IBS: Interactive Quality Management June 2011 IBS America T H E P R O D U C T I V I T Y A D V A N T A G E
Interactive Quality on the Shop Floor
Sep 12, 2014
View the latest webinar from IBS America about managing quality on the shop floor.
Visit IBS America to learn more about quality management software systems: www.ibs-us.com
Don't forget to sign up for the next webinar in July, 2011: check out our blog for details!
http://info.ibs-us.com
Visit IBS America to learn more about quality management software systems: www.ibs-us.com
Don't forget to sign up for the next webinar in July, 2011: check out our blog for details!
http://info.ibs-us.com
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
IBS: Interactive Quality Management June 2011
IBS AmericaT H E P R O D U C T I V I T Y A D V A N T A G E
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Qsys and IBS Overview
PDCA Process Walk-Through
Q&A
The Case for Interactive Quality
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Quality
© IBS AG Slide 3
Solve Quality Issues Early in the Cycle
Warranty and Recall costs $$$$
Scrap and Rework $$$
Non Conforming Purchased Items $$
Interruptions in Production $$$
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Shop Floor Quality
© IBS AG Slide 4
Solve Quality Issues Early in the Cycle: How?Design and Plan for reliability, quality $$$$Verify Supplier QualityMonitor Production QualityUse Proven Improvement Processes Continuously:
SPCCAPAFMEAPDCA
THE PRODUCTIVITY ADVANTAGEIBS Overview
The Case for Interactive Shop Floor Quality
© IBS AG Slide 5
Examples of Savings From This Approach
TRW Warranty Cost Savings $3 Mill
BP Increased Production Rates ROI < 1 Year
Delphi ROI < 12 Months plus reduced materials cost and increased production
BMW Reduced Assembly Costs by $30 Mill
Ceramtec ROI < 12 Months + reduced liability
THE PRODUCTIVITY ADVANTAGEIBS Overview
Reduce Costs
© IBS AG Slide 6
Design Quality Issues Out
Increase Production
Ship 100% Quality
Stop Adding Value to Non-Conformities
Efficiently Handle Complaints
Use SPC
Identify Non-Conforming Purchases
Root Cause Analysis
Corrective actions
Maintain Control
THE PRODUCTIVITY ADVANTAGEIBS Overview
Reduce Costs
Design Quality Issues Out Increase Production Ship 100% QualityStop Adding Value to
Non-ConformitiesEfficiently Handle
Complaints Use SPC Identify Non-Conforming
PurchasesRoot Cause AnalysisCorrective actionsMaintain Control
© IBS AG Slide 7
APQP/FEMA
Inspection Planning/First Article
Outgoing Goods Inspection
In Process Inspection
Complaint Management Process
SPC Analysis
Incoming Goods Inspection
CAPA
CAPA
Audits/Alerts
Strategy Implement:
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Discussion / Goals
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
•
Act Plan
DoChec
k
FMEAControl Plan
Flowchart
Inspection Planning
Project Management
Production
Incoming Goods
Outgoing GoodsQuality Control
Panel Supplier Assessment
SPC
Problem Solving Process
Action Management
Audit Management
IBS Quality Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
Act Plan
DoChec
k
Fine planning
Process Overview /Online-Visualization
KPI (OEE, FPY)Analysing (PAA, CPK)
ODA
Resource Planning
PRISMA
DB
Admin/Konfig. Koppel-PC
ACC
Koppel-SPSAndon Board
Diagnose-Touch Panel
Info-Point
Masch.-SPSMobil-Scanner
Docking-Station
Handy
Auswertung
...
LiTab
Prozess-Netz (Ethernet)
MDA
Problem Solving Process
ActionManagement
Audit Management
Order Management
PaperlessRepair
© IBS AG Slide 10
IBS Quality Execution Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Traceability solutions for product and process traceability
Customer
Supplier
Plant 1Plant n
Transport
Purchased Parts
Standard Assembly Groups
Standard Components
TraceabilityKPI‘s
Cockpit
© IBS AG Slide 11
THE PRODUCTIVITY ADVANTAGEIBS Overview
Agenda
Agenda and Introduction
Solution Overview
Company Overview
Discussion / Goals
Customer Case Studies / Benefit Analysis
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS America, Inc.
Group with 5 companies Germany, USA, Lithuania plus
Support office in in China
Publicly traded since 2000 Revenue 2008: ~ $30 million
Founded in 1982 Today about 180 employees
Supporting over 4000 customer installations globally (spanning over 50 countries and 5 continents)
THE PRODUCTIVITY ADVANTAGEIBS Overview
Key Competences & Positioning
Industry independent Process consulting
Implementation
Training
Project Management
ServicesInnovativeSoftwareSolutions
Integration withcorporate
IT-Systems
MIS
MaintenanceOperationImplementation
Machinecontrol
ERP
Process control
MESCompany mgmt.
Production
Directors
Dat
a flo
w
THE PRODUCTIVITY ADVANTAGEIBS Overview
IBS Customers Save Money
The Cost of Quality as % of RevenueSource: Aberdeen Group 2009
IBS customers achieve substantial cost reductions
with better than average performance (e.g. first pass yields, on time shipments).
0%
50%
100%
IBS Average Average Laggard
18% 24% 29%
THE PRODUCTIVITY ADVANTAGEIBS Presentation
•
Act Plan
DoChec
k
FMEAControl Plan
Flowchart
Inspection Planning
Project Management
Production
Incoming Goods
Outgoing GoodsQuality Control
Panel Supplier Assessment
SPC
Problem Solving Process
Action Management
Audit Management
© IBS AG Slide 16
IBS Quality Management Solution: PDCA-cycle
THE PRODUCTIVITY ADVANTAGEIBS Presentation
CustomerRequirements
One Knowledge Database for Engineering
APQP/First Article Inspection Project plan and
Checklists
Design Engineering
Customer DrawingPart Master
Process Engineering
Design FMEA
OperationsProcess Flow ChartProcess FMEAControl Plan
Spend time on the “floor” = Identify and gather data
First SampleInspection
THE PRODUCTIVITY ADVANTAGEIBS Presentation
1
2
3
APQP - Data flow between Process Flow Chart, FMEA, Control Plan
THE PRODUCTIVITY ADVANTAGEIBS Presentation
THE PRODUCTIVITY ADVANTAGEIBS Presentation
SPC Evaluation
Statistical Process Control - Analytics
Single Value Chart
Control Chart
Shopfloor data is immediately availablefor evaluation
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Supplier Assessment
Suppliers are assessed on four main criteria:
Supplier Assessment
Product Quality
Accuratedelivery dates
Accuratedelivery quantities
Softcriteria
Data collected for each deliveryData valid for apre-defined period.
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Supplier Portal
Error analysis and corrective actions
Supplier Complaint passed to the Supplier Portal
Supplier completes analysis and actions
Optional: Display keyquality indicators from the Supplier Assessment module
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Action items
Insert documents or photos of any type
Create actions with a due date, escalation profile and responsible person
Concern and Complaint Management
Email integration
THE PRODUCTIVITY ADVANTAGEIBS Presentation
Concern and Complaint Management - Reporting
Define reporting periods and get immediate visual results
Drill-Down and Drill-Up functionality
Export into Excel
THE PRODUCTIVITY ADVANTAGEIBS Presentation
QSYS Modules - Overview
Related Documents
