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R Vasu (Vice President & Corp. MR)
K N Sudharsan (Manager)
Brakes India Private Limited Chennai , India
" Systems As The Way We Work –
Innovation in QMS Implementation "
Company Profile
Challenges in QMS and Need for Innovation
Innovative Ideas in Audit Planning, Execution &
Continual Improvement
Integration of Six Sigma with QMS
Contents
2
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
Executive summary
3
Our Joint Venture
Established 1962, Joint Venture with Lucas PLC UK
Net Sales (31/03/15) 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 Light Vehicle, Commercial, Off Highway, Specialty
Manufacturing Sites Brake Division – 15 Foundry - 1
Global Infrastructure Office in US
51% 49%
Brakes India Private Limited
4
Mother Plant Support Plant Satellite Plant
Chennai (Padi,Avadi & SEZ)
Sholinghur (3)
Polambakkam
Sittarganj Gurgaon (2)
Waki (Pune)
Nanjangud
Sholinghur(foundry)
Reduction of Losses
Elimination of Waste
Total Employee Involvement
Proximity to Customers
Flexible Delivery
Flexible Packing
Quick Response
Total Productivity Management
Customer Centricity
Manufacturing Locations
Jamshedpur
Sanand
Jhagadia
5
.
Hose Assemblies Clutch Hydraulics
Light Vehicle Product Portfolio
Master Cylinder Booster
Drum Brakes
Valves
Calipers
Pads
Slip Control
3 million p.a.
2.63 million Master Cyl
1.40 million Boosters
6.9 million p.a. 15.84 million p.a.
1.7 million p.a.
12 million p.a.
4.80 million p.a. +
0.6 million p.a.
(DIH)
0.05 million p.a.
Plastic Master Cylinder
Lining
4.5 million p.a.
* Also leading Manufacturer of Brake Systems for Commercial, Tractor
& Off Highway Vehicles
6
:
2003
2005
2007 TPM Excellence
Award
TPM Excellence in
Consistent Award
TPM Special
Award
TPM Advance
Special Award TPM Milestones
Our TPM Journey
TPM Awards by JIPm, Japan.
Goal
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
Plan What to do?
How to do it ?
Do • Do what was
planned ?
Act • How to improve
next time ?
Check • Did things happen
according to plan?
1) Innovation in
System Audit plan
- Planetary system
3) Innovation in
New Products audit
- APQP stages
Innovations in
4) PFMEA GYR coding
5) Integration of Six Sigma with
other Management Systems
What are the Innovative approaches ?
2) Innovation in Audit
Scoring - Color Coding
System
11
Plan
What to do?
How to do it ?
Do
• Do what was
planned ?
Act
• How to improve
next time ?
Check • Did things happen
according to plan?
1) Innovation in
System Audit plan
- Planetary system
12
1. Innovative Approach in QMS Audit plan
Assembly
Plants
Sub Assy
Plants
Mother
plants
Dedicated
Satellite
Plants
Corporate
Depts
Earlier Methodology
• QMS audit carried out independently
• Not considering the interdependency
• Unable to capture Internal Customer voice
What is the Innovation in QMS Audit plan ?
Warehouse Stand alone system
13
c
Assembly plants
closer to OEM
Sub assy plants
Dedicated
Satellite plants
Corp
Departments
Warehouse
Mother
plants
Innovation in QMS Audit plan is …..
Better QMS coordination between plants
Internal Customer voice captured
Planetary system
14
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
Benefits
15
Plan What to do?
How to do it ?
Do • Do what was
planned ?
Act • How to improve
next time ?
Check • Did things happen
according to plan?
2. QMS Audit scoring
- Color coded Dashboards
2. Innovative approach in QMS audit scoring
16
QMS Audit - Objective Score card system
What is the Innovation in Audit scoring ?
