IQA- FÓRUM DA QUALIDADE AUTOMOTIVA

Transcription

1 IQA- FÓRUM DA QUALIDADE AUTOMOTIVA A Qualidade na Cadeia de Autopeças Flávio Teixeira 23/Set/ Security Classification

2 New Delphi: Market-Driven Product Lines, Segmented into Five Divisions Electrical/Electronic Architecture - Electrical/Electronic Distribution Systems - Connection Systems Electronics & Safety - Electronic Controls - Infotainment & Driver Interface Powertrain Systems - Gas Engine Management Systems - Diesel Engine Management Systems Thermal Systems - Thermal Automotive - Thermal Residential and Commercial Heat Exchangers Product & Service Solutions - Diesel - Independent Aftermarket - Original Equipment Service 2 Security Classification

3 Delphi South America Current Products Electrical/Electronic Architecture Powertrain Systems Thermal Systems Electronics & Safety DPSS 3 Security Classification

4 Delphi South America Operations Itabirito Wiring Harness Paraisópolis Wiring Harness Technical Center Contagem Customer Service Center Conceição dos Ouros Wiring Harness Espírito Santo do Pinhal Wiring Harness Jacutinga Wiring Harness Jambeiro Connectors, Terminals, Fuse Box, Electrical Center Application Center: Components Brasil Jaguariúna Condenser, Compressor, PTC, HVAC Application Center: Thermal Cotia Filter, Fuel Injector, Pump, EMS Components Application Center: Diesel EMS Piracicaba ETC, Fuel Pump, Fuel Rail, IAFM, Ignition Coil, MRA, Sensor&Solenoid Technical Center: EMS/ Thermal Distribution Center: DPSS São Caetano do Sul Central Office Technical Center: Electric/ Electronic Buenos Aires Central Office Application Center: IDI San Juan Wiring Harness Brazil & Argentina: 2012 Sales: US$1 Bi Manufacturing Facilities: 11 Employment: Security Classification ISO TS ISO OHSAS QSB (GM/Fiat) ISO Rio Grande Alarm, BCM, BSM, Can Node, Dome Lamp, ECM, Immobilizer, Sensor Lamp RF Key, Radio, Ultrasonic Sensor Central Office E/EA E&S PT Thermal

5 Delphi South America Electrical/Electronic Architecture Plants Paraisópolis Espírito Santo do Pinhal Jacutinga Jambeiro Itabirito Conceição dos Ouros 5 Security Classification

6 Delphi South America Powertrain Plants Piracicaba Cotia 6 Security Classification

7 Delphi South America Electronics & Safety and Thermal Plants Rio Grande - Argentina Jaguariúna 7 Security Classification

8 Delphi South America Technical and Application Centers Technical Centers Piracicaba - SP EMS / Thermal São Caetano do Sul - SP Electric / Electronic Paraisópolis MG Electric / Electronic Application Centers Jaguariúna - SP Application Center (Thermal) Buenos Aires - Argentina Electric / Electronic Jambeiro SP Application Center (Components) Contagem- MG Customer Service Center Cotia - SP Application Center (Diesel) 8 Security Classification

9 Enterprise Operating System The EOS is a management system to operate the company to achieve excellence in Business Performance results while meeting all Stakeholders Requirements. OUR CULTURE.. EXCELLENCE OUR VALUES THE PRINCIPLES OUR BEHAVIOR..THE ABSOLUTES OUR OPERATING SYSTEM.. DBS 1 Managing Stakeholders Requirements Developing Developing Providing Pursuing Strategies & Products & Goods & Business Capabilities Processes Services Monitoring and Continually Improving The Enterprise Operating System describes how work is done by Business Process commonly referred to as a Flow Security Classification 9

