Presentation Transcript

1. Presentation of the QIPV2.0Manufacturing Performance Assessment

   May 2013
2. 1 ? ? Contents 2 INTRODUCTION EVALUATION PROCESS 3 EVALUATION WORKSHEET & SCORING MATRIX 4 REQUIREMENTS OVERVIEW 5 EXAMPLES OF SCORING
3. ? ? 1 INTRODUCTION
4. Assessmenttools – Present Situation QIPV2.0 F2, F3Audits Tool Kick Off SOP Selection Phase Design Phase Indus Phase Serial Phase One Single Common Referential QIP QIP SourcingApprovalMatrix. (PSA / PCPA / …) QSB PCPA ProcessSpecific Audits Enterprise Performance Checklist & Process audit
5. Main Specifications (1/2)The key principles QSB+ Structural audit NSAnew supplier ass. PCPAprocess audit QIPV2.0 One single assessment referential  3 differents tools 76 / 92 Requirements Certification 59 / 92 Requirements 92 Requirements 49 / 92 Requirements
6. Main Specifications (2/2)Common characteristics Versatile toolswhich can be used on every manufacturing site & every process Evaluation covers the entire manufacturing scope (quality / logistics / Industrial efficiency) Logistics Quality What is the difference between ISO/TSand QIPV2.0 ? ISO/TSis the high level review performed by an independent 3rdparty. QIPV2.0is a much closer look performed by the Customer. GM & PSA check on the shop floorhow systems are being used whereas ISO/TSchecks that there are Quality Systems in place. Efficiency
7. QSB+ structural audit 76 / 92 Requirements The new tool to replace the QIPV1.0Assessment Certificationassociatedwith an impact on Supplier Scoring (BIDLIST) Scope: A complete supplier plant Purpose: Evaluate the overall robustness of processes on site: Manufacturing System requirements are fully met and work effectively Drive the continous improvement (identification of weak points & axes of improvement) Operational Requirements Maximum duration of the evaluation on site: 2 days Self-assessment can be done by supplier himself Updated continously to integrate the impact of the events in the relationship Project Manufacturing System 0 / 7 76 / 76 Part & Process 0 / 9 Nb of Requirements Certification
8. NSAnew supplier ass. 59 / 92 Requirements The new tool to replace the Diagnostic audit Scope: A complete supplier plant Purpose: Evaluate the manufacturing maturity of a new supplier: Basics are in place At the beginning of a project, evaluate the effectiveness of operational launch organization on supplier site Operational Requirements Maximum duration of the evaluation on site: 1,5  2 days Self-assessment by supplier before evaluation: Optional Project Manufacturing System 7 / 7 48 / 76 Part & Process 4 / 9 Nb of Requirements
9. PCPAprocess audit 49 / 92 Requirements Scope: A completeprocess in a supplier plant Purpose: At the end of a project, Confirm the qualification status of the process: Parts & Process controls are in place to ensure final product quality During mass production phase after major issues, Diagnostic tool to identify weak points Operational Requirements Maximum duration of the evaluation on site: 1 days Self-assessment by supplier before evaluation: Optional Manufacturing System Project 0 / 7 40 / 76 Part & Process 9 / 9 Nb of Requirements
10. One Single assessment referential QSB+ PCPA NSA Bidlist(supplier plant scoring) Manufacturing System Project 76 7 40 48 Part & Process Certification 4 9 Same questionnaire (samerequirements) used for all the 3 types of audit Continousassessmentof supplier’smanufacturing system via audits All the audit resultsaffect to Bidlist performance (supplier plant scoring)
11. BIDLIST Vision (Supplier Plant Scoring)Details of impacts (implemented in 2014) Points deduction Certified (QIPv2.0 Green: Score > 85%) Waiver and Not Applicable 0 pts Not Certified (QIPv2.0 Yellow:Score 75% - 85%)  90 days Forecast: Supplier Self-assessment available & audit planned  6 months Temporary 0 pts Not Certified (not evaluated or QIPv2.0 Red:Score < 75%) Certification expired (after 3 years) -10 pts
12. QIPV2.0Life CyclecontinuousAssessmentwith the sameQuestionnnaire QSB+ Structural audit NSA new supplier ass. PCPA process audit QIPV2.0 First self assessment Verificationafter Major issue Annual Update by supplier Diagnosis of the supplier plant Confirmation of the qualification status Certification Audit Selection Phase Design Phase Indus Phase Mass Production Phase Tool Kick Off SOP BIDLIST (Supplier Plant Scoring)
13. QIPV2.0 Production Site AssessmentStructure of the questionnaire The referential is « self-understandable » For each Requirement, a list of criteria describes precisely customer expectations These criteria are used for the scoring
14. 2 QSB+ CERTIFICATION PROCESS
15. QSB+ Structural auditThe main Steps – QSB+ life cycle Certification granted for 3 years Process Monitor performance / PCPA Major issue Responsibility Leadtime
16. QSB+ Structural audit – The Main StepsSupplier Self-Assessment Intent Supplier awareness of requirements Gap analysisbetweenrequirements and supplier current system Getstatus about readinessbeforecustomer on-site assessment In case of revocation: identifywhy system fails Process New Audit presentation (live conversation) Send « audit package » 15 workingdays for complete self assessment Hint Highlightthatis a gap analysis: redresult has no anynegative affect but help to identifyweak points Obtain a full scoringwith all necessarycomments (explanations of the supplier are as important as the scoring)
17. QSB+ Structural audit – The Main StepsEvaluation of Supplier Self-Assessment Intent CalibrateSupplier’sevaluationcriteria Identify items where training isneeded Identifywhere action plans must berequested Process (2 possibilities) « Theoretical » calibration: self-assessmentreviews (meetings or conf-call) On-site Assessment Complete audit resultingcustomerscoring Crosscheckrequirements to validate supplier evaluation Important: Supplier canbecertifiedatthisstep if: Self-certification has been verified on site by customer Final score > 85% with no red key element Note: Self-assessmentcanberefused if the scoringis not robust(important gap betweencustomerevaluation & supplier self-ass.)
