Application of Measurement System Analysis at the ABC Company Asst. Prof. Dr. Gökhan İZBIRAK Supervisor Mohammad Khanjani Student 1
the purpose of this thesis Critical Part ISO 9001, ISO 14001, OHSAS 18001 Quality Planning 1 Miner non- conformit y Gage R&R (Xbar/R) for D1 OPERATOR * PART Interaction 8.0 O PERA TO R 1 2 7.5 Average 7.0 6.5 6.0 1 2 3 4 5 PART 2
Quality • A degree of excellence • Conformance with requirements • The totality of characteristics of an entity that bear on its ability to satisfy stated or implied needs. • Fitness for use • Fitness for purpose “ the degree to which a set of fundamental characteristics fulfils the requirements ” The need, requirements or expectation S the degree to which a set of t fundamental characteristics fulfils a a need or expectation that is stated, n generally implied or obligatory d a r The performance level d Time 3
Real case: Transmission problem (US domestic plant and Japanese supplier) Cost of Guarantee USL LSL Japan United $ States Target US Japan Montgomery (2005a) has defined quality term as a proportion to variability. This definition implies that if variability in the key characteristic of a product decrease, the quality of the product increases 4
Real case in IRAN: Honda motor company in Qhazvin city. About 8 years ago the managers decided to make one of the main parts in house, Shock absorber . After 2 years , they were successful to pass all of the testing requirements from Honda of Japan . But in the first try, all of the motorcycle were claimed by the customer, Why? The claim reports base on the customer voice : the flexibility is high the flexibility is low A team conducted survey and they took 200 samples from the original Shock absorber that have been assembled to the motorcycle before from the market . 5
PIONEERS OF SCQM The performance indicators of Dell show that this company manufactures more than 50,000 computers every day, but carries only four days of inventory (competition carries 20 – 30 days). From quality issues point of view Dell launched the Critical Supplier Partnership Program resulting in improvement in quality metrics and continuity of supply. This program reduced early field failures by 37% and manufacturing line failures fell from 15,000 to 3000 defective parts per million (dppm) 6
The automotive industry is the biggest industry in the world. Advanced Product Quality Planning (APQP) Failure Mode and Effective Analysis (FMEA) Statistical Process Control (SPC) AIAG Measurement System Analysis (MSA) Automotive International Action Part product approval process (PPAP) Group 7
T he purpose of this thesis is to find a solution for improvement of the controls among the product realization in designer and manufacturer of the gas turbine blades with applying the two Automotive Supply Chain tools which are known as Measurement System Analysis ( MSA ) and Advanced Product Quality Planning ( APQP ) This idea is taken from works of Carol J. Robinson et al. (2004) in which illustrate the Supply Chain Quality Management characteristics and works of M. Bobrek et al. (2005) in which investigate the APQP model in other sectors as a basic concept for designing and implementation of Integrated Management System (IMS) 8
QUALITY IN THE SUPPLY CHAIN MANAGEMENT Developing and maintaining strong relationships between firms and their suppliers, as well as among suppliers at different layers of the supply chain, has become an important strategic issue. Many have suggested that supply chain management can lead to faster product development, decreased production lead-times, reduced cost, and increased quality (Choi. T. Y, 1999). T an et al. (1999) conducted a survey on quality directors and vice- presidents from a broad range of industries , and concluded that successful management and well-defined linkages between Total Quality Management (TQM) practices and performance is the key to long-term success. In addition, they concluded that many strategic quality approaches and Supply Chain Management tools are positively correlated with firm performance. 9
Some of the related questions which supported this idea are: • Training in basic statistical techniques such as histograms and control charts. • Training in advanced statistical techniques (design of experiments and regression). • Quality awareness provided to managers and supervisors. • Development of procedures for monitoring key indicators of competitor and customer satisfaction performance. • Quality department plays an active role in providing specific training such as Variation concepts and SPC. Carol J. Robinson, et al. (2004) conducted a comprehensive review in quality management system among SCM and provided a new definition for it as Supply Chain Quality Management (SCQM). 10
SCQM evolution -Acceptance -Zero defects -TQM Sampling - Program solving Supply Chain - Control charts - Quality circles - ISO9001 Supply Chain Quality Management Programs - Statistical quality - SPC - Baldrige Award Management - Six-sigma (SCQM) Control - DOE - Inspection Years 11920-1960 1960-1980 1980-1990 1990-present 2004-present Focus Internal Internal - Supply-base All supply channel All supply channel Organization Organization - Organization members and mostly members and mostly - Customer exception internal organization external organization Traditional quality programs focusing on approaches such as TQM, the Malcolm Baldrige National Quality Award (MBNQA) and ISO 9001 (international quality management system standard), must now transform to a supply chain perspective in order to simultaneously make use of supply chain partner relationships and quality improvement gains essential to marketplace satisfaction. A case study of a firm that is a first-tier supplier in an automotive supply chain is presented to better illustrate the SCQM themes and their treatment in industrial practice. Information for this case study was gathered during ISO 9001:2000 pre-assessment auditing and a detailed structured interview with the Assistant Vice President of the firm. 11
For many firms, obtaining acceptable levels of quality starts with the registration of a QMS for itself and its suppliers to ISO 9001. Q uality Assurance registration does not necessarily ensure product quality, but gives guidance on the implementation of the systems needed to trace and control quality problems (Robert et al., 2007). From reliability (how often does the product fail?) point of view, J. D. Booker et al. (2001) argued that, reliability prediction will remain a debatable technique until the statistical methods for quantifying design parameter becomes embedded in everyday engineering. Attention needs to be focused on the quality and reliability of the design as early as possible in the product process development. A lack of understanding of variability in manufacturing and service conditions at the design stage is a major contributor to poor product quality and reliability To communicating reliability problem: FMEA, QFD, DOE 12
APQP The goal of Product Quality Planning (PQP) is to with everyone involved to assure that all required steps facilitate communication are completed in time (M. Bobrek a. et al., 2005). Control Control Control Control Control Control Control Control Sheet Sheet Sheet Sheet Sheet Sheet Sheet Sheet 13
Advanced Product Quality Planning (APQP) (g) Control plans (a) Organize the team (d) Training (h) Concern resolution (e) Customer and supplier (b) Define the scope involvement (f) Parallel engineering (c) Team-to-team 14
Most of the application of APQP has been used for production process in the manufacturing industry by many researches. First significant application of APQP in integrated management system ( IMS ) design has been employed by M. Boberk et al. (2005) Integrated Management System: ISO 9001+ISO 14001+OHSAS 18001 This model as a procedure has been tested on over the 30 certified quality management systems and 2 environmental management systems. 15
The process improvement cycle 1- ANALYZE THE PROCESS 2- MAINTAIN THE PROCESS • What should the process be • Monitor process doing? performance. • What can go wrong? • Detect special cause • What is the process doing? variation and act upon it. • Achieve a state of statistical control • Determine capability PLAN DO PLAN DO 1 2 ACT STUDY ACT STUDY 3- Improve the process PLAN DO • Change the process to better Understand common cause variation. 3 • Reduce the common cause variation ACT STUDY 1. Basic understanding of the process among identifying common and special causes and achieving a state of statistical control. 2. Due to processes are dynamic and will change, the performance of the process must be monitored with effective measures. 3.To covering the customer needs which are sensitive to excessive variation within engineering specification , additional process analysis tools, including more advanced statistical method such as designed for experiment (DOE) and advanced control charts (such as cumulative control chart) may be useful in the third stage. 16
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