Case Study
Large Automotive OEM – FMEA
Managed Service
Failure Mode & Effects Methodology
Process Flow
Block
Diagram
Customer
Requirements
Design Inputs
Process
FMEA
System
FMEA
Control Plans
Shop Floor
Checklists
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Automotive OEM – FMEA Managed Service
Design Failure Mode and Effects Analysis
-- Distribution of Recommended Actions
After AQP
Before AQP
Process Issue
13%
Other
5%
Analytical /
Math
12%
Verification /
Testing
13%
Physical Test
10%
Review, Investigate,
Evaluate
48%
SSR
11%
Analytical
9%
Design Change
7%
Supplier
6%
© 2010 Omnex Inc
Benchmark
20%
Monitor
2%
Process Escalation
Review
1%
3%
Design
Improvements
40%
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Initial Quality of U.S. and Import Brands
1999-2010
Note: Import Brands Include Europe and Asia
Case Study
Large Aerospace Engine
Manufacturer
New Product Introduction & PPV
Program
Start
Experimental
Product & Process
Planning
Production
PPV Activities
Consolidation
Planning
Product Design and Dev.
Ongoing Part &
Process Control
Process Design and Development
Industrialization
Product and Process Validation
Production
Corrective Action Board activity
Plan &
Define
Program
© 2010 Omnex Inc
Product
Design &
Development
Verification
Process
Design &
Development
Verification
Product &
Process
Validation
CAB Activity
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Large Aerospace Engine Manufacturer
• Conducting PPV (Product and Process
Validation including FAI) training and facilitation
for internal resources and 200 suppliers
• Rollout PPV to ensure product and process
conformance for all new products
• Currently in initial stages – 10% to 30%
improvement expected in RCNs
Case Study
Truck – System Supplier
Operations Excellence
MANUFACTURING
Materials
FUNCTIONAL
EXCELLENCE
Purchasing
Quality
6S/VISUAL WORKPLACE
Team Skills
FOUNDATIONAL
EXCELLENCE
© 2010 Omnex Inc
QOS
Global 8D
TS16949/APQP/PPAP
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Truck Industry Large Sub System Provider
187 DPM
Improvement
Before
After
Comments
Quality
Rejects measured in
percentages
3 Years – 187 PPM
Implementation of APQP
and PPAP internally and
with Supply Base
Semiconductor
Industry Transition
Semiconductor Assembly Council –
Representing 95% of Chip Industry
Outside Japan
Semiconductor Industry Methodology
8-D
Customer
Involvement Similar
to Aerospace Industry
MSA, SPC, and Process Control
ISO TS 16949 plus APQP and PPAP
© 2010 Omnex Inc
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Customer Driven Changes: 1998 to 2004
• Productivity improvements: 10% – 30%
– Equipment
– People
• Yield improvement
– Subcontractor yields improved to 99.6%
• Performance to schedule improvement
– Consistently sustaining 100%
• Number of customer complaints decreased
– Up to 15x reduction
• PPM improved by over 100 times to under 30 PPM
© 2010 Omnex Inc
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