18. QSB+ Structural audit – The Main StepsTraining & Action plan Training Intent Understand Audit Requirements & expectations Review & implementexamples to supplier system Process Supplier self-training based on QIPV2.0material package Service provider training (approved3rd party)  Available in 2014 Complete Action Plan Intent Cover Gap between supplier current system & QIPV2.0requirements. Base for close follow up of implementation Prepare supplier for Certification audit Process Maximum leadtime for full implementation is 6 months In due dates it needs to be considered that system has to operate, not only implemented Hint Verify action plan after receiving (actions definition, due dates are realistic) Organize regular calls for checking completion of action plan and guide supplier to right direction
19. QSB+ Structural audit – The Main StepsCertification Audit Intent On-site customer assessment to verify that all the Requirements are met Result in Certified status for next 3 years Process It can be done only by customerauditor(no exception even for strategic suppliers) Maximum 1.5 - 2 days assessment Result is reported out in the Audit Sheet
20. QSB+ Structural audit – The Main StepsSupplier Annual Update Intent To ensure that QIPv2.0system works after audit To ensure awareness of QIPv2.0requirement in case of new staff Process Supplier need to send self-assessment with associated action plan Every 12 months after initial certification, 60 days after any key management change (Plant manager, Quality Manager or Operation Manager) or repeat Quality issue. If self-assessment is missed to submit, certification can be revoked If PCPA meanwhile performed, not necessarily need to submit self-assessment
21. QSB+ Strcutural audit – The Main StepsRevoke Certification Intent To complete all certification process to ensure that QIPV2.0system is operating and work effectively again Process In case of major issue, repetitive failed PCPA or degradation of supplier performance, SD site initiate revoke process with agreement of management According to vision, audit result will have on-line link with Bidlist
22. 3 EVALUATION WORKSHEET & SCORING MATRIX
23. QIPV2.0 Production Site AssessmentQIP Evaluation Worksheets Instructions Description of usage of QIP questionnaire. QSB+ process Special instruction for QSB+ evaluation. Glossary Complete list of abbreviations used in audit list. Header Input of basic information and selection of audit scope. Summary Result of audit/self assessment calculated automatically. Audit Common questionnaire list. Action plan Supplier action plan to close gaps identified during self assessment or audit. Change request Proposal for changes/suggestions to be considered for next review
24. QIPV2.0 Production Site AssessmentAn example of requirement General Definition Summary of the intent of requirement Detailed deployment of 'Requirement' in bullet points Supplier has to operate a system to meet listed expectations Auditor hints and techniques how and what need to be checked besides 'Criteria of Requirement’ Two types of Criteria of the Requirement are identified: basic criteria are identified with Bold type, cover basic key requirements (must have) additional criteria are identified with unbold type, cover additional requirements (recommended best practice). Furthermore it is used for collecting evidences and setting up scoring
25. QIPV2.0 Production Site AssessmentThe ScoringPrinciples Axiom #1: Standardize all your activities & Strictly apply your standards Axiom #2: Measure your real effectiveness to achieve customer expectations & improve it
26. QIP Principles Criteria Requirements To evaluatestandardization and implementationof requirement Implementationscoring supplier Main processes Organization QualitymanualsProcedures supplier To evaluate real effectiveness to achievecustomer expectation and continousimprovement Work Instructions Guides flowchart QIPV2.0Production Site AssessmentScoringDefinition Operational Standards Effectivenessscoring Process Metrics Result Metrics
27. QIPV2.0 Production Site AssessmentScoring Structure & application Key Element #1 Implementation scoring of each individual requirement Effectiveness scoring at the end of each key element Key Element #2
28. Each Requirement is scored from 0 to 4 according to the following scoring matrix: Principles Criteria Implementationscoring Main processes Organization Audit Failed IMPLEMENTATION SCORiNGFor EachRequirement Operational Standards
29. EFFECTIVENESSSCORINGIntroduction Is system working well when ? Fast Response fully implemented, but there are several long lasting customer complaints, Non-conforming materials are controlled, but operating with high scrap rate without any improvement activities, LPA is performed in all level according to schedule , concerns documented and action defined, but there are lots of repetitive finding on LPA  System is in place, but not working effectively!
