastructure
4
Light Vehicle, Commercial, Off Highway, Specialty
Brake Division – 15
Office in US
Foundry - 1
Manufacturing Locations
Total Productivity Management
Gurgaon (2)
Sittarganj
Reduction of Losses
Elimination of Waste
Jhagadia
Total Employee Involvement
Sanand
Jamshedpur
Customer Centricity
Proximity to Customers
Waki (Pune)
Chennai (Padi,Avadi & SEZ)
Nanjangud
Sholinghur (3)
Flexible Delivery
Flexible Packing
Sholinghur(foundry)
Quick Response
Mother Plant
5
Support Plant
Satellite Plant
Polambakkam
Light Vehicle Product Portfolio
Clutch Hydraulics
Plastic Master Cylinder
3 million p.a.
Hose Assemblies
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.
(DIH)
Slip Control
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
Special Award
TPM Milestones
TPM Special
Award
TPM Excellence in
Consistent Award
Goal
:
2007
TPM Excellence
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
other Management Systems
Act
• How to improve
next time ?
Check
• Did things happen
according to plan?
3) Innovation in
New Products audit
- APQP stages
11
Plan
1) Innovation in
System Audit plan
- Planetary system
What to do?
How to do it ?
Do
• Do what was
planned ?
2) Innovation in Audit
Scoring - Color Coding
System
1. Innovative Approach in QMS Audit plan
Act
• How to improve
What to do?
next time ?
How to do it ?
Check
• Did things happen
according to plan?
12
Plan
Do
• Do what was
planned ?
1) Innovation in
System Audit plan
- Planetary system
What is the Innovation in QMS Audit plan ?
Earlier Methodology
Stand alone system
Assembly
Plants
Dedicated
Satellite
Plants
Corporate
Depts
•
•
•
13
QMS audit carried out independently
Not considering the interdependency
Unable to capture Internal Customer voice
Warehouse
Sub Assy
Plants
Mother
plants
Innovation in QMS Audit plan is …..
Planetary system
Assembly plants
closer to OEM
Sub assy plants
Warehouse
Dedicated
Satellite plants
Mother
c
plants
14
 Better QMS coordination between plants
 Internal Customer voice captured
Corp
Departments
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
• How to improve
next time ?
Check
• Did things happen
according to plan?
Plan
What to do?
How to do it ?
Do
• Do what was
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 ?
ISO / TS
16949
ISO / TS
16949
Standard
VDA6.3
Standard
Scoring
Brakes
India QMS
Procedure
Self
Audit
Check
List
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
Domain
Function
Wise
checklist
Various
Customer/
ZF TRW
Audit
Forms
QMSA
Score
GYR
Status
How ?
Evaluation Criteria
Full compliance with
requirements
VDA 6.3
Methodology
Earlier BI
Methodology
New Methodology
Final Report
Element
Score
Final
Scor
e
Report
Element
Score
Final
Score
Conformance
10
A
Conformance
5
90 – 100
B
Opportunity
for
Improvement
(OFI)/
Observations
Requirements mainly satisfied;
Minor deviation
8
Requirements partially satisfied;
significant deviation
6
Requirements Inadequately
satisfied; major deviation
19
ISO/TS
16949
Methodology
80 – 89
4
3
Non
Conformance
Minor NCR
4
2
C
Requirement not satisfied
0
Major NCR
1
NA-Not Applicable /NV-Not
Valuated
NA/NV
NA / NV
NA / NV
70 – 79
60 – 69
50 – 59
40 – 49
30 – 39
20 – 29
10 – 19
0–9
Sample scoring sheet
20
Sample scoring sheet
Final Score results
TS Element
Element
Score Details
TS Clause
21
Brakes India
Procedure
Element
Score
Look for
Objective
evidence
Elemental Scoring Methodology
Proposed Brakes India
Methodology
Evaluation Criteria
Element Score
22
Full compliance with
requirements
5
Requirements mainly
satisfied;
Minor deviation
4
Requirements partially
satisfied;
significant
deviation
3
Requirements
Inadequately satisfied;
major deviation
2
Requirement not
satisfied
1
NA-Not Applicable /NVNot Valuated
NA / NV
90 – 100
80 – 89
70 – 79
60 – 69
50 – 59
40 – 49
30 – 39
20 – 29
10 – 19
0–9
Final Scoring Methodology
Evaluation Criteria
Proposed Brakes
India
Methodology
Final Score
Full compliance with
requirements
Requirements mainly satisfied;
Minor deviation
90 – 100
80 – 89
70 – 79
Requirements partially
satisfied;
significant
deviation
Requirements Inadequately
satisfied; major deviation
60 – 69
50 – 59
40 – 49
30 – 39
20 – 29
Requirement not satisfied
NA-Not Applicable /NV-Not
Valuated
10 – 19
0–9
Benefits
24

