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Implementing Global Quality Audits at a Tier 1 Auto Supplier

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This presentation discusses the lessons learned implementing a global advanced quality and IATF 16949 auditing program with a Tier 1 supplier.

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Implementing Global Quality Audits at a Tier 1 Auto Supplier

  1. 1. Optimizing Global Quality Audits on Mobile Devices
  2. 2. About GKN Driveline • “GKN Driveline is the leading automotive driveline technology and systems engineer.” • 29,000+ Employees • 49 Manufacturing Locations • £4.62 Billion / $6.02 Billion in Sales
  3. 3. Background: GKN Driveline Quality Program • Various AIAG / VGA / OEM requirements and bespoke in house Leadership Standards of Work (LSW) along with robust product development. • Model cells to show what good should look like and regular management engagement in the non-production areas as well as the production areas of the business as well as a quality first culture. • Stronger GKN AQE leadership team focused on systems and processes to deliver program quality
  4. 4. Why Change? GKN Driveline • Lessons learnt from previous OEM launches • Importance of built in / designed in quality and the ability to have a positive effect on new launches through managing the quality in the program development instead of having a product that the plants don’t get involved with until it is time to industrialize the product. • Get rid of Excel!
  5. 5. Goals of Project at GKN • Improve the time taken to complete the audit • Standardized responses • Ease of audit • The ability to assign direct actions during the audit that can be tracked and managed. • Trend analysis on issues and target training to improve business
  6. 6. Quality Auditing in the 21st century • Implement a global quality auditing system with a fraction of the typical resources • Standardize audit procedures across 20 countries, multiple languages, and cultures • Keep OEM requirements up to date across 53 facilities
  7. 7. Quality Mobile Auditing in the 21st Century 1. Manage audit schedules around the world 2. Tie employee bonuses to audit performance and schedule adherence 3. Track data across multiple locations 4. Conduct audits on mobile devices 5. Assign responsibilities for non-conformities and tracking follow-up 6. Ensure non-conformities are re-assessed for effective root cause within 1 year of the issue
  8. 8. 1- Audit Schedules: Multiple and Changing • Jurisdiction specific requirements (safety) – Delay of 9 months due to changed requirements not incorporated into audit schedule • Industry standards (AIAG…) • OEM Requirements (Ford, GM,…) - with no clear change management
  9. 9. 1 – Standard Audit Scheduling • 15 step process! • Illegible due to number of steps • Too many areas for human error, delays and miscommunication – especially with paper, word, excel, email…
  10. 10. Quality Auditing in the 21st century • Global Operations • Multi-Lingual • Multi-cultural • Training, Training, Training • Visibility across operations and suppliers
  11. 11. 1- Audit Schedules: Visibility is the Key • 1200 Suppliers to Tier 1 Supplier Company • Spread over 25 countries • Many suppliers were getting audited multiple times by the Tier 1 Supplier as different divisions and factories were auditing the same supplier
  12. 12. 2- Employee Alignment Around Audit Program • Staff must: • Perform audits on time • Issue audit reports and corrective actions on time • Close corrective actions on time • Various enforcement tactics are used
  13. 13. 3 - Tracking Data: GKN Tracking Non-Conformities • If a Non-Conformity is Found, Corrective Action must be closed within three weeks or it impacts bonus • Tracked through one central weekly report that is automatically generated
  14. 14. 3 - Tracking Data: Tracking Non-Conformities
  15. 15. 4 – Audit on Mobile Devices • GKN was using a mix of PDF, Word and paper • Centralize all the audits in one location with reference material • Centrally manage the reference material • Mobile devices can work offline and online and sync automatically • Multiple people can audit together
  16. 16. 4 – Audit on Mobile Devices
  17. 17. 4 – Audit on Mobile Devices
  18. 18. 4 – Operational Effectiveness • Reduce the human element • Standardize the procedure • Remove subjectivity and bias • Your plan is only as good as your people’s training and skills
  19. 19. 4 – Operational Effectiveness
  20. 20. 5 – Corrective Actions • Assign to a person or Function • Clear due date tied to level of non- conformity • Clear action to take • Evidence non-conformity, annotated photo
  21. 21. 5 – Annotated Photos Make Big Difference
  22. 22. 5 – Assigning Corrective Action Responsibility
  23. 23. 5 – Complete Corrective Action • Complete Corrective Action with: • Date, GPS and Time Stamp automatically • Note explaining Completion • Attach evidence – Photos, Documents… • Manager approves/rejects action notes
  24. 24. 5 – Complete Corrective Action Report
  25. 25. 6 – Effectiveness Assessments • Used in Aviation and Military • Return to non-conformity after a set time – 6 months to a year • Determine if the non-conformity was permanently solved with the corrective action • If not effective, conduct further analysis
  26. 26. 6 – Prioritize Effectiveness Assessments • Generate Problematic Items Report to see: • Items that appear across audits by supplier, OEM, product line or other metrics • By audit type ; IATF 16949, VDA 6.0…
  27. 27. 6 – Recurring Non-Compliances
  28. 28. Three Biggest Challenges at GKN • Language • Training time • Governance of standard of the audit
  29. 29. Three Biggest Challenges at GKN
  30. 30. Language Barriers at GKN • Even though the business language is English we still see some interpretation of certain requirements but this we manage through governance and training. • Translated in to some local languages for key audiences China/Mexico for example.
  31. 31. Next Steps in Auditing Process • More Automation • More Context for Auditors to understand IATF Requirements • Framework already in place for GKN transition to PSSO IATF 16949
  32. 32. Lessons Learned at GKN Key Elements: – Ease of use – Tracking of open issues – Quick turnaround on modifying the audit questions to meet new requirements – Power of the reporting and ability to capture shop floor issues immediately on camera in phone and link them directly to the audit questions.
  33. 33. Lessons Learned at GKN “Ability to attach standards to the questions is absolutely immeasurable, especially when they can be referenced or reviewed on the shop floor.”
  34. 34. Summary • Key Points • Select EASY to use software with global support • Have auditor test the software • Focus on data, not dashboards • Focus on performance bonuses and motivators to stick to the system • Start small and grow!
  35. 35. Contact Thank you and good luck! Jonathan Brun jbrun@nimonik.com +1-514-712-0637

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