30. the Key notions The customer (internal or external) The measurement of satisfaction Metricssharedwithcustomer (target & management) Effectivenessisevaluatedthrough a specificrequirementat the end of each section A list of relevant metricsrelated to the evaluatedprocess Principles Criteria Effectivenessscoring Main processes Organization Example of requirement eFFEctIvENESSSCORINGfor a complete section Operational Standards 30
31. SCORINGThresholds for resultcalculation Red / Yellow / Green visualization applied Thresholds are defined on 2 levels On each Requirement: score < 2 => Overall result goes Red On each Key Element: score < 75% => Overall result goes Red Conditions to be certified No Red item (Key Element or Requirement) Overall result ≥ 85%
32. SCORINGEquivalenciesQIPV2.0 QIPV1.0 QIPV2.0 Requirements  QIPV1.0 Requirements QIPV1.0 Requirements  QIPV2.0 Requirements Old Scoring  New Scoring
33. 4 REQUIREMENTS OVERVIEW
34. QIPV2.0 Production Site Assessment15 Key Elements
35. QIPV2.0Production Site AssessmentDetailed Content#1: FastResponse (FR) Detection & Tracking of the internal/external major issues Daily production meeting Fast response Board Problem solving standardize methodology Used for all type of concerns 6 steps: define, contain, root cause id, correction, validation, institutionalization System to manage lessons learned Organization Procedure / forms
36. QIPV2.0Production Site AssessmentDetailed Content#2: Control of Non-conforming Product (CNC) Traceability Compliance to specific customer requirements Equipments & Organization associated FIFO Management Identification mode of the non-conforming or suspect material Alert issue Upstream: Tier N Downstream: Customer Containment process Rework process Management of the deviations (customer “derogations”)
37. QIPV2.0Production Site AssessmentDetailed Content#3: Verification Station & Error Proof Verification (VS) Final Checking Organization Standards Alarm system Thresholds definition Escalation process Error proofing systems Management of the EPS Management of the malfunctionning/ failures
38. QIPV2.0Production Site AssessmentDetailed Content#4: StandardizedWork (SW) Workplace organization Standardize Layout 5S management Ergonomics & Painfulness concerns Rules related to ergonomics Assessment of the workstation Operator involvement Working instructions (production process operations & logistics) Standards Procedure to validate start of production Visual & appearance items (boundary samples) Procedure Management of the boundary samples Control devices – Calibration & Capability Management of the devices (identification) Capability & Calibration
39. QIPV2.0Production Site AssessmentDetailed Content#5: Training (TR) Training organization Needs identification / Organization Infrastructures & skills for training activity Training material Safety Policy Safety handbook Training on safety Employees Qualification / Flexibility Chart Qualification process / follow up qualification status Calibration process for the quality control activity Training refreshment Motivation of Staff Process of motivation Individual interviews
40. QIPV2.0Production Site AssessmentDetailed Content#6: LayeredProcess Audit (LPA) Generic layered process audit Procedure and working standards Auditors training LPA on operational activities (under manufacturing dep. responsability) Master planning Complete coverage with relevant frequency Involvement of the different level of management LPA results follow-up Deviations record Action plans associated Countermeasures sheet Continuous improvement
41. QIPV2.0Production Site AssessmentDetailed Content#7: RiskReduction (RR) PFMEA management Periodical reviews Cross-functional approach Management of the highest risk items Identification & analysis Action plans follow-up Reverse PFMEA Real and effective risks verification at the workstation Findings taken into account to improve process General Risks management to guarantee manufacturing activity Natural risks (floods, fire,…) “Supply chain” risks (loss of energy, loss of supply)
42. QIPV2.0Production Site AssessmentDetailed Content#8: Contamination Control (CC) Main topic: cleanliness of the process Risk analysis on the complete shopfloor Compliance to customer specifications when needed Management of the sensible areas (clean rooms, paintshop,…) Management of the foreign material in parts Management of the dirts in parts or paint
43. QIPV2.0Production Site AssessmentDetailed Content#9: Supply Chain Management (SCM) Management of the Tier N suppliers Procedures to evaluate & select supplier Cascading of the customer requirements to the Tier N CSEtranfer Traceability requirements Product change management Escalation process Management of the single issues Audit policy Target definition and performance review Bidlist and business hold Incoming inspection process Components Control plan Sampling rules records