17
ISO / TS
16949
VDA6.3
BI
QMS Procedure
ISO / TS
16949
Standard
Brakes
India QMS
Procedure
Self
Audit
Check
List
VDA6.3
Standard
Scoring
Domain
Function
Wise
checklist
Various
Customer/
ZF TRW
Audit
Forms
QMSA
Score
GYR
Status
What is the Innovation in Audit scoring ?
• Integration of TS , VDA & BI QMS Audit requirements
• From Subjective report to Objective score card
• Visual Dashboard for quick look
18
Evaluation Criteria
ISO/TS
16949
Methodology
VDA 6.3
Methodology
Earlier BI
Methodology New Methodology
Final Report Element
Score
Final
Scor
e
Report Element
Score
Final
Score
Full compliance with
requirements Conformance 10 A Conformance 5 90 – 100
Requirements mainly satisfied;
Minor deviation
Non
Conformance
8 B
Opportunity
for
Improvement
(OFI)/
Observations
4
80 – 89
70 – 79
Requirements partially satisfied;
significant deviation 6
C
Minor NCR
3 60 – 69
50 – 59
Requirements Inadequately
satisfied; major deviation 4 2
40 – 49
30 – 39
Requirement not satisfied 0 Major NCR 1 20 – 29
10 – 19
NA-Not Applicable /NV-Not
Valuated NA/NV NA / NV NA / NV 0 – 9
How ?
19
Sample scoring sheet
20
TS Element
TS Clause
Look for
Objective
evidence Brakes India
Procedure
Element
Score
Final Score results
Element
Score Details
Sample scoring sheet
21
Evaluation Criteria
Proposed Brakes India
Methodology
Element Score
Full compliance with
requirements 5 90 – 100
Requirements mainly
satisfied;
Minor deviation
4 80 – 89
70 – 79
Requirements partially
satisfied; significant
deviation
3
60 – 69
50 – 59
Requirements
Inadequately satisfied;
major deviation
2
40 – 49
30 – 39
Requirement not
satisfied 1
20 – 29
10 – 19
NA-Not Applicable /NV-
Not Valuated NA / NV 0 – 9
Elemental Scoring Methodology
22
Evaluation Criteria
Proposed Brakes
India
Methodology
Final Score
Full compliance with
requirements 90 – 100
Requirements mainly satisfied;
Minor deviation
80 – 89
70 – 79
Requirements partially
satisfied; significant
deviation
60 – 69
50 – 59
Requirements Inadequately
satisfied; major deviation
40 – 49
30 – 39
Requirement not satisfied 20 – 29
10 – 19
NA-Not Applicable /NV-Not
Valuated 0 – 9
Final Scoring Methodology
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
Benefits
24
Plan What to do?
How to do it ?
Do • Do what was
planned ?
Act • How to improve
next time ?
Check • Did things happen
according to plan?
3. New Product System audit
- at various APQP stages
3. Innovative approach in New Product audits ..
25
Introduced System Audit at different APQP phases
Phases of APQP
– Approval to Develop
– Quote Approval
– Proposal Acceptance
– Concept Verification
– Design Verification
– Product & Process validation
– Product Launch
– Program Close out
Phase 1 : After Design Verification
Phase 2 : After Product & Process
validation
Phase 3 : After PPAP & Before
one month of SOP
What is the Innovation ?
Phase 1
Phase 2
Phase 3
26
Focus Elements:
• Readiness to meet Customer Requirements
• Product / Process Design Readiness Review
• Supplier Readiness
• Plant /People Readiness
• APQP Process Compliance
How New Product audit being Done ?
27
Check Points
• Readiness to meet Customer requirements
Customer special Requirement
Response to customer concern
• Product / Process Design Readiness Review
Design documentation readiness
Product / Process Design Change management
Review of CV / DV / PV testing results
Process design / application readiness
Packaging readiness
How New Product audit being Done ?
• Supplier Readiness
New supplier evaluation
BOM Readiness
PCM (Product Characteristics Matrix) & SLP
(Safe Launch Plan) Readiness and / or
implementation
Supplier launch readiness
Supplier PPAP readiness (including Supplier
packaging readiness)
Supplier Run @ rate results
Incoming control readiness
28
• 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
How New Product audit being Done ?
