QUALITY METERING PRODUCTS TAKE TEAMWORK FROM EVERYONE. Eric Quesnel Itron - Oconee

Transcription

1 QUALITY METERING PRODUCTS TAKE TEAMWORK FROM EVERYONE Eric Quesnel Itron - Oconee

2 WHY ITRON METERING Over 100 years of metering history Frost & Sullivan Market Leadership in Metering and Advanced Metering Infrastructure Initiatives Advanced Metering Infrastructure/Smart Metering Product Quality Leadership PM50 Award for Manufacturing Excellence Company commitment to utility industry Financial strength GridVision Award Made in USA

3 ITRON QUALITY NETWORK - TEAMS Purchasing IT Manufacturing Quality Assurance R&D Logistics Marketing Quality Metering Products Customers Consistently delivering innovative metering products with highest quality and competitive pricing requires EVERYONE!!

4 PLAN DO CHECK ACT (PDCA) CYCLE QUALITY METERING IS CONTINUOUS PLAN Common Development Process (CDP) ACT DO CHECK Itron s - Common Development Process ensures quality every step of the way requiring teamwork from all departments to ensure project deliverables are met.

5 METER SPECIFICATIONS & FIRST ARTICLES» Essential communication between Utility Customers and Itron Sales Executives lead to creation of Meter Order Specification form (MOSF) Upon creation of MOSF, meter build details are reviewed for content and accuracy» Communication between Document Control, R&D Engineering, Marketing, Manufacturing, Purchasing, Logistics, and Quality teams required to develop key items not limited to: Bill of Materials / Customer Part Numbers / RATI Part Selection - Planning / Ordering / Specifications / Purchasing Hardware & Software Specifications Required Testing & Critical Quality Parameters» Marketing & Quality First Articles conducted Marketing First Article - Review of MOSF with information loaded into Itron s system Quality First Article Ensure Meters built per Customer Specifications & MOSF

6 FOUR QUALITY AREAS OF FOCUS - PURCHASING» New Supplier Qualification Procedure established for qualifying new suppliers Supplier Qualification Form Requires supplier on-site audit with Purchasing, Quality & Technical expertise» Supplier Audits Formal standard audit process & forms Target new and legacy suppliers Performance objective» Supplier Evaluations Issued quarterly Quality = 60%, Delivery = 30%, Support = 10%» Supplier Reviews ( QBR) Topics include: supplier evaluation, production forecast, NPI, market trends, productivity improvements Performance objective

7 STANDARDS USED FOR TESTING 1. ANSI C ANSI C CFE G CFE CWH IEC IEC IEC IEC JIS C

8 FULL QUALIFICATION TESTS 1. No Load 2. Starting Load 3. Load Performance 4. Effect of Variation of Power Factor 5. Effect of Variation of Voltage 6. Effect of Variation of Frequency 7. Equality of Current Circuits 8. Stability of Performance 9. Effect of External Magnetic Field 10.Effect of Polyphase Loading 11.Effect of Internal Heating 12.Effect of Temporary Overloads 13.Effect of Current Surge in Ground Conductor 14.Internal Meter Losses 15.Effect of Variation of Ambient Temperature 16.Insulation 17.Voltage Interruption 18.High Voltage Line Surges Impulse and Ringing Waveform 19.Fast Transient

9 FULL QUALIFICATION TESTS 20.Damped Oscillatory Waveform 21.Effect of ESD 22.Effect of Operating Temperature 23.Effect of Humidity 24.Variation of Voltage Secondary Time Base 25.Temperature Rise 26.Mechanical Shock 27.Transportation Drop 28.Mechanical Vibration 29.Transportation Vibration 30.Weatherization 31.Salt Spray 32.Raintightness 33.Effect of Radio Frequency Interference 34.FCC Part 15, Class B Radiated and Conducted Emissions 35.Demand Interval Test 36.Energy Test