44. QIPV2.0Production Site AssessmentDetailed Content#10: Managing Changes (MC) All type of changes (planned & unexpected) Procedure for monitoring product/process changes Project management Communication with the customer Management of the deliverables (documents…) Risk analysis before any change Production Trial Run (PTR) process Banking process Planning Stock build-up Management of the long term storage Alternative processes / Bypass processes Identified alternative processes Authorizing process Specific countermeasures
45. QIPV2.0Production Site AssessmentDetailed Content#11: Maintenance (MAI) Maintenance organization & strategy Perimeter covered Available ressources & facilities Communication with manufacturing dep. TPM strategy & implementation / Standardization Policy Maintenance activities (planning & tracking) Preventive maintenance master planning / Corrective maintenance activities Working standards & technical documentation Maintenance records (equipments diary) L1 Maintenance management Definition of L1 maintenance operations Planning & follow-up Spare parts management Critical spare parts Stock management & storage conditions Management of the customer specific tools Tools identification Diary sheet and operation records Storage & handling conditions
46. QIPV2.0Production Site AssessmentDetailed Content#12: Manufacturing & Material Flow Management (MMFM) Manufacturing scheduling Business Planning (=> fix the capacity) Master production schedule (MPS => manage the ressources) Daily manufacturing program Constraints management (Bottlenecks) Identification updated in real time Equipment level of load permanently followed Product Packaging Storage areas & handling conditions Supply of workstations Supply organization Improvement Process
47. QIPV2.0Production Site AssessmentDetailed Content#13: ExternalLogistic (ELG) Supply process Master schedule of deliveries Logistic protocol with TIER N Service rate of the TIER N Supplier Securization of the supplies Identification of the risky supplies Securing plans Safety Stocks management Shipping process Shipping planning Preparation process Bogus truck EDI & logistic Electronic Protocol
48. QIPV2.0Production Site AssessmentDetailed Content#14: Strategy / Project Management (SPM) => NSA Used only for new supplier or for a new project Industrial Strategy & Vision (=> 5 yrs) Site organization & human ressources management Site Involvment during project Quality organization Job desciptions New equipments validation process Qualification process Project milestones Deliverables management Spare parts production Specific process “End of life” management PR storage Packaging design
49. QIPV2.0Production Site AssessmentDetailed Content#15: Part & Process Control (PPC) => NSA & PCPA Management of the documents Identification of the KPC (CSE) Process flow diagram and link with PFMEA Process control plan SPC and records management Product audits Customer contractual Safety Stocks (Optional requirement)
50. ! ! 5 EXAMPLES OF SCORING
51. Example Of Scoring Implementation 1/2 – LPA1 0 - No LPA Procedure / No check sheet defined. 1- Generic check sheet defined but not covering items related to safety, manufacturing or quality 2 - Generic check sheet established but there’s no auditor training or some key items for safety, quality and manufacturing are not covered 3 - Few auditors are not trained or check sheet not defined for supporting areas 4 – Check sheet covering all items. Evidence that all auditors were trained. Check sheet defined for supporting areas
52. Example Of Scoring Implementation 2/2 – LPA2 0 - No LPA scheduled and performed 1- LPA not performed but scheduled according to action plan or audits performed occasionally but no shcedule available 2- LPA conducted in all shifts but no scheduled for all levels following an established frequency 3- LPA missed for few workstations. Minor concerns related to documentation (e.g.: readability, dates, issues fix immediately are not documented…) 4 - LPA conducted according to schedule by all level (all shifts/workstations) and documented properly
53. Example Of Scoring Effectiveness 1/2 – LPA Key Element 0: No metric in place. Supplier has no global vision of the LPA implementation and LPA results (Eg: number of late LPA,…) 1: Supplier is tracking LPA planning. He is able to know if he is late or not. There are no metric to track results (Eg: mean nb of deviation by LPA, pareto of deviations,…) 2: Supplier is tracking LPA planning and LPA results. Some metrics are not correctly managed (no target, heterogeneous situation from a line to another,…). Team leader is free to do or not
54. Example Of Scoring Effectiveness 2/2 – LPA Key Element 3: Supplier is tracking LPA planning and LPA results. Metrics are well managed (target defined, metrics standardized, action plan to reach the target…). Target not reached on some line & several road blocks (customer issues, repetitive deviation, late action plans,…) 4: Same situation Cross check activites on the different metrics (Eg: Gap analysis between product line, between hierarchical level,…) Stabilize Metrics & No open issue.