10 Operating System Deployment through Quality System OUR CULTURE.. EXCELLENCE OUR VALUES THE PRINCIPLES OUR BEHAVIOR..THE ABSOLUTES OUR OPERATING SYSTEM.. DBS Policy Manual arranged by the EOS Level 0 (owned by Corporate) intended to be in 6 chapters/flow order by end of 2007 OUR OPERATING SYSTEM DBS EEA Supplement (Owned by the President & G.E.C.) arranged by E/EA Level 1 Sub Pipe Categories and includes cross-reference to Policy 1 Managing Stakeholders Requirements Developing Developing Providing Pursuing Strategies & Products & Goods & Business Capabilities Processes Services Monitoring and Continually Improving DPGP Cutting & Lead Prep Quality Requirements Effective: 1 May, 2006 Page 1 of 2 Process finder to define connections and ownership of process How work is performed with process details and connections to supporting documents CPR s (owned by Corporate) Corporate team is reviewing for standardization in content depth and purpose E/EA Procedures (owned by Functions and Flow Owners) based on Level 2 Process Flow Maps and where required Policy Letters Functional Work Instructions (Owned by Functions), Bills of Process/Design, Forms and Attachments Work Instruction WHAT materials, equipment, infrastructure and/or references are used in the process? DBS Glossary Cutting BOP 4 1 Manufacturing Set up equipment per applicable POS/PWI or equipment manual. Maintenance Inspection Authority Objective: Specify minimum requirements necessary to verify correct set-up and quality of product coming off cable cutting & stripping and terminating processes. Scope: All Manufacturing Operations where terminal crimping process is used. This procedure does not cover ignition or wire larger than 8.0 mm2 2 Inspection Authority Check product after set-up per the appropriate quality requirements and document results DPGP A1 3 WHO is involved and what competence/skills training are needed? Process Owner/SME: Mary Pat Meade, Manager, Global Quality Systems SME: Juan Zamora Process Support: Manufacturing, Die Center Personnel, Maintenance and Quality Training on proper usage of de-crimpers, pull tester, lead length measuring devices, verniers, gages, procedure requirements, and Visual Product Standards (VPS) Inspection Authority SET-UP CONTROL TOLERANCES FOR CCH AND LEAD LENGTH The following are the guidelines for set-up control: A: Measure 2 consecutive pieces If 2 pieces are within the green/run zone - RUN If 1 or 2 pieces are out of tolerance (red/reject zone); then DO NOT run, scrap nonconforming samples, reject nonconforming material, readjust the process - go to A If 1 piece is within the yellow/adjust zone and 1 piece is within the green/run zone - go to B: If 2 pieces are within the yellow/adjust zone; readjust process - go to A: B: Measure 2 additional consecutive pieces; If 2 pieces are within the green/run zone - RUN If 1 or 2 pieces are out of tolerance (red/reject zone); then DO NOT run, scrap nonconforming samples, reject nonconforming material, readjust the process - go to A If 1 or 2 pieces are within the yellow/adjust zone; readjust the process - go to A: NOTES: The green/run, yellow/adjust, and red/reject zones are defined by the tolerances within the CCH and Lead Length sections. The green/run, yellow/adjust, and red/reject zones described are not intended to imply charting or documentation requirements. Any measurements found to be in the red zone on the end of run check and in process check must have a documented root cause of the out-of-control points. Follow the Control of NonConforming Product (DPGP 4.9-2) procedure and/or any other applicable regional/local procedure for the appropriate material disposition. Inputs Control Plan POS/PWI Raw Material What Methods/Procedures &/or Techniques are used to describe HOW the process is done? Lead Prep Set-up and Run-Time Monitoring Quality Requirements DPGP A1 Visual Product Standards Cutting BOP Control of Non-Conforming Product DPGP Die Center Quality Gate DPGP Document is uncontrolled when printed unless properly identified as controlled. Follow Control of Non- Conforming Product DPGP Return to step 1 to adjust the portion of the setup that is out of specification. DPGP Print N N 5 Does product meet quality requirements? Does product meet quality requirements? Approved by Name/Title: John McClearn, Dir. Global Customer Satisfaction Y Mfg / Inspection Authority Document results and release product for use. Y Proceed in processing product and refer to appropriate quality requirement checks and document results. DPGP A1 Customer Complaints FTQ data Date: 21 Mar, 2006 Outputs Verification of correct equipment set-up and product quality What METRICS are used to report the effectiveness and efficiency of the process? Packard Electrical/ Electronic Architecture CCH Tolerances Limit Upper Limit Lower Zone Green/Run to to Yellow/Adjust LEAD LENGTH LFT, Lead Loaders and ORIMPER Cutters Set-up Length Tolerances Examples Wire Length Conversion to Wire Length Set-up Letter Length Set up Length Letter Length Length Lower Limit Upper Limit Zone Conversion 0 to Green/Run to to +8 Yellow/Adjust 501 and up Green/Run to to +13 Yellow/Adjust Komax, Megomat, CS9 and Other Processes Set-up Length Tolerances Examples Wire Length Conversion to Wire Length Set-up Letter Length Set-up Length Letter Length Length Lower Limit Upper Limit Zone Conversion 0 to Green/Run Yellow/Adjust Green/Run to to +4 Yellow/Adjust Green/Run to to +5 Yellow/Adjust 2538 and up Green/Run to to +7 Yellow/Adjust NOTES: The green/run and yellow/adjust tolerances are based upon set-up length not wire length letter. All tolerances listed are in-process tolerances and are superseded by the product print. Security Classification

11 Product & Process Development Security Classification

12 I&CIM-Innovation&Continuous Improv. Methodologies PROCESS Delphi Problem Solving Process Contain No Select Containment Required Correct Prevent? Yes DPS Process Identify Define Develop Optimize Validate DFSS Framework Robust Engineering Shainin Red X Common Delphi Problem Prevention & Problem Solving Processes Requirements Definition Concept Creation & Selection Innovation Design & Development Test & Validation Parts Continuous No Parts / Improvement Business Process Problem Causes are Constant Problem Causes are Changing Design for Six Sigma Green Y Validation Six Sigma 46 I&CIM Projects in Security Classification

13 Voice of the Customer Elements Quality, Delivery, Service (Warranty) Product Development Execution (Launch) Technology, Commercial Status Process Flow Monthly/Quarterly Customer Specific Data Gathered Site-Operations VOC Reviews Action Plans & Continuous Improvement - 13 Security Classification

14 Awards SAE 2011 Outstanding Technology VW Argentina 2011 Quality and Crystal Awards AutoData 2011 Best System Suppliers TWO Fiat Lean Academy Awards 2011 Fiat SuPER 2011 AutoData 2012 Best System Supplier Automotive Business 2012 Best Electric Electronic Supplier Fiat SuPER 2012 Fiat Lean Academy 2012 SGS Certificate of Innovation Toyota Best supplier of the year GM Best supplier of the year GM Best supplier of the year AEA years Flex Technology in Brasil AutoData 2013 Sustainability Automobil Produktion Most Innovative Technology 14 Security Classification