Case Study

Case StudyNeunkirchener Achsenfabrik AGAlways on the Move with High-performance Drives

Case Study

© IBS AG© IBS AG

Neunkirchener Achsenfabrik AG (NAF) is a leading glo-bal manufacturer of high-performance drives for off-road vehicles and mobile processing machines. The company

is also the world market leader in bogie axles for forest har-vesting equipment. The company, which employs a 450-strong workforce at its 20,000m² head office in Neunkirchen am Brand (Bavaria, Germany), manufactures an annual volume of:

16,000 steering and rigid axles 7,000 bogie axles 8,000 gearboxes 5,000 differential/planetary gears

The company has further sites and subsidiaries in Munich (Germany), Edmonton (Canada), Ekaterinburg (Russia) and Qingdao (China).

In 2012 NAF generated a turnover of 100M EUR, shipping its products to customers in 30 countries across the globe.

ACTUAL Situation Prior to Project Launch

The initial situation prior to the project launch, which invol-ved the selection and implementation of a comprehensive qua-lity management system (CAQ software), was comprised of an undeveloped overall concept for the use of CAQ modules at NAF AG. Although various applications, stand-alone software solutions and in-house developments were already in opera-tion alongside Microsoft Office applications such as Excel, etc., there was no interaction between the different systems. There was also no interface to the ERP system in operation.

Goals

The aim of the project was the implementation of an interlinked, fully-integrated CAQ system, designed to eliminate stand-alone solutions and put the company in a position to meet all future customer requirements with the use of the relevant modules. An interface with the ERP system was therefore essential.

Additional adjustments were also required to ensure fulfilment of the requirements prescribed by the TS 16949 standard. This standard, which stipulates the requirements of the car manu-facturing and automotive supplier indus-

try, serves as a basis for the derivation of guidelines, such as those that NAF has set itself in order to be equipped to face the challenges of the future.

System Selection and Reasoning

Following a referral visit, and comparison of the functionalities and costs, the company opted for IBS AG‘s quality manage-ment solution in 2010.

The reasons for selecting the IBS system included the fact that CAQ=QSYS Professional is a fully-developed CAQ soft-ware system that can also be integrated on a cross-company or cross-site basis. The software solution enables NAF to fulfil all of its current customer requirements. Commissioning of the individual modules can be effected separately and within the scope of a staggered, sequential approach. The overall offer was ultimately very attractive in terms of functionality and price.

Step-by-step Implementation

Due to limited personnel resources during the implementation phase, CAQ=QSYS was introduced in stages at NAF. Imple-mentation of the Concern and Complaint Management module began in early 2011. The first and second quarters of 2011 pri-marily involved the compilation of inspection plans for the in-process (SPC), incoming goods and first sample inspections. Acquisition of the first measurement values began during the third quarter of 2011. Implementation activities during 2012 focussed on the Audit module and Gauge Management.

The following modules are in use on over 200 PCs and termi-nals at NAF today:

Concern and Complaint ManagementSince its implementation at NAF, the concern and complaint management tool has been used intensively for the acquisi-tion of internal and external complaints, including complaint cost data. Fully-integrated activity management in all modules ensures timely, priority-controlled processing by the respective employee. The integrated, comprehensive evaluation and ana-lysis options optimally support the continuous improvement of quality and productivity.

NAF has identified further benefits in continuous process auto-mation, e.g. automatically informing the operator of possible series defects upon acquisition of a new complaint and ena-

bling the execution of a preliminary defect evaluation. Fur-

try, serves as a basis for the derivation of guidelines, such as try, serves as a basis for the derivation of guidelines, such as those that NAF has set itself in order to be equipped to face

Following a referral visit, and comparison of the functionalities and costs, the company opted for IBS AG‘s quality manage-

Always on the Move with High-performance Drives Manufactured by

Neunkirchener Achsenfabrik AGThe IBS quality management solution, used by a manufacturer of drive

components for processing machines

Case Study

© IBS AG

NAF attaches particular importance to process automation. Tolerance limit violations thus lead to automatic complaint generation and a problem-solving action that is forwarded to the relevant quality assurance personnel. Warning and inter-vention limits can be defined or calculated for SPC monitoring in series manufacturing. The allocation of gauges ensures and documents that only calibrated gauges are used for the inspec-tions.

First Sample InspectionFirst sample reporting is a convenient method for the creation, evaluation and administration of reports in accordance with VDA and QS-9000. A first sample inspection is carried out at NAF, not only for purchased parts but also for the company‘s own end products.

Audit ManagementUse of the Audit module results in lower administration effort (and costs) due to the acceptance of identical question cata-logues. Simplified evaluations and lists also facilitate the detec-tion of vulnerabilities. The Audit Management module also offers convenient action tracking and handling.

NAF carries out a number of supplier, internal process, system and product audits every year, as well as customer and certifi-cation audits in accordance with ISO 9001 and ISO 14001.

Inspection ReportsThis module supports inspection certification for non-specific and specific inspections carried out in accordance with DIN EN 10204. Order compliance, factory and acceptance test certifica-tion are all automatically generated and dispatched. Following creation, templates can be automatically populated with the latest measurement values.

