Académique Documents
Professionnel Documents
Culture Documents
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About Omnex
• Headquartered in Ann Arbor, Michigan with offices in major global markets.
• In 1995-97 provided global roll out supplier training and development for Ford Motor
Company to support their emerging market strategy.
• Trained more than 100,000 individuals in over 30 countries.
• Workforce of over 500 professionals, speaking over 18 languages.
• Former Delegation Leader of the International Automotive Task Force (IATF) responsible for
ISO/TS16949.
• Served on committees that wrote QOS, ISO 9001:2000, QS-9000 and its Semiconductor
Supplement, and ISO IWA 1 (ISO 9000 for healthcare).
• Member of AIAG manual writing committees for FMEA, SPC, MSA, Sub-tier Supplier
Development, Error Proofing, and Effective Problem Solving (EPS).
• Provider of Lean and Six Sigma to the Automotive Industry as a partner of AIAG
The Automotive supply chains extend globally to every hemisphere. The semiconductor
and electronics supply chain extend to the US, Europe, SE Asia, Taiwan, and China.
The Aerospace supply chain is based more in the US and Europe, but is quickly moving
into China and India.
• Risk with Controls used Severity x Occurrence x Detection – this is known as residual risk
• Risk mitigation is often focused on items with High Severity, High Risk, or High Residual Risk
• Optimizes “flow”
– Cost of Poor Flow
– Pull systems
– One piece flow
Value Added – 5%
Systematic:
– Projects follow the Six Sigma process
• Project proposal and • Select project Y • Identify possible • Identify and test • Process control plan
selection • Data collection causes solutions • Plan and implement
• Building your team • Display data • Narrow to root cause • Refine solutions • Align systems and
• Building a sense of • Compute Process • Quantify opportunities • Pilot solutions structures
urgency Sigma • Tollgate presentation • Cost benefit analysis • Close and hand-off
• Define customer • Tollgate presentation • Tollgate presentation project
requirements
• Tollgate presentation
Rejects Warranty
claims
Rework
Additional
Scrap labor hours
New Product Development – Risk of Poor Quality, Late Prototypes and PPAP/FAI
What is Risk?
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New Product Development
Risk Mitigation – Supply Chain One supplier in the
supply chain can hold
up a product launch
- Product or Process
problems can equally
cause problems
Most organizations do
not have visibility
beyond one tier
• New Product Launch Tracking: Timing and completion of deliverables and use of Quality of
the Event Checklists
– The supplier is required to implement DFSS (Design for Six Sigma) and or DFM/DFA
How about Lean and Six Sigma during New Product Development Launch?
Functional Design
Functional
Safety Concept Technical Safety
Safety Concept Concept
These standards (ISO 26262) Focus on Electronics and Electrical and extend to software and hardware
+ +
Capacity Analysis and Run at Rate
Ongoing Monitoring (ERP)
& MMOG for Shipping/Logistics Contingency Planning
and Scorecards
• Yield improvement
– Subcontractor yields improved to 99.6%
APQP Projects
PPAP Projects
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APQP Task Documents
Routed and accepted deliverables are saved in a folder structure in a document manager (link with suite)
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Linked DFMEAs, PFMEAs, Control Plans and Standardized Work
using Enterprise Software Connects
Dynamic Linkage of Documents
DESIGN to
Shop floor
Linkages of Print Documents
requirements
To Shop Floor
DVP&R System/Design
(Test Plan) FMEA System
DFMEA
DVP&R
(Test Plan)
Cause and Effect
Relationship
(Requirements decompose to characteristics)
Important
Important
System
Sub-System
Traceability between Functions, Testing, and Characteristics
Component
Important
Important
Design Process
Failures Failures
Historical
Product Family
Warranty,
Field Failure,
Plant Failure.
42
Copyright 2016 Omnex, Inc. All Rights Reserved.
LEAN SIX SIGMA – LOGISTICS
Case Study
43 WWW.OMNEX.COM
Project Definition
Project Name: Logistics
Receiving : Current = 17% same day; 7% next day; 76% 2 or more days
Current = 4% same day; 4% next day; 92%
2 or more days through second segment
Goal = 80% same day; 20% next day;
Nuss
Avg 43% Vol EES
CT Avg 3 min 1 day 2 min 5 min 0.5 min electronic 1 day 1 min 1 day ? min
Nuss
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Lean and Six Sigma in the Enterprise
Enterprise
Raw
Part A
Supply Chain management Mat
encompasses planning and
management of all activities
involved in sourcing, procurement,
conversion, and logistics. CSMP
Versus
Enterprise
Sub Raw
Customer Mat
System
Raw
Part A
Mat
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Options for Implementation
• Option I: Six Sigma – Green Belt Projects
• Option IV: Lean and Six Sigma – Green Belt Projects that have COPF and
COPQ mixed together for improvement
• Option V: Lean and Six Sigma – Black Belt Projects that have COPF and
COPQ mixed together for improvement