Automotive Quality

TS 16949 / VDA 6.1 The StandardIn the Automotive Industry

Helmond, 21.06.2012

Introduction

+ Clemens van den Berghe ([email protected])

+ Physics and Business Economics

+ Philips Semiconductors, European Space Agency, Kema, Dekra,

+ Currently Director of PQ+ Netherlands B.V. together with Max van Vriesland

+ Acted as:

+ Customer

+ Supplier

+ Certification Body

+ Certification Auditor

+ Consultant

+ In the consumer, automotive, space industry

+ Present with two collegues:

+ Hans van Beek ([email protected])

+ Herman Ahrens ([email protected])

09.12.201509.12.2015 © PQ Unternehmensberatung GmbH 2

+ Founded 2005

+ By experienced former Daimler Executives

+ Focus on Implementation and Delivery

+ First Projects with Philips and Vishay

+ Dutch branch since 2008 – PQ+ Netherlands

+ Unique through Proprietary Technology

09.12.2015 3© PQ Unternehmensberatung GmbH

How PQ+ started: Philips APM

+ Automotive Excellence Program required by Customer Siemens

+ Strong implementation approach led by Max van Vriesland (Philips)

+ Concise Program supporting key elements of future successful programs

+ Top-down KPIs followed through by top management

+ „War Room“ for project management

+ Cross-site teams with specific team charters


IMPLEMENTATION SUPPORT: HANDS ON COOPERATION AND CONTINOUS VISUALIZATION (EXAMPLE)IMPLEMENTATION SUPPORT: HANDS ON COOPERATION AND CONTINOUS VISUALIZATION (EXAMPLE)

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What does the Automotive Industry need?

+ If you (supplier) develop something new you should release the new product in a proper way (Problem prevention through thorough design and process risk identification and process control resulting in high quality and low PPM from day 1).

+ If you (supplier) change something you should prove that it is better than the old product/process (less PPM).

+ If there is a problem they (customer) want quick resolution and no re-occurrence.

+ Compliance to the standard will only provide a good baseline.

+ But:

+ They (customer) will still want proof of effective implementation and use for each product they buy. This means prove of better innovation, improved productivity, etc.


What is ISO/TS 16949?

+ ISO/TS is a Technical Specification prepared by a technical committee of the International Organization for Standardization.

+ A Technical Specification represents an agreement between the members of a technical committee and is accepted for publication if it is approved by 2/3 of the members.

+ ISO/TS 16949 was prepared by the International Automotive Task Force (IATF).

+ IATF consist of

+ nine OEM’s

+ BMW, Chrysler, Daimler, Fiat, Ford, GM, PSA, Renault, VW

+ Five national associations

+ ANFIA (IT), AIAG (US), FIEV (FR), SMMT (UK) and VDA (DE)

+ ISO/TS 16949 defines the quality management system requirements for the design and development, production and, when relevant, installation and service of automotive-related products.

+ Only manufacturing sites where production and/or service parts are manufactured and supplied to customers subscribing to ISO/TS 16949 are eligible for certification.


What is VDA 6.1/6.2/6.3/6.4/6.5/6.6?

+ VDA – Verband der Automobilindustrie e.V.

+ VDA 6.1 is a German quality management system standard. It was initiated by the automobile industry.

+ BMW, Daimler, VW

+ Fagro, Kloeckner-Moeller, Johann A. Krause Maschinenfabrik, KUKA Schweissanlagen, August Laepple, Mannesmann Dematic, Schenk Rotec, Schuler Pressen, Schuler Werkzeuge, Sealed Power Europe, Siemens, VDMA, Vetter Inject System, ZVEI

+ Based on TS 16949.

+ The VDA standard is broken into parts:

+ Part 1; Quality System Audit

+ Part 2; Quality System Audit Services

+ Part 3; Process Audit

+ Part 4; Quality System Audit Production Means

+ Part 5; Product Audit

+ Part 6; Services Audit


How do you (supplier) get a certificate?