10 SMT TESTING & TRACEABILITY» 6 SMT assembly lines Laser board serialization (2D Matrix) Process tracking & 100% SMT Component Traceability Pb and Pb-free processing Moisture Sensitive Component Tracking Placement capacity: >500K parts per hour (2.3 Billion Parts in 2011) SMT Technologies - Single and Double sided placement chip components (0201 capable) -.5 mm pitch BGA, QFN and QFP packages - Pin-N-Paste

11 TODAY S CAPABILITY» 6 SMT assembly lines (Cont.) In-line: Automated Optical Inspection (AOI) - 3D solder paste AOI - Component AOI X-Ray inspection of Ball Grid Array parts ESD Flooring and Grounding Stations

12 POST SMT ASSEMBLY & TEST» In-Circuit Testing 12 systems (Teradyne and Digital Test) 1 flying probe ICT system» Conformal Coating 3 auto-application and curing lines» Flash Programming: 15 Custom board level systems» Functional Verification: 20 custom systems RF performance to 2.4 GHz. Transmitter and Receiver» Automated Assembly Systems Centron Display Automation OpenWay Secondary assembly and Display Automation» 100% Board History Tracking System Complete history from born-on date to customer meter serial number

13 RISK MITIGATION - SPC AND MSA Itron Advantages: Ease of integration with Itron SQL Severs Corrective Action Module Many Process Control Options (Variable and Attribute Data) Automated Data Analysis Software Selection Process Itron Advantages: Measurement System Analysis Gauge Reliability and Repeatability Linearity / Bias Studies Design of Experiments Regression / Correlation Analysis of Variance Descriptive / Graphical Statistics

14 RISK MITIGATION - CONTROL PLAN / PFMEA PFMEA Prioritizes & Ranks Risk Displays Failure Modes Action Plan for Risk Reduction Activities Control Plan Identifies Methods for Controlling Risk Record Specifications Established SPC Parameters ` FMEA (Process) AIAG Third Edition Test / Item/Process Openway Automation Process Responsibility: Manufacturing Engineering / FMEA Number Openway#1 Quality Subsystem CENTRON Page 1 of 1 Model Years 2007-Now Prepared by: Eric Quesnel Core Team: Openway Automation FMEA Date 8/8/2008 Process Step Potential Failure Mode Install Base ID Assemble Studs Install Hanger Assemble Disconnect Links & Conductors Solder Leads Base ID Stuck / Jammed on Applicator -Improperly Adjusted Horn -Incorrect Stud Placement Hanger placed incorrectly -Improperly Seated Screws -Broken / defective tabs on bases -Damaged part Potential Effect(s) of Failure Misread at Barcode Scanner -Uneven stud welding / Excessive Flash -Damaged Part Minor / Scrap $ -Meter may not function / power up properly -Intermitent -Improper amount shorts of solder applied -Reduce product -Defective leads / wire performance S e v # #. Potential Cause(s) / Mechanism(s) of Failure -Equipment Adjustment -Cleaning Required -Ultrasonic horn is not keyed for repeatability -Operator Error O c c # Operator Error 3 # # -Operator Error -Supplier Defect -Bulk Packing -Operator Error -Internal Supplier Defect # # # #. Current Process Controls Visual Inspection / Barcode Scanners Visual Inspection Visual Inspection -Visual Inspection -In Process Testing -Visual Inspection -In Process Testing D e t. R. P. N. Recommende d Action(s) # ###### # ###### # ###### # ###### # ###### The development and updating of these critical documents throughout project completion saved Itron time and focused resources on items with greatest risk.

