TS 16949 / VDA 6.1 The Standard Helmond, 21.06 - PQ+ · PDF file+ Part 1; Quality System Audit...
Transcript of TS 16949 / VDA 6.1 The Standard Helmond, 21.06 - PQ+ · PDF file+ Part 1; Quality System Audit...
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])
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+ 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
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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
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IMPLEMENTATION SUPPORT: HANDS ON COOPERATION AND CONTINOUS VISUALIZATION (EXAMPLE)IMPLEMENTATION SUPPORT: HANDS ON COOPERATION AND CONTINOUS VISUALIZATION (EXAMPLE)
E xit Criterion 1 – F la wles s Launch of DVD M 3.5E xit Criterion 1 – F la wles s Launch of DVD M 3.5
P roject KP I’s (1)
J .W.B.cw515
- Consultant support extentet
- Addtional ECP as s is tant requested
- Tas k fore team established
Address red ECOs2.1
A.W.cw515Involve consultantsKPIs not defined2.2
B. M.cw515Contact Philips Nijmegen Involve supplier
(PAT & BIN)3.1
M.v.V.cw515Most suitable SW Databas e to be ordered Pending first meas urement
1.1
Resp.Due DateCorrective ActionIs sueProject
J .W.B.cw515
- Consultant support extentet
- Addtional ECP as s is tant requested
- Tas k fore team established
Address red ECOs2.1
A.W.cw515Involve consultantsKPIs not defined2.2
B. M.cw515Contact Philips Nijmegen Involve supplier
(PAT & BIN)3.1
M.v.V.cw515Most suitable SW Databas e to be ordered Pending first meas urement
1.1
Resp.Due DateCorrective ActionIs sueProject
P roject KP I’s (1)
J .W.B.cw515
- Consultant support extentet
- Addtional ECP as s is tant requested
- Tas k fore team established
Address red ECOs2.1
A.W.cw515Involve consultantsKPIs not defined2.2
B. M.cw515Contact Philips Nijmegen Involve supplier
(PAT & BIN)3.1
M.v.V.cw515Most suitable SW Databas e to be ordered Pending first meas urement
1.1
Resp.Due DateCorrective ActionIs sueProject
J .W.B.cw515
- Consultant support extentet
- Addtional ECP as s is tant requested
- Tas k fore team established
Address red ECOs2.1
A.W.cw515Involve consultantsKPIs not defined2.2
B. M.cw515Contact Philips Nijmegen Involve supplier
(PAT & BIN)3.1
M.v.V.cw515Most suitable SW Databas e to be ordered Pending first meas urement
1.1
Resp.Due DateCorrective ActionIs sueProject
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.
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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.
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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
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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%.
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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
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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
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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
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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
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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.
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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.
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Discussion
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