Linkage to the ERP SystemThe exchange of data with the ERP system will fully integrate the company’s quality management into its operational proce-dures, creating transparency. Data stock is automatically syn-chronised, reducing administration effort and data redundancy.

Benefits and Synergies

Consistent use of the IBS quality management system has led to a significant increase in efficiency in all areas. All customer specifications and other certification requirements are fulfilled and documented.

A notable optimisation of the company‘s concern and complaint procedures, including supplier and customer communication, has also been achieved. The documentation of initiated inves-tigations and the respective results, and the associated docu-mentation of removal actions and subsequent effectiveness checks, have also been considerably improved.

thermore, problem-solving processes can be set up to cover multiple defects of the same type. 8D reports can also be crea-ted from generated complaints, at the push of a button.

Inspection PlanningThe inspection criteria of each of the company‘s quality-rele-vant activities are defined in this central component of the qua-lity management solution. The inspection plans may contain variable, attributive and visual characteristics. Changes made to the inspection plans are documented with a revision num-ber. In addition to detailed inspection instructions, pictures and documents may also be added to the individual inspection steps.

At NAF AG, inspection plans for incoming goods inspections are not only written for items such as geared parts, but also for the first sample inspection of unmachined parts (blanks) and other purchased parts. NAF‘s in-house production processes involve the use of inspection plans, e.g. during machining of the bogie axle support and in the assembly hall, where the vari-ous tolerances and allowables need to be documented.

Gauge Management SystemThe Gauge Management System module enables the manage-ment of gauges and the assessment of gauge capabilities. The individual gauges may be allocated a wide range of master data, such as inspection intervals, usage location or the current status. The gauges to be calibrated can thus be conveniently filtered and calibrated in accordance with the respective inspec-tion plans. Gauge capability can be calculated in accordance with Method 1 (repeatability) and Method 2 (reproducibility).

Incoming Goods Inspection and Supplier AssessmentThe quality control of purchased parts is carried out in the inco-ming goods area. At NAF, these are largely accounted for by geared parts and castings. The inspection results attained from random samples and dynamisation procedures for the basis of the supplier assessment. This increases product quality status and supplier transparency, facilitating the selection of appropri-ate business partners.

In-Process Production Testing (SPC)This module supports the optimisation of production process control. Breakdowns are detected at an early stage and their causes removed. SPC establishes the necessary basis for zero defect production.

Case Study

Centralised inspection planning enables quick and easy inspec-tion plan creation. The inspection procedures is supported and enhanced by no-fuss inspection data acquisition, the real-time creation of inspection reports and comprehensive, informative evaluations.

Since implementation of the IBS CAQ system, NAF has been named „Supplier of the year 2012“ and awarded a prize for „Innovation“ by key customers.

Outlook

The on-going commissioning of un-used modules is scheduled to continue until 2015. Further optimisation of the modules and processes already in use is also planned.

The System Solution at a GlanceIndustry:

Manufacturer of drive components for processing machines

Project:

Implementation of a quality management system (CAQ sys-tem)

Products and modules in use:

CAQ=QSYS Professional with the modules APQP, Audit, FMEA, IP, ICG/OGC, SAM, FSI, SPC, IRC, GMS, CCM, WFM, Toolcom, Netcom for ERP systems

NAF Neunkirchener Achsenfabrik AG

NAF AG is based in the Upper Franconian town of Neun-kirchen am Brand (Bavaria, Germany). The medium-sized, family-owned company, which today employs a 450-strong workforce, has been developing and manufacturing axles and gearboxes for self-propelled construction, forestry and agricultural machines since 1960 and is the world market leader in bogie axles.

NAF‘s product range includes planetary drives, gearboxes, differentials, planetary steering axles, planetary rigid axles, bogie axles, portal bogie axles, planetary bogie axles and various drive components.

IBS AG I Rathausstrasse 56 I 56203 Hoehr-Grenzhausen, GermanyPhone: +49 (0) 26 24/91 80-0 I Fax: +49 (0) 26 24/91 80-200http://www.ibs-ag.de I info@ibs-ag.deLOCATIONS: Hoehr-Grenzhausen (DE) · Neu-Anspach (DE) · Boston (USA) · Kaunas (Lt) · Shanghai (PRC)

Rainer Kern, Head of Quality Management and Service at NAF

„We have opted for the IBS AG quality management solution in order to further improve our products and avoid was-tage and defects. The holistic, integra-ted quality management system provi-ded by IBS meets all our requirements.“

Dr. Siegfried Effenberger, Quality Manager at NAF

„The responsibility of manufacturing and delivering perfect quality products lies with each and every employee of the company. A distinct employee awa-reness of responsibility and a flexible, integrated quality management system – such as we have here with IBS AG‘s CAQ=QSYS system – constitute the ideal prerequisites for producing and ensuring quality for our customers on a day-to-day basis.“

Felix Heck, Quality Manager at NAF

„The IBS AG quality management solu-tion provides the perfect platform for the optimisation of our processes. The sys-tem can be easily configured to meet individual requirements and needs. The biggest challenge was convincing each and every employee of the benefits of CAQ=QSYS, but that is something we were able to do.“