Aditi Sharma - Cummins Sharma AMaZe(Accelerated Move towards Zero-defects) is a company wide Quality...
Transcript of Aditi Sharma - Cummins Sharma AMaZe(Accelerated Move towards Zero-defects) is a company wide Quality...
1. Design for Zero Defect Product2. Supplier Quality Improvements3. Plant Quality Improvements4. Product Quality & Reliability Improvements5. Service Quality Excellence6. Quality Functional Excellence & Quality Systems7. Continuously Improve using 6 Sigma & COS
AMaZe Methodology – Example HHP
Projects & Initiatives –Action Tracker
KJ Analysis S Curve
Quality Function Strategic Initiatives
VOC/VOB
3
Quality Framework
3
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: 2009
Cummins Operating System
Plant Product ServiceSupplier Design
4 Cummins Confidential
Area Leader
AMaZe Program Nitin Deshpande
Design Quality Kavita Kaushik
Supplier Quality Sanjay Tamhankar
Plant Quality Siva G
Product Quality &
Reliability
Rohan Mengale
Service Quality Sundaram Babu
Sponsors Sandeep Sinha &
Aditi Sharma
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 sustained basis.
This initiative is expected to play a significant role in bringing dependable
products & services to the marketplace on a sustained basis
Accelerated Move towards Zero-defects
5
Pillars Critical Processes / Tools
Design 1. VPCR Execution Process
2. IQA Process
3. Customer Engineering Approval Process
Supplier 1. Source Release & PPAP for new & VPI parts
2. Supplier Improvement Program
3. Supplier Non-Conformance Management
Plant 1. Statistical Process Control (SPC)
2. Conformance of Production (COP)
3. EASE implementation
Product 1. PPS Database
2. Warranty Data Analytics
3. BIS Process
Service 1. Communication Flow from Business to Field
Personnel from Distribution Business
2. Parts Availability – Repair Event Cycle Time
3. Technical Capability
keeping the entire
product life cycle in mind
all bought out, semi-finished
and finished products
product to deliver performance
before and after-in-service
all manufacturing processes
ensuring Right First Time
through enhanced
responsiveness to
service events
6
AMaZe Review Mechanism
Deployment started from April 2015 post AMaZe launch in March 2015
Convened by Quality Champion
Attendees: Quality Leaders, BU AMaZe
Program Leaders
Convened by AMaZe Leader
Attendees: Quality Leaders & CF Team
Convened byCMD & COO
Attendees: SLT, OLT members & CF Team
Convened byCOO & Quality Champion
Attendees:OLT members, Quality Leaders
& CF Team
Convened by BU Leader & Quality Leader
Attendees: Quality Champion, Quality
Leaders, BU HOD & CF Team
Convened by AMaZe Leader
Attendees: Quality Leaders, HOD & CF Team
Function Business
Leadership
Launch AMaZe program in Q1’’15 across all business units in India ABO.
100% participation from Leadership.
Structured review mechanism.
Synergize across business units.
Journey and Key Learnings
Q2’ 14 – Q4’ 14
2015
Q4’ 13 – Q1’ 14
Focus on Engine Business
(EBU) and Power Generation
Business (PGBU)
Best Practice – HHP and
HMLD
DBU and Components – out
of scope
Best Practice – HHP
Challenges – Sustained
leadership engagement and
reviews within HMLD and
PGBU
Launch AMaZe across India ABO
Leadership engagement
Structured review mechanism
Synergize across business units
Sharing best practices
7
Supplier Partner’s increased collaboration on AMaZe
8
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
Cummins’ Support
Benefits
Reduction in supplier, BIS, ELF,
testing PPM
Improvement in STU
Less product failures at customer
end
More satisfied customers
We are looking for your collaboration on the front of design quality and supplier quality