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
3. Innovative approach in New Product audits ..
Act
• How to improve
next time ?
Check
• Did things happen
according to plan?
3. New Product System audit
- at various APQP stages
25
Plan
What to do?
How to do it ?
Do
• Do what was
planned ?
What is the Innovation ?
Introduced System Audit at different APQP phases
Phase 1 : After Design Verification
Phase 2 : After Product & Process
validation
Phase 3 : After PPAP & Before
one month of SOP
Phases of APQP
– Approval to Develop
– Quote Approval
– Proposal Acceptance
– Concept Verification
– Design Verification
– Product & Process validation
– Product Launch
– Program Close out
26
Phase 1
Phase 2
Phase 3
How New Product audit being Done ?
Focus Elements:
27
•
Readiness to meet Customer Requirements
•
Product / Process Design Readiness Review
•
Supplier Readiness
•
Plant /People Readiness
•
APQP Process Compliance
How New Product audit being Done ?
Check Points
•
Readiness to meet Customer requirements
Customer special Requirement
Response to customer concern
•
Supplier Readiness
New supplier evaluation
BOM Readiness
Product / Process Design Readiness Review
PCM (Product Characteristics Matrix) & SLP
(Safe Launch Plan) Readiness and / or
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
Process design / application readiness
Packaging readiness
28
•
Supplier Run @ rate results
Incoming control readiness
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 TRW’s 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%
Phase II < 70%
Phase III < 75%
Related actions are
required to be completed
within one month
Verification of
Proposed Action
status
Pending as off
proposed target
High Risk, Escalate
Team member and review
Action for completion with
revised target
Completed as per
target date
34
Successful action
by Program Manager
Graduation
Phase I / II > or equal to 70 %
Phase III > or equal to 75%
Phase III > Or equal to 90%
Sample NP Audit score - Dashboard
SYSTEMS READINESS AUDIT SCORE
CUSTOMER
PROGRAM DESCRIPTION
CATEGORY
RB Caliper
SlNo
Project
I PJ0029 T,V,D,E
HCV
Project Description
Mfg Unit
Unit 64
RB 60 Caliper withh xxxxx Pad , RB 68 Caliper with
Xxxxx Pad )
AQP Audit - Phase I
Feb 2015
Score
April 2015
Score
July 2015
Score
33
67
67
50
60
75
43
57
71
1 Design readiness
3 Supplier readiness
TOTAL
PG0029
Site
Plbk
Remarks
.