• Plant Readiness
Mistake Proofing
Line walk audit
Plant PPAP Readiness
Safe Launch Plan
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 Phase I < 70%
Phase II < 70%
Phase III < 75%
Caution status Related actions are
required to be completed
within one month
Successful action
by Program Manager Phase I / II > or equal to 70 %
Phase III > or equal to 75%
High Risk, Escalate
Team member and review
Action for completion with
revised target
Graduation
Phase III > Or equal to 90%
Verification of
Proposed Action
status
Pending as off
proposed target
Completed as per
target date
34
Sample NP Audit score - Dashboard
1
3
SYSTEMS READINESS AUDIT SCORE CUSTOMER PROGRAM DESCRIPTION CATEGORY
PG0029 RB Caliper HCV
I PJ0029 T,V,D,E RB 60 Caliper withh xxxxx Pad , RB 68 Caliper with Xxxxx Pad )
TOTAL 43
SlNo Project Project Description Mfg Unit Site
Plbk Unit 64
Friction TD to be released .
71
July 2015
Score
67
75 60
57
Design readiness
Supplier readiness
Score
67
Score
33
AQP Audit - Phase I Feb 2015 April 2015
50
Remarks
0 10 20 30 40 50 60 70 80 90 100
Design readiness
Supplier readiness
TOTAL
July 2015
April 2015
Feb 2015
1
3
4 Plant Readiness - 211- Mistake Proofing
5
6
8
100
75
83
Score
56
50
17
25
0
Plant Readiness - E212 - Documents
33
33
Feb 2015
27
Plant Readiness - G54 - Line Sign Off
Plant Readiness - E213 - Safe Launch
Score
33
50
17
25
0
33
Supplier readiness
TOTAL
Design readiness
AQP Audit - Phase Il
83
April 2015 July 2015 Remarks
100
Score
78
75
0 10 20 30 40 50 60 70 80 90 100
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
July 2015
April 2015
Feb 2015
Sample NP Audit score - Dashboard
36
1
2
3
4
5
6
7
8
9
10
70
April 2015
35
60
100
31
20
50
10
20
20
50
10
20
30
30
10
Score
30
30
10
Feb 2015
Score
30
60
Packing Approval from TML
PPAP / Re-PPAP Point. 70
80
50
50
Line Sign off to be done.
GDPIM Process Compliance
TOTAL
Plant Readiness - PPAP
Plant Readiness - 211- Mistake Proofing
Plant Readiness - E213 - Safe Launch
People Readiness
Plant Readiness - G54 - Line Sign Off
AQP Audit - Phase Ill
Design readiness
Customer Readiness
Supplier Readiness
Plant Readiness - E212 - Documents
Score
70
90
80
70
70
30
80
74
July 2015 Remarks
Implementation of SLP
0 10 20 30 40 50 60 70 80 90 100
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
July 2015
April 2015
Feb 2015
Sample NP Audit score - Dashboard
37
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
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
Benefits
38
Plan What to do?
How to do it ?
Do • Do what was
planned ?
Act • How to improve
next time ?
Check • Did things happen
according to plan?
4. PFMEA - GYR approach
4. Innovative approach in PFMEA
39
PFMEA – GYR codification
(Process Failure Mode Effective Analysis)
What is the Innovation ?
40
PFMEA
Final /Sub
Assembly Other Mfg .Process
Category-1
SC / CC
Category-2
Non SC/CC
Category-3
SC / CC
Category-4
Non SC/CC
PFMEA
All Types of Assemblies &
Other Mfg Process
Action for High RPN
S x O x D = RPN S vs O S vs D S vs O S vs D
R
Y
G
R
Y
G
R
Y
G
R
Y
G
S vs O S vs D S vs O S vs D
R
Y
G
R
Y
G
R
Y
G
R
Y
G
ZONE SEVERITY OCCURRENCE DETECTION Recommendations Actions
RED High High - PPM Low – DETECTION LEVELS Error Proofing, Poka Yoke, 100% Testing Investments are
prioritized
YELLOW Medium Medium - PPM Medium – DETECTION LEVELS Controls are medium like First off, Last off
GREEN Low Low - PPM High – DETECTION LEVELS Controls are relaxed
Earlier Method Current Guidelines
R
What is the Innovation ?
