3. Automotive Needs And Requirements
VDA 2
QA of deliveries
VDA 3 (Part 1 and 2)
Reliability assurance at
suppliers and OEM‘s
VDA 4 and VDA 4.3
QA before serial production
VDA 5
MSA
VDA 6.3
Process Audit 2010
VDA 13
Development of SW band
systems
VDA 19
Technical cleanness
VDA RGA
Maturity level assurance for
new parts incl. components
requirements
VDA RPP & FAA
Robust production process
AIAG
2nd edition APQP
LEGAL REQUIREMENTS
INTERNATIONAL REQ’TS
AUTOMOTIVE OEM REQ’T
AUTOMOTIVE SUPPLIER
DIN ISO 9000
VDA, AIAG
& ISO/TS-16949
QSK,
special terms,..
SUPPLIER
BUSINESS
PROCESS
Highly Regulated & Rigid Industry
INPUT
OUTPUT
4. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analyses (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
5. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analyses (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
6. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analysis (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
7. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analyses (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
8. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analyses (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
9. Project Related Requirements
VDA 2
VDA 3 (1&2)
VDA 4 & 4.3
VDA 13
VDA 19
VDA RPP
Supplier selection, QA agreement, Production
process and product approval
Part 1 - Reliability management over PLM
Part 2 - Methods and tools to estimate reliability
Risk analyses (FMEA, FTA and SWOT, Poke
Yoke)
Development of software band systems –
requirements for processes and products
Technical cleanliness in assembly, environment,
Logistics, Personnel and Assembly Equip.
Robust Production Processes implemented,
Evaluated, influencing factors, and Improvement
10. Product Life Cycle management (PLM)
Development Delays Inevitably Lead to Poor
SOP Performance – Contribution Margin Drainer
[effort] [units]
[time]
SOP
Product Development Gates
Today’s
Performance
Needed
Performance
PLM Maturity Gates
effort
units
Important Fact:
11. PLM Gating Process
Off-Process
A B C D SOP MP ELV
Home Location
100
80
60
40
20
DesignReadiness
Mass Production
Prototype
Off-tool
End-of-Life
Vehicles
Start of
Production
Product Development Gates
Management Support is Paramount at Gate
Reviews – Removing Roadblocks
Important Fact:
12. Prototype Gate Key Requirements
A B C D SOP MP ELV
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Planning and Resources Allocation is
Paramount at This Gate – Quality not Quantity
§ Customer Requirements
§ Feasibility Study
§ ESI
§ Design Goals
§ Quality Plan
§ Lessons Learned
§ Teams and Tools!
Important Fact:
13. Off Tool Gate Key Requirements
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
In Depth and on Time Design Reviews Will Save the
Organization Significant Embarrassment Down the Road
Off-tool
§ Design Verification
§ Critical Char Ctrl
§ Supplier Selection & Award
§ dFMEA
§ DFA, DFM
§ Industrialization Concept
A B C D SOP MP ELV
Important Fact:
14. Off Process Gate Key Requirements
10
0
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Product Industrialization - Optimized Cell
Design and NO Significant Changes
Off-tool
§ pFMEA
§ Process Capability plan
§ MSA
§ Process Optimization
§ Supplier Readiness
Off-Process
A B C D SOP MP ELV
Important Fact:
15. Home Location Gate Key Requirements
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Equipments Validation, Material Flow, Line
Readiness Leading to Successful PPAP
Off-tool
§ PFD
§ Process Verification
§ Process Control Plan
§ EE training
§ Capability study
§ PPAP
Off-Process
Home Location
A B C D SOP MP ELV
Important Fact:
16. SOP Gate Key Gate Requirements
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Safe Launch and Quick Response is Key During
Production Ramp up
Off-tool
§ R@R Volume Ramp
§ EE Readiness
§ Safe Launch
§ Launch Voice of
Customer
Off-Process
Home Location
Start of
Production
A B C D SOP MP ELV
Important Fact:
17. Mass-Production Gate Key Req’ts
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Variation Control and Continuous
Improvements
Off-tool § Variations Control
§ Delivered Quality
§ Analysis TAT
Off-Process
Home Location
Start of
Production
Mass Production
A B C D SOP MP ELV
Important Fact:
18. ELV Gate Key Requirements
100
80
60
40
20
DesignReadiness
Prototype
Product Development Gates
Proper Materials Disposition – Good Corporate
Stewardship
Off-tool
§ Warranty Mgmt.
§ Service agreement
§ HAZMAT
Off-Process
Home Location
Start of
Production
Mass Production
A B C D SOP MP ELV
End-of-Life
Vehicles
Important Fact:
19. Summary
1. Legal, International and OEM specific regulations governs the
Automotive Industry
2. Vehicle manufacturers SOP doesn’t move
3. Delays in the PLM process could lead to exclusion from entire
product cycle and will impact financial performance
4. Management visibility and involvement is paramount in order
to preserve margins and credibility
5. Protecting customer launch is key to success and repeat
business
6. Engage customers in early discussion on P&P changes
7. Do not get caught unaware - develop own PLM process and
Automotive specific technology roadmap