Friction TD to be released
TOTAL
July 2015
April 2015
Feb 2015
Supplier readiness
Design readiness
0
10
20
30
40
50
60
70
80
90
100
Sample NP Audit score - Dashboard
AQP Audit - Phase Il
1
3
4
5
6
8
Feb 2015
Score
April 2015
Score
July 2015
Score
33
50
17
25
0
33
27
56
50
17
25
0
33
33
78
75
83
100
75
100
83
Design readiness
Supplier readiness
Plant Readiness - 211- Mistake Proofing
Plant Readiness - E212 - Documents
Plant Readiness - G54 - Line Sign Off
Plant Readiness - E213 - Safe Launch
TOTAL
Remarks
TOTAL
Plant Readiness - E213 - Safe Launch
Plant Readiness - G54 - Line Sign Off
July 2015
April 2015
Feb 2015
Plant Readiness - E212 - Documents
Plant Readiness - 211- Mistake Proofing
Supplier readiness
Design readiness
0
36
10
20
30
40
50
60
70
80
90 100
Sample NP Audit score - Dashboard
AQP Audit - Phase Ill
1
2
3
4
5
6
7
8
9
10
Design readiness
Customer Readiness
Supplier Readiness
Plant Readiness - 211- Mistake Proofing
Plant Readiness - E212 - Documents
Plant Readiness - G54 - Line Sign Off
Plant Readiness - PPAP
Plant Readiness - E213 - Safe Launch
People Readiness
GDPIM Process Compliance
TOTAL
Feb 2015
Score
April 2015
Score
July 2015
Score
30
60
50
30
30
10
10
20
20
50
31
50
70
60
30
30
10
10
20
20
50
35
70
90
70
80
80
70
70
30
100
80
74
Remarks
Packing Approval from TML
PPAP / Re-PPAP Point.
Line Sign off to be done.
Implementation of SLP
TOTAL
GDPIM Process Compliance
People Readiness
Plant Readiness - E213 - Safe Launch
Plant Readiness - PPAP
July 2015
April 2015
Feb 2015
Plant Readiness - G54 - Line Sign Off
Plant Readiness - E212 - Documents
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
38

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
4. Innovative approach in PFMEA
4. PFMEA - GYR approach
Act
• How to improve
next time ?
Check
• Did things happen
according to plan?
39
Plan
What to do?
How to do it ?
Do
• Do what was
planned ?
What is the Innovation ?
PFMEA – GYR codification
(Process Failure Mode Effective Analysis)
40
What is the Innovation ?
Current Guidelines
Earlier Method
PFMEA
PFMEA
Final /Sub
Assembly
All Types of Assemblies &
Other Mfg Process
Category-1
SC / CC
Other Mfg .Process
Category-2
Non SC/CC
Category-3
SC / CC
Category-4
Non SC/CC
S x O x D = RPN
Action for High 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
R
R
R
R
R
R
R
R
Y
Y
G
ZONE
RED
YELLOW
GREEN
41
SEVERITY
High
OCCURRENCE
High - PPM
DETECTION
Low – DETECTION LEVELS
Y
G
Y
G
Y
G
Y
G
Y
G
Recommendations
Error Proofing, Poka Yoke, 100% Testing
Y
G
Actions
Investments are
prioritized
Medium
Medium - PPM
Medium – DETECTION LEVELS
Controls are medium like First off, Last off
Low
Low - PPM
High – DETECTION LEVELS
Controls are relaxed
G
How ?
PFMEA Table Matrix
Assembly /
Sub assy
( SC / CC)
Assembly /
Sub assy
( Non SC / CC)
Machining /
Pressing /
Moulding etc
( SC / CC )
Machining /
Pressing /
Moulding etc
Non ( SC / CC )
Severity &
Occurrence
Table 1
Table 3
Table 5
Table 7
Severity &
Detection
Table 2
Table 4
Table 6
Table 8
How ?
PFMEA Tables
Severity x Detection
Severity x Occurrence
Table 7
Table 5
Table 3
Table 1
43
Table 8
Table 6
Table 4
Table 2
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
• How to improve
next time ?
Check
• Did things happen
according to plan?
45
Plan
What to do?
How to do it ?
Do
• Do what was
planned ?
How we integrate ?
