Quality Lifecycle Management Strategies Paul Attwell CEng, Customer Application Specialist CIMTEK UK Ltd
www.cimtek.com
Quality Lifecycle Management “Nobody has looked at quality as a lifecycle process. It has been very disconnected” Alison Smith AMR Research – comments to Managing Automation
•
A holistic treatment of quality for the cycles of product innovation. • A holistic treatment of quality throughout the lifetime of individual products from design to the end of aftermarket support • A holistic approach to quality for each individual unit from bin of parts to disposal
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QLM and Product Lifecycles
QLM tools can directly speed up • Feedback Ever faster innovation the implementation from all new innovation stages of Steeperofstart-up curves
Revenue
QLM process pulls experience from one innovation to the next
the process yields benefits
Development cycle - ever tightening coil? 3
QLM - A Case Study Brand Owner (OEM)
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Case Study – The Challenges Brand Owner (OEM) Location: Stockholm
EMS
Location: China
sub ass
Components
Supplier
Location: Germany
Subsidiary
Assembly Plant Location: Poland
Service Agent
FG
Users
Sub Assemblies
Service Agent
Supplier
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM) Sen d des out ign
Location: Stockholm
Send out design
Subsidiary sub FG Design Content Assembly Plant ass Location: China Location: Poland Drawings Users Parts lists Components CAD files Sub Assemblies Support hardware Supplier - especially Supplier EOL functional test Location: Germany EMS
Service Agent Service Agent
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM) Sen d des out ign
Location: Stockholm
Send out design
Service Subsidiary sub FG Design Transfer Process Agent Assembly Plant ass Location: China Location: Poland Handhold production firstUsers runs Service Monitor production data and yields Agent Components carefully Sub Assemblies Support install of test platforms Supplier Supplier Location: Germany
EMS
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM)
Ma nu fa c da turi ta ng
EMS
Location: China
Components
Supplier
Location: Germany
Location: Stockholm
Manufacturing data
sub ass
Subsidiary
Assembly Plant Location: Poland
Sub Assemblies
Service Agent
FG
Users
Service Agent
Supplier
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM) EMS Data Available
Ma nu fa c da turi ta ng
EMS
Location: China
Location: Stockholm
sub ass
Components
AOI X Ray Manufacturing data ICT Functional Test … Subsidiary FG
Service Agent
Assembly Plant Location: Poland
Users
Sub Assemblies
Supplier
Service Agent
Supplier
Location: Germany
Location: Denmark
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Case Study – The Challenges Brand
Ma nu fa c da turi ta ng
EMS
Location: China
Components
Supplier
Location: Germany
sub ass
Data Available EMS Owner But some is(OEM) not shared – Location: Stockholm typically for EMS the early process data is obscured Data is rarely real time Manufacturing databe filtered Data may In some rare cases data shared may be tampered with Subsidiary FG Assembly Plant Location: Poland
Sub Assemblies
Users
Service Agent Service Agent
Supplier
Location: Denmark
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Case Study Data – The Challenges Available - Subsidiaries
Where plants are part of the same corporation Brand data should be available from all processes.
Owner (OEM)
Ma nu fa c da turi ta ng
Location: Stockholm
Here the challenge is having all plants standardising their systems and having the Manufacturing infrastructure to report all the data. data
EMS
Location: China
sub ass
Components
Subsidiary
Assembly Plant Location: Poland
Service Agent
FG
Users
Sub Assemblies
Supplier
Service Agent
Supplier
Location: Germany
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM) Location: Stockholm
Sus tain ing
EMS
Location: China
Components
Sustaining
Subsidiary sub FG Sustaining Engineering Assembly Plant ass Poland New testLocation: programs Users Bugs ProcessSub issues Assemblies
Service Agent Service Agent
Supplier Usually means Supplieron-site visits
Location: Germany
Location: Denmark
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Case Study – The Challenges Brand Suppliers Owner (OEM) Another part of the product
Ma nu fa c da turi ta ng
EMS
Location: China
Components
Supplier
Location: Germany
Location: Stockholm lifecycle often
sub ass
considered problematic is the data from the supply chain. Manufacturing Component data may be the data vital missing part in manufacturing problem. Service Subsidiary Suppliers do not FG always want to Agent Assembly sharePlant this data however. Location: Poland
Users
Sub Assemblies
Service Agent
Supplier
Location: Denmark
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Case Study – The Challenges Brand Owner (OEM)
Ma Location: Stockholm nu fa ctu da riService Chain RMA and ta ng Predominantly a manualManufacturing process. Data is sometimes subjective. data
In the data are vital clues to sub flaws.Subsidiary EMSor design process Assembly Plant ass Location: China Location: Poland
Components
Supplier
Location: Germany
Sub Assemblies
Service Agent
FG
Users
Service Agent
Supplier
Location: Denmark
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Case Sudy – The Solution Ma nu fa c da turi ta ng
EMS
Location: China
Components
Supplier
Location: Germany
What would a fully managed lifecycle look like?
