Implementing Global Quality Audits at a Tier 1 Auto Supplier

Optimizing Global Quality Audits on Mobile Devices

About GKN Driveline

• “GKN Driveline is the leading automotive driveline technology and systems engineer.”

• 29,000+ Employees

• 49 Manufacturing Locations

• £4.62 Billion / $6.02 Billion in Sales

Background: GKN Driveline Quality Program

• Various AIAG / VGA / OEM requirements and bespoke in house Leadership Standards of Work (LSW) along with robust product development.

• Model cells to show what good should look like and regular management engagement in the non-production areas as well as the production areas of the business as well as a quality first culture.

• Stronger GKN AQE leadership team focused on systems and processes to deliver program quality

Why Change? GKN Driveline

• Lessons learnt from previous OEM launches

• Importance of built in / designed in quality and the ability to have a positive effect on new launches through managing the quality in the program development instead of having a product that the plants don’t get involved with until it is time to industrialize the product.

• Get rid of Excel!

Goals of Project at GKN

• Improve the time taken to complete the audit

• Standardized responses

• Ease of audit

• The ability to assign direct actions during the audit that can be tracked and managed.

• Trend analysis on issues and target training to improve business

Quality Auditing in the 21st century

• Implement a global quality auditing

system with a fraction of the typical

resources

• Standardize audit procedures across 20

countries, multiple languages, and

cultures

• Keep OEM requirements up to date

across 53 facilities

Quality Mobile Auditing in the 21st Century

1. Manage audit schedules around the world

2. Tie employee bonuses to audit performance and

schedule adherence

3. Track data across multiple locations

4. Conduct audits on mobile devices

5. Assign responsibilities for non-conformities and

tracking follow-up

6. Ensure non-conformities are re-assessed for

effective root cause within 1 year of the issue

1- Audit Schedules: Multiple and Changing

• Jurisdiction specific

requirements (safety) – Delay

of 9 months due to changed

requirements not incorporated

into audit schedule

• Industry standards (AIAG…)

• OEM Requirements (Ford,

GM,…) - with no clear change

management

1 – Standard Audit Scheduling

• 15 step process!

• Illegible due to number of

steps

• Too many areas for human

error, delays and

miscommunication –

especially with paper, word,

excel, email…

Quality Auditing in the 21st century

• Global Operations

• Multi-Lingual

• Multi-cultural

• Training, Training, Training

• Visibility across operations and

suppliers

1- Audit Schedules: Visibility is the Key

• 1200 Suppliers to Tier 1 Supplier

Company

• Spread over 25 countries

• Many suppliers were getting audited

multiple times by the Tier 1 Supplier as

different divisions and factories were

auditing the same supplier

2- Employee Alignment Around Audit Program

• Staff must:

• Perform audits on time

• Issue audit reports and corrective

actions on time

• Close corrective actions on time

• Various enforcement tactics are used

3 - Tracking Data: GKN Tracking Non-Conformities

• If a Non-Conformity is Found, Corrective

Action must be closed within three weeks

or it impacts bonus

• Tracked through one central weekly report

that is automatically generated

3 - Tracking Data: Tracking Non-Conformities

4 – Audit on Mobile Devices

• GKN was using a mix of PDF, Word and

paper

• Centralize all the audits in one location

with reference material

• Centrally manage the reference material

• Mobile devices can work offline and online

and sync automatically

• Multiple people can audit together

4 – Audit on Mobile Devices

4 – Audit on Mobile Devices

4 – Operational Effectiveness

• Reduce the human element

• Standardize the procedure

• Remove subjectivity and bias

• Your plan is only as good as your people’s

training and skills

4 – Operational Effectiveness

5 – Corrective Actions

• Assign to a person or Function

• Clear due date tied to level of non-

conformity

• Clear action to take

• Evidence non-conformity, annotated photo

5 – Annotated Photos Make Big Difference

5 – Assigning Corrective Action Responsibility

5 – Complete Corrective Action

• Complete Corrective Action with:

• Date, GPS and Time Stamp

automatically

• Note explaining Completion

• Attach evidence – Photos,

Documents…

• Manager approves/rejects action notes

5 – Complete Corrective Action Report

6 – Effectiveness Assessments

• Used in Aviation and Military

• Return to non-conformity after a set time

– 6 months to a year

• Determine if the non-conformity was

permanently solved with the corrective

action

• If not effective, conduct further analysis

6 – Prioritize Effectiveness Assessments

• Generate Problematic Items Report to

see:

• Items that appear across audits by

supplier, OEM, product line or other

metrics

• By audit type ; IATF 16949, VDA 6.0…

6 – Recurring Non-Compliances

Three Biggest Challenges at GKN

• Language

• Training time

• Governance of standard of the audit

Three Biggest Challenges at GKN

Language Barriers at GKN

• Even though the business language is English we still see some interpretation of certain requirements but this we manage through governance and training.

• Translated in to some local languages for key audiences China/Mexico for example.

Next Steps in Auditing Process

• More Automation

• More Context for Auditors to understand IATF Requirements

• Framework already in place for GKN transition to PSSO IATF 16949

Lessons Learned at GKN

Key Elements:

– Ease of use

– Tracking of open issues

– Quick turnaround on modifying the audit questions to meet new requirements

– Power of the reporting and ability to capture shop floor issues immediately on camera in phone and link them directly to the audit questions.

Lessons Learned at GKN

“Ability to attach standards to the questions is absolutely immeasurable, especially when they can be referenced or reviewed on the shop floor.”

Summary

• Key Points

• Select EASY to use software with

global support

• Have auditor test the software

• Focus on data, not dashboards

• Focus on performance bonuses and

motivators to stick to the system

• Start small and grow!

Contact

Thank you and good luck!

Jonathan Brun

[email protected]

+1-514-712-0637