Integrating Six Sigma with Other Systems
Customer
Set
Objectives
Company
ISO /TS 16949
TPM Objective ISO 14001
Medium Term Process Measurable
& Targets
Objectives &
Objectives
Objectives & Targets of Each Pillar
Targets
Regular
Products
Yes
Monitor the Trends against the
Targets & Benchmarks
Trends with
OHSAS
Objectives
& Targets
Energy
Objectives
& Targets
New
Products/
Process
No
in Targets
Process
Optimization / Re
validation / VA VE
Identify the team
(preferably members from
Unit Tech Module / QC)
Take the Current
Process Parameters
46
Problem
Solving
Scope of project
(Not Resolved nearly for
more than 6 months)
Nature of project
(Really do not know the
“Root Cause” of variation)
New Process
Validation
Identify the team
(preferably members from
Unit Tech Module / QC)
Take the Initial
Process Parameters
How we integrate ?
47
Six Sigma – Deployment
Site Heads
Leader/
Champion
Master Black Belt
(MBB)
Black Belts (BB)
Green Belts (GB)
Project Team Members
( Yellow Belt –YB )
48
Corp QMS
Functional Heads /
Module leaders
Module leaders / Engineers
First line supervisors
Result : Six Sigma Skill set ( Plant wise )
Location
MBB
Black
Belt
Green
Belt
Yellow
Belt
GB & BB
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 &
Sundaram Polymer
-
6
12
14
18
BI – SEZ, Rolltec,Waki,
Sitarganj, MRC1, MRC2
Gurgaon Plants
-
-
15
27
21
Corporate
Departments (ER&D,
Marketing, Corp QA,
SDI, Corp MSE, QHSE,
Padi Finance)
3
8
33
48
47
TOTAL
3
45
107
189
205
49
Six Sigma Project focus
Project Themes
•
•
•
•
•
OEE Improvement
Throughput Improvement
Reliability Improvement
Supply Chain Optimization
Waste Elimination
Project Themes
Cost
Focus
•
•
•
•
Customer
Focus
Quality Improvement
Lead time reduction
Responsiveness
Customer Experience
Project Themes
•
•
•
•
SHE Focus
50
Energy Recovery
Effluent Reduction
Water/fuel conservation
Safety Improvement
Over All Summary
Benefits
Innovative Approaches
51
Qualitative
Quantitative
1. QMS Audit Planning –
Planetary audits
Audit plan and execution
easier
Reduced mandays CAR
reply time less
2. QMS Audit Report – Score card / dashboard
Audit is objective & colour
coded
Audit is Quantified with
Score - GYR Status
3. New Product audits - @
diff. APQP stages
Able to address system
gaps prior to product launch
Reduction in Safe
launch PPM
4. PFMEA – Color coding
Trigger actions based on
GYR status
5. Six sigma integration with
Management systems
- Improving analytical skill
of employees
- Production / Product
variation reduction
Cost benefits, No. of
GB, BB, YB
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
Core
Top
Management
Mother Plants
Location
Padi (0 Kms)
Polambakkam
( 100 kms)
Export Plants
Rolltec Avadi
( 22 kms)
SEZ
( 65 kms)
Assembly Plants
Waki
( 1148 Kms )
Sholinghur
( 102 Kms)
Nanjangud
( 490 kms)
Jhagadia
( 1654 Kms )
Gurgaon 1
( 2292 Kms)
Gurgaon 2
( 2312 kms)
Sitarganj
( 2245 Kms)
Rolltec DTA
( 25 kms)
Sub assy Plants
Freins Engg
( 55 Kms)
Wichitra 1
( 8 kms)
Aztec
( 7 kms)
Aztec JSR
(1581 Kms)
Aztec
Chakan
( 1225 Kms)
Dedicated Satellite
plants
Wichitra 2 &3
( 12 Kms)
Friens Metals
( 10 Kms)
Modular Auto
1&2
( 8 kms)
Trans Energy
( 12 kms)
Task Press
( 12 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 JV’s
• BMW Group
• General Motor Corporation
• Daimler AG
• PSA Peugeot Citroen
• Fiat Chrysler Automotive
• Renault
• Ford Motor Company
• Volkswagen AG
IATF Subscribers
56
Red Zone
area is more
57
Red Zone
area is less
58