Brand Owner (OEM) Location: Stockholm
Manufacturing data
sub ass
Subsidiary
Assembly Plant Location: Poland
Service Agent
FG
Users
Sub Assemblies
Service Agent
Supplier
Location: Denmark
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Case Sudy – The Solution Brand Owner (OEM) Location: Stockholm
EMS
Location: China
Service
Subsidiary sub FG Agent Harmonized and Assembly Plant ass All data Location: – all Poland complete data can be
processes real-time Minimum Components maintenance Subfrom Assemblies local IT Supplier Remote access to Supplier Location: Germany Location: Denmark equipment 16
Bi-directional communications with internal and external partners
Users
monitored by aService handful of staff Agent Alarms can be triggered by bad routing or limit violations
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Case Sudy – The Solution Reduce innovation costs and speed up NPI
Brand Owner (OEM) Location: Stockholm
EMS
Location: China
sub ass
Subsidiary
Assembly Plant Location: Poland
Use Standardisation remote control of Components tools quality andequipment. camerasSub to Assemblies Egspeed Re-usable up
Supplier deployment functional test and Supplier
Location: Germany 17
FG
Service Agent Standardisation of Users Service quality equipment. Agent E.g. Eg Re-usable Re-usable functional test platforms.
Location: Denmark
reduce platforms. travel costs
Case Sudy – The Solution Brand Owner (OEM)
Data captured from suppliers
EMS
Location: China
Components
Supplier
Location: Germany
Location: Stockholm
sub ass
Subsidiary
Assembly Plant Location: Poland
Sub Assemblies
Simple Agent to upload data without creating work for supplierService IS FG Agent
Users
Service Agent
Supplier
Location: Denmark
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Case Sudy – The Solution Brand
Data Harvested from the RMA Owner (OEM) Location: Stockholm Chain -structured -global capture
EMS
Location: China
Components
Supplier
Location: Germany
sub ass
Subsidiary
Assembly Plant
Service Agent
FG
Location: Poland
Web forms for manual entry of data Sub Assemblies Support for automated systems Supplier when available
Users
Service Agent
Location: Denmark
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Case Sudy – The Solution Overload! Brand Owner (OEM) Location: Stockholm
With all the data being captured the Subsidiary sub EMS Assembly Plant process of ass Location: China Location: Poland managing the storage, parsing Components Sub Assemblies and reporting begins Supplier Supplier Location: Germany
Service Agent
FG
Users
Service Agent
Location: Denmark
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Case Sudy – The Solution Overload! Brand Owner (OEM) Location: Stockholm
IS / IT staff are needed and hardware Subsidiary sub maintained. EMS Assembly Plant ass Location: China Software needs to be Location: Poland developed and this also needs long term Components support. This usually Sub Assemblies means substantial Supplier ongoing expenditure. Supplier Location: Germany
Service Agent
FG
Users
Service Agent
Location: Denmark
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Case Sudy – The Solution Brand Owner (OEM)
Is there help out sub EMS ass Location: there? China Components
Supplier
Location: Germany
SaaS – QLM
Subsidiary
Assembly Plant Location: Poland
Sub Assemblies
Outsourced Service
remove FGsolutions canAgent much of the overhead and can share the Users Service benefit with the whole Agent partnership