41
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 Table Matrix
How ?
PFMEA Tables
Severity x Occurrence Severity x Detection
Table 1
Table 3
Table 5
Table 7
Table 2
Table 4
Table 6
Table 8
43
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
Benefits
44
Plan What to do?
How to do it ?
Do • Do what was
planned ?
Act • How to improve
next time ?
Check • Did things happen
according to plan?
5. Six Sigma integration with other
Management Systems
5. Innovative approach in Integration
of Six Sigma
45
Integrating Six Sigma with Other Systems Integrating Six Sigma with Other Systems
ISO /TS 16949 Process Measurable Objectives & Targets
TPM Objective & Targets
of Each Pillar
ISO 14001 Objectives &
Targets
OHSAS Objectives & Targets
Company Medium Term
Objectives
Monitor the Trends against the Targets & Benchmarks
Trends with
in Targets
Process Optimization / Re validation / VA VE
Problem Solving
Yes No
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
Take the Current Process Parameters
Take the Initial Process Parameters
Identify the team (preferably members from
Unit Tech Module / QC)
Identify the team (preferably members from
Unit Tech Module / QC)
New Products/ Process
Regular Products
Energy Objectives & Targets
Customer Set
Objectives
How we integrate ?
46
How we integrate ?
47
Leader/
Champion
Master Black Belt
(MBB)
Black Belts (BB)
Green Belts (GB)
Project Team Members
( Yellow Belt –YB )
Site Heads
Functional Heads /
Module leaders
Corp QMS
First line supervisors
Module leaders / Engineers
Six Sigma – Deployment
48
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
Result : Six Sigma Skill set ( Plant wise )
49
Six Sigma Project focus
Project Themes
• OEE Improvement
• Throughput Improvement
• Reliability Improvement
• Supply Chain Optimization
• Waste Elimination
Project Themes
• Quality Improvement
• Lead time reduction
• Responsiveness
• Customer Experience
Project Themes
• Energy Recovery
• Effluent Reduction
• Water/fuel conservation
• Safety Improvement
Cost
Focus Customer
Focus
SHE Focus
50
Over All Summary
Innovative Approaches
Benefits
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
4. PFMEA – Color coding Trigger actions based on
GYR status
3. New Product audits - @
diff. APQP stages
Able to address system
gaps prior to product launch
Reduction in Safe
launch PPM
5. Six sigma integration with
Management systems
- Improving analytical skill
of employees
- Production / Product
variation reduction
Cost benefits, No. of
GB, BB, YB
51
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
Core Top
Management
Mother Plants
Location Padi (0 Kms)
Polambakkam
( 100 kms)
Sholinghur
( 102 Kms)
Nanjangud
( 490 kms)
Jhagadia
( 1654 Kms )
Export Plants Rolltec Avadi
( 22 kms)
SEZ
( 65 kms)
Assembly Plants Waki
( 1148 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 )
Locations across India
BI Plants - Location Matrix
54
Processes in Brakes India
55
• 6 Vehicle Segments requirements
• 52 OEM expectations
• 28 Product catalogs
• Higher product Mix
• New Technological Products
• New multiple JV’s
CUSTOMER
IATF Subscribers
• BMW Group
• Daimler AG
• Fiat Chrysler Automotive
• Ford Motor Company
• General Motor Corporation
• PSA Peugeot Citroen
• Renault
• Volkswagen AG
Brakes India – Customer / Product scope
56
Red Zone area is more
57
Red Zone area is less
58