+ TS 16949

+ Comply to the requirements of the standard

+ Knowledge and implementation of Quality Tools

+ 3rd Party Audit by CB (Certifying Body)

+ Non-conformity Management - completion

+ Certificate of Compliance

+ Certificate

+ VDA

+ Comply to the requirements of the standard

+ Questions of the standard need to be implemented and proven to be effective

+ 3rd Party Audit - Auditor is registered as a Lead Auditor with the VDA.

+ Each question will be rated and awarded with a percentage of compliance

+ All questions together will result in a percentage of compliance

+ A VDA 6.1 Certificate Supplement to an ISO 9001 certificate is awarded at an overall level of compliance exceeding 90%.


What is certification?

+ A Lead Auditor will check if you have implemented the standard effectively+ Check a sample of your processes+ Internal Audit+ Management Review

+ Certification Manager+ Checks the audit program+ Checks the audit report+ Checks the resolution of non-conformities+ Takes decision on certification

+ Dekra, SGS, DNV, etc.+ Makes a quotation for certification+ Assigns certification manager

+ RvA Raad voor Accreditatie

+ Audits Dekra, SGS, DNV, etc. and give authority to certify (certifying body CB)

+ EL&I in the Netherlands

+ RvA is a ZBO (Zelfstandig bestuursorgaan) under the responsibility of the minister

+ RvA is audited by a team of experts from RvA’s of different countries


Why is certifciation a lot of work?

+ You (supplier) have to prove connection between all your processes

+ Example:

+ Complaint Handling - Development

+ Field problem – improved design

+ 8D, PFMEA, Control Plan, DFMEA

+ Example:

+ Change – Low PPM

+ Move to another factory – production proces

+ PFMEA, Control Plan, MSA, proof of low PPM

+ Example:

+ Development - Operations

+ New design – transfer to production – prove of concept – design for low ppm – lessons learnt


What does certification cost?

+ Rough Guess - €100.000,- / € 150.000,-

+ 1 to 2 man-year of work

+ Some SW tooling to support Quality Tools

+ External Support & Training

+ Certification Cost

+ Certification Cost are depending on size of the organization

+ Example for recertification


Employees Audit Days

1-14 2.0

15-28 2.5

29-49 3.0

50-80 3.5

etc. ect.

Why do organizations fail certification?

Topics often not sufficiently covered before certification:

① Management Responsibility and involvement

a) Understand the connection between processes

b) Know how to organize for this

c) Understand why your Quality Management System is (not) delivering low PPM

② Management understanding of root causes of problems/complaints

③ Understanding the purpose of Quality Tools and how they are connected

a) DFMEA, PFMEA, control plan, etc.

④ Understanding continuous improvement

a) Automotive needs continuous improvement


Why is certification not perfect?

+ You can have a perfect product with zero PPM without this standard.

+ You can have a product with low quality and high PPM with this standard.

+ But:

+ It provides a common base line in the industry.

+ Provides a common language between supplier and customer.

+ Helps to improve and achieve higher quality levels.

+ And:

+ The automotive industry has a good track record using these standards.


Accredited certification delivers real added value, May 2012 by IAF Communications and Marketing Committee

+ To gain a clearer understanding of the ‘value’ of accredited certification, IAF carried out a survey of businesses in 40 different economies. The survey aimed to clarify the drivers for seeking certification, the factors involved in choosing a certification body, and the extent of any benefit derived from the certification process.

+ Over 4,000 responses were received from businesses of all sizes operating across a diverse range of industries.

+ The real value of certification

+ Over 80% of all respondents reported that certification had added value to their organization. As a more quantifiable measure, around half of all participants have seen an increase in sales as a direct result of the certification.

+ Internal business improvement was given by nearly half of all participants as the main driver for seeking certification.


Discussion


Automotive Quality

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