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Interactive Quality on the Shop Floor

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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.com

Published in: Business, Technology
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Interactive Quality on the Shop Floor

  1. 1. IBS: Interactive Quality Management June 2011IBS AmericaTHE PRODUCTIVITY ADVANTAGE
  2. 2. Agenda The Case for Interactive Quality Qsys and IBS Overview PDCA Process Walk-Through Q&A IBS Overview THE PRODUCTIVITY ADVANTAGE
  3. 3. The Case for Interactive Quality  Solve Quality Issues Early in the Cycle  Warranty and Recall costs $$$$  Scrap and Rework $$$  Non Conforming Purchased Items $$  Interruptions in Production $$$© IBS AG Slide 3 IBS Overview THE PRODUCTIVITY ADVANTAGE
  4. 4. The Case for Interactive Shop Floor Quality  Solve Quality Issues Early in the Cycle: How?  Design and Plan for reliability, quality $$$$  Verify Supplier Quality  Monitor Production Quality  Use Proven Improvement Processes Continuously:  SPC  CAPA  FMEA  PDCA© IBS AG Slide 4 IBS Overview THE PRODUCTIVITY ADVANTAGE
  5. 5. The Case for Interactive Shop Floor Quality  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© IBS AG Slide 5 IBS Overview THE PRODUCTIVITY ADVANTAGE
  6. 6. Reduce Costs  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© IBS AG Slide 6 IBS Overview THE PRODUCTIVITY ADVANTAGE
  7. 7. Reduce Costs Strategy Implement:  Design Quality Issues Out APQP/FEMA  Increase Production Inspection Planning/First Article  Ship 100% Quality Outgoing Goods Inspection Stop Adding Value to Non- In Process Inspection Conformities  Efficiently Handle Complaints Complaint Management Process  Use SPC SPC Analysis Identify Non-Conforming Incoming Goods Inspection Purchases  Root Cause Analysis CAPA  Corrective actions CAPA  Maintain Control Audits/Alerts© IBS AG Slide 7 IBS Overview THE PRODUCTIVITY ADVANTAGE
  8. 8. Agenda Agenda and Introduction Customer Case Studies / Benefit Analysis Solution Overview Company Overview Discussion / Goals IBS Overview THE PRODUCTIVITY ADVANTAGE
  9. 9. IBS Quality Management Solution: PDCA-cycle Action Management Project FMEA Problem Management Control Plan Solving Flowchart Process Act Plan Audit Management Inspection Planning Incoming Goods SPC Check Do •Quality Control Production Panel Supplier Outgoing Goods Assessment IBS Overview THE PRODUCTIVITY ADVANTAGE
  10. 10. IBS Quality Execution Management Solution: PDCA-cycle Action Order Management Resource Management Planning Problem Solving Process Act Plan Audit Management Fine planning Process Overview / Online-Visualization Paperless Check Do Repair PRISMA Auswertung DB ... LiTab ACC Handy Docking- Station Admin/Konfig. Koppel-PC Diagnose- Touch Panel Koppel-SPS Andon Board Info-Point Prozess-Netz (Ethernet) KPI (OEE, FPY) Mobil- Masch.-SPS Scanner Analysing (PAA, CPK) MDA ODA© IBS AG Slide 10 IBS Overview THE PRODUCTIVITY ADVANTAGE
  11. 11. IBS Traceability solutions for product and process traceability Purchased Parts Transport Customer Supplier Traceability KPI„s Cockpit Standard Components Standard Assembly Groups Plant n Plant 1© IBS AG Slide 11 IBS Overview THE PRODUCTIVITY ADVANTAGE
  12. 12. Agenda Agenda and Introduction Customer Case Studies / Benefit Analysis Solution Overview Company Overview Discussion / Goals IBS Overview THE PRODUCTIVITY ADVANTAGE
  13. 13. 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) IBS Overview THE PRODUCTIVITY ADVANTAGE
  14. 14. Key Competences & Positioning Innovative Integration with Services Software corporate Solutions IT-Systems Directors Industry independent MIS Process consulting ERP Implementation Company mgmt. MES Process Training control Project Management Production Machine control Implementation Operation Maintenance IBS Overview THE PRODUCTIVITY ADVANTAGE
  15. 15. IBS Customers Save Money The Cost of Quality as % of Revenue Source: Aberdeen Group 2009 100% 18% 24% 29% 50% 0% IBS Average Average LaggardIBS customers achieve substantial cost reductionswith better than average performance (e.g. first pass yields, on time shipments). IBS Overview THE PRODUCTIVITY ADVANTAGE
  16. 16. IBS Quality Management Solution: PDCA-cycle Action Management Project FMEA Problem Management Control PlanSolving Process Flowchart Act Plan Audit Inspection Management Planning Incoming Goods SPC Check Do • Quality Control Production Panel Supplier Outgoing Goods Assessment© IBS AG Slide 16 IBS Presentation THE PRODUCTIVITY ADVANTAGE
  17. 17. One Knowledge Database for Engineering Customer Design Engineering RequirementsAPQP/First ArticleInspection Project plan and Checklists First Sample Inspection Design FMEA Part Master Customer Drawing Control Plan Process FMEA Process Flow Chart Operations Spend time on the “floor” = Identify and gather data Process Engineering IBS Presentation THE PRODUCTIVITY ADVANTAGE
  18. 18. APQP - Data flow between Process Flow Chart, FMEA, Control Plan 21 3 IBS Presentation THE PRODUCTIVITY ADVANTAGE
  19. 19. IBS Presentation THE PRODUCTIVITY ADVANTAGE
  20. 20. Statistical Process Control - AnalyticsSPC Evaluation Control Chart Shopfloor data is immediately availableSingle Value Chart for evaluation IBS Presentation THE PRODUCTIVITY ADVANTAGE
  21. 21. Supplier Assessment Suppliers are assessed on four main criteria: Supplier Assessment Product Accurate Accurate Soft Quality delivery dates delivery quantities criteria Data valid for a Data collected for each delivery pre-defined period. IBS Presentation THE PRODUCTIVITY ADVANTAGE
  22. 22. Supplier PortalSupplier Complaint passed to the Supplier Portal Supplier completes analysis and actions Optional: Display key quality indicators Error analysis and corrective actions from the Supplier Assessment module IBS Presentation THE PRODUCTIVITY ADVANTAGE
  23. 23. Concern and Complaint ManagementAction items Create actions with a due date, escalation profile and responsible person Email integration Insert documents or photos of any type IBS Presentation THE PRODUCTIVITY ADVANTAGE
  24. 24. Concern and Complaint Management - Reporting Define reporting periods and get immediate visual results Drill-Down and Drill-Up functionality Export into Excel IBS Presentation THE PRODUCTIVITY ADVANTAGE
  25. 25. QSYS Modules - Overview IBS Presentation THE PRODUCTIVITY ADVANTAGE

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