15 OPERATOR TRAINING & QUALIFICATION All employee training is entered into the training database once completed and covers the following documents: Standard Operating Procedures (SOP s) Work Station Instructions (WSI s) New Production Operators must were a Red Trainee badge until Signed Off and Fully Trained Test Plans Employee Certification / Recertification Programs: Electrical Component Identification Handling Moisture Sensitive Devices IPC ESD Control IPC-A-610 Acceptability of Electronic Assemblies J-STD-001 Requirements of Soldered Electrical and Electronic Assemblies

16 LEAN MANUFACTURING TECHNIQUES Lean Manufacturing: The identification and elimination of waste (Muda), which creates production inefficiency and prevents customers from getting the right product at the right time. 7 Types of Wastes: Overproduction, Waiting, Transportation, Over-processing, Inventory, Movement, Defects Andon: A visual control device in production area, typically lighted overhead display, giving current status of production and alerting team members when there is a problem. InView Display Light Stacks Tri-Color Light Indicator Poka-Yoke: Mistakeproofing device or procedure to prevent a defect during product manufacturing. Proximity / Optical Sensors Intelligent Fixture Design Autonomation / Jidoka - Transferring human intelligence to automated machinery so machines are able to detect a problem and identify operator of defective condition. Vision Inspection & Verify Camera Based Systems Production Dashboard: * Quality Stars * Process Metrics Schedule Data Screens: (Hourly Rate, Yield, Takt Time)

17 FACTORY ACCEPTANCE TESTING Factory Acceptance Testing includes - Acceptance Test Plans (ATP s), Design / Programming Reviews, Electrical / Pneumatic / Toolmaker checklists at both the Individual Station and System level. Good communication and teamwork is essential to ensure high quality results! Design / Programming Reviews Electrician Checklist Acceptance Test Plan (ATP) Toolmaker Checklist

18 ANNUAL INTERNAL COMPLIANCE AUDITING Itron is committed to conducting continuous internal audits of the ISO system throughout the year. Audit teams are split up into functional groups based on areas to be audited. Reporting responsibility is assigned to the Audit Team Leader. This process provides: Continuous feedback on compliance to the ISO system Assignment of Corrective Actions when necessary Cross functional teams committed to reviewing & improving the system

19 ISO 9001:2008 TRIENNIAL RESULTS New Certificate was issued to the ISO9001:2008 standard. There were No Observations found during the audit. Dave Ladd mentioned during the closing meeting The strength of any company is its people. All personnel were helpful, cooperative and knowledgeable and were able to demonstrate their abilities and dedication to producing good quality products. Additional strengths mentioned were: Internal Audit System: Very thorough and collects much objective evidence during audits Strategic Purchasing: Detailed Supplier Evaluation system used Production: Very Flexible, Innovative, and Adaptable to Change People / Equipment: Forward Thinking is displayed with addition of Robotic and Automated Equipment Training Records: Detailed and Concise

20 IT SECURITY / DATA STORAGE / REPORTING» Develop wireless infrastructure to bring people together» Translate data into decision making information Develop Itron server based dashboards for KPIs, goals, reports, and trend analysis» Security Maintaining data security and integrity Ensure Certicom system performance Monitor data exchange such as Zigbee Certificates and Security Keys

21 LOGISTICS IMPACTING QUALITY» Help enforce first article process Constraints built into scheduling & shipping applications Prevent production runs from occurring until the customer has approved a first piece Ensure the customer is getting exactly what they desire Ensure repeatable delivery of the correctly configured product

22 LOGISTICS IMPACTING QUALITY» Order integrity process Review part number, description, price, and address information scheduled to build match customer PO Prevent unnecessary rework caused by keying errors» Meter related file creation Includes meter data, ASNs, security key files, ESN files Automated file generation and delivery Systematic constraints to ensure every meter has been through all processes before data can be generated

23 POSITIVE UTILITY CUSTOMER FEEDBACK Southern California Edison Installs Four Millionth Itron Smart Meter, Expands Energy Management Programs and Services for Consumers "Itron is a top tier metering system provider with proven smart meter solutions, extensive utility experience, and a clear commitment to ensuring BC Hydro achieves our Smart Metering objectives," said Gary Murphy, Chief Project Officer, BC Hydro. "With Itron's next-generation utility technology, DTE Energy is modernizing our grid and lowering the cost of energy delivery to our customers," said Bob Sitkauskas, manager of AMI

24 THANK YOU