Aditi Sharma. 29 th June 2016 Public
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1 Aditi Sharma 29 th June 2016 Public
2 AMaZe Methodology Example HHP VOC/VOB Quality Function Strategic Initiatives KJ Analysis S Curve Projects & Initiatives Action Tracker 3 1. Design for Zero Defect Product 2. Supplier Quality Improvements 3. Plant Quality Improvements 4. Product Quality & Reliability Improvements 5. Service Quality Excellence 6. Quality Functional Excellence & Quality Systems 7. Continuously Improve using 6 Sigma & COS
3 Quality Framework Design Supplier Plant Product Service Quality Functional Excellence Processes, Tools & People Change Management IQA Process VPI/VPC Process ESW Process (Product/Application) FIRG Process Reliability Standard Work System integration Supplier non conformance Mgmt. APQP / PPAP SIP Supplier Improvement Plans SPC & Process Capabilities (PPCM) Design Quality Review MQV Conformance of Production (COP) Statistical Process Control (SPC) EASE Control of Non confirming material Purchased Parts Inspection Manufacturing PPAP Product Problem Solving (PPS) Warranty Analytics BIS Process PQC - Product Quality Committee Global Problem Reoccurrence Prevention (GPRP) Communication Flow Parts Availability - Repair Event Cycle Time Technical Capability Infant Care NEPI Compliance Calibration, Measurement & Test Support services, Standards Laboratory & Materials Laboratory (NABL Accreditation) Audits Process Audits, Product Audits, Dock Audits, Layered Process Audits, COP Audits Database Metric Stream CQMS - CAR, SCAR, MNC/PNC, QSi Document Control, GPS Continuous Improvement - Six Sigma (DMAIC, DFSS & TDFSS) Capable People Certified ASQ Engineers, Lead Auditors, Six Sigma MBB, BB & GBs, SME s Quality Management Systems ISO 9001:2008, TS 16949: Cummins Operating System
4 AMaZe (Accelerated Move towards Zero-defects) is a company wide Quality Function initiative launched to accelerate improvements in five crucial areas - Design Quality, Supplier Quality, Plant Quality, Product Quality & Reliability, and Service Quality. This initiative is expected to play a significant role in bringing dependable products and services to the marketplace on a sustainedbasis. Area AMaZe Program Design Quality Supplier Quality Plant Quality Product Quality & Reliability Service Quality Sponsors Leader Nitin Deshpande Kavita Kaushik Sanjay Tamhankar Siva G Rohan Mengale Sundaram Babu Sandeep Sinha & Aditi Sharma 4 Cummins Confidential
5 Accelerated Move towards Zero-defects Pillars Critical Processes / Tools Design 1. VPCR Execution Process keeping the entire 2. IQA Process product life cycle in mind 3. Customer Engineering Approval Process Supplier 1. Source Release & PPAP for new & VPI parts all bought out, semi-finished 2. Supplier Improvement Program and finished products 3. Supplier Non-Conformance Management Plant 1. Statistical Process Control (SPC) all manufacturing processes 2. Conformance of Production (COP) ensuring Right First Time 3. EASE implementation Product 1. PPS Database product to deliver performance 2. Warranty Data Analytics before and after-in-service 3. BIS Process Service through enhanced 1. Communication Flow from Business to Field Personnel from Distribution Business responsiveness to 2. Parts Availability Repair Event Cycle Time service events 3. Technical Capability This initiative is expected to play a significant role in bringing dependable products & services to the marketplace on a sustained basis 5
6 AMaZe Review Mechanism Leadership CMD & COO SLT, OLT members & CF Team COO & Quality Champion OLT members, Quality Leaders & CF Team Function Quality Champion Quality Leaders, BU AMaZe Program Leaders Business BU Leader & Quality Leader Quality Champion, Quality Leaders, BU HOD & CF Team AMaZe Leader Quality Leaders & CF Team AMaZe Leader Quality Leaders, HOD & CF Team 6 Deployment started from April 2015 post AMaZe launch in March 2015
7 Journey and Key Learnings 2015 Q2 14 Q Q4 13 Q1 14 Best Practice HHP Challenges Sustained leadership engagement and reviews within HMLD and PGBU Focus on Engine Business (EBU) and Power Generation Launch AMaZe program in Q1 15 Business (PGBU) across all business units in India Best Practice HHP and ABO. HMLD 100% participation from DBU and Components Leadership. out of scope Structured review mechanism. Synergize across business units. Launch AMaZe across India ABO Leadership engagement Structured review mechanism Synergize across business units Sharing best practices
8 Supplier Partner s increased collaboration on AMaZe We are looking for your collaboration on the front of design quality and supplier quality Cummins Support Benefits Design Quality: Earlier engagement in design Change Management IQA process VPI/VPC process Supplier Quality: Supplier non-conformance mangement APQP / PPAP SIP Supplier improvement Plans Product Quality: PPS Database Warranty Data Analytics BIS Process Reduction in supplier, BIS, ELF, testing PPM Improvement in STU Less product failures at customer end More satisfied customers 8
9 Insert Data Classification 9
10
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