QUALITY
Quality
Special Processes
The goal of the AIAG Special Process Initiative is the reduction of
campaigns, spills, recalls and warranty claims related to components
from “Special Processes.” The Special Process Initiative is comprised of
individual work groups that develop assessments that are based on best
practices and designed to provide a means of continual improvement,
emphasizing defect prevention and reduction of variation and waste in
the supply chain
The AIAG Special Process System Assessments are applicable to
sites where customer-specified parts for production and/or service are
processed throughout the automotive supply chain.
Special Process: Plating & Coating Work Group
The first edition of both the CQI-11 and CQI 12 were released in August
2007 and like CQI-9 Heat Treat, quickly became the global “standard”
for assessing an organizations plating or coating processes. The 2nd
editions of both documents were published in 2012 and provided
additional clarification for global users, more user-friendly format based
on customer feedback, and new process tables were added to both
documents.
The Plating and Coating work groups are now working together as one
team to develop 3rd editions of each Plating and Coating Assessments.
The team will harmonize common practices between the Plating,
Coating and Heat Treat assessments on the pyrometry requirements,
including instrumentation, thermocouple checks, and temperature
uniformity surveys, where appropriate. The Management Responsibility
and Quality Planning section, and Floor and Material Handling
Responsibility section of the Plating and Coating assessments will also
be harmonized.
Special Process: Heat Treat Work Group
The first edition of CQI-9 was released in March 2006 and quickly
became the global “standard” for assessing an organizations heat
treat processes. Over the years the Heat Treat work group has received
questions asking for clarification and suggestions on how they could
For more information on AIAG’s Quality Initiatives please contact:
Scott Gray: sgray@aiag.org or Karen Krutsch: kkrutsch@aiag.org
improve the assessment. The 2nd edition was published in 2007
and provided additional clarification considering global users, and a
new process table was added for Annealing, Normalizing and Stress
Relieving. The 3rd edition was published in October 2011 and included
three new process tables, changes in frequency for SAT and Instrument
Calibration, formatting and clarification among other items too numerous
to list.
The work group is now developing the 4th edition of the Heat Treat
Assessment. This new edition will focus on clarification to the process
tables and pyrometry requirements, and a major change to the
formatting of the assessment from Excel to a Word format to allow for
greater flexibility in writing observations and notes, and will include
hyperlinks to the Process Tables.
Special Process: Molding/Casting training
This one-day class will teach you to understand and learn how to use
the Molding Special Process System Assessment as a foundation to
assure control of these special processes and deliver quality parts and
materials.
• Review requirements for assessment procedures and frequencies
• Review the internal assessment process and assessor qualifications
• Review the documented assessment procedure, checklists, and
share best practices
This one day class will teach you to understand and learn how to use
the Casting Special Process System Assessment as a foundation to
assure control of these special processes and deliver quality parts and
materials.
• Review requirements for assessment procedures and frequencies
• Review the internal assessment process and assessor qualifications
• Review the documented assessment procedure, checklists, and
share best practices
QUALITY
Quality
New Projects
Risk-Based Audit Days
It is critical for the industry that there is alignment between
achievement/maintenance of ISO/TS16949 certification and the
actual quality performance of the site. One of the current issues
is that in the audit scheme for TS, the length of the audits
(days) is based solely on the number of employees at the site.
The focus of this work group is to define a “Risk Based” model
where complexity factors such as type of product, (brakes,
steering, etc.), site QMS “maturity” factors such as stability
of leadership, stability of business, number of new product
launches, quality culture, etc., and demonstrated quality
performance are the basis for the calculation of audit days for
the site.
AIAG-VDA FMEA Alignment
Currently suppliers providing products to both German and N.A.
OEM’s are required to assess their products’ failure modes and
effects differently, based on differences between the processes
and the Severity, Occurrence, and Detection rating tables in
the VDA and AIAG FMEA Manuals. This causes confusion
and adds complexity to the product development and process
improvement activities of the suppliers.
The focus of the work group is to come up with a common set
of FMEA requirements and guidance that will enable suppliers
to have a single FMEA business process and associated set of
methods and tools to produce robust, accurate and complete
FMEA’s and meet the needs and expectations of any of their
customers.
For more information on AIAG’s Quality Initiatives please contact:
Scott Gray: sgray@aiag.org or Karen Krutsch: kkrutsch@aiag.org
Traceability
There currently isn’t any single reference manual on the
subject for the industry to use. The work group believes that
the industry would benefit from one consistent application of
traceability requirements throughout the supply chain including
OEM’s. An improvement in traceability capabilities throughout
the supply chain supports improvement of containment,
problem solving, and management of engineering changes. The
Traceability work group is working on developing a document
that will highlight best practices and showcase applications/
case studies of latest technology solutions.
Problem Solving
In 2015 AIAG’s Quality 2020 survey found that OEMs and suppliers
rank problem solving as the most critical issue impacting quality.
The study stated that over one-third of respondents felt there
was significant potential for improvement in problem solving.
In November 2015 AIAG convened a group of industry problem
solving professionals to study the survey results with the goal of
identifying what improvements could be made to make problem
solving more effective.
The AIAG Problem Solving work group has determined there is an
opportunity to improve the existing CQI-20 and CQI- 21 Effective
Problem Solving documents by adding guidance for the items that
were identified as problematic in the industry survey.
If you would like to provide ideas to help the industry improve its
problem solving, contact AIAG today!
QUALITY
Quality
Product Development
Industry data shows that 70% of the global vehicle portfolio
will be refreshed in the next five years, with reports
highlighting that there will be at least 60 new Model launches
each year. At the same time, OEMs and suppliers confirm that
technology in vehicles and supplied components/systems is
advancing at an even faster rate. Progressive companies that
want to best support their innovation strategies are achieving
breakthrough results by deploying Lean Product Development.
Be part of the future - get involved with the Lean Product
Development project team as we identify the best practices
that will help suppliers develop and launch innovative product
solutions faster.
Model Based Enterprise (MBE) Work Group
AIAG’s Model Based Enterprise (MBE) Work Group vision is to
move the Automotive Industry to a 3D Model Based Enterprise,
through the adoption of Model Based Definition (MBD)
practices. This requires the 3D CAD model to include all of the
information that completely defines a product (such as physical
geometry, configuration, functional requirement relationships,
attributes and procedural information). This information can
then be consumed throughout the extended enterprise enabling
seamless sharing, reduced costs, increased efficiencies and
quality. The MBE Workgroup believes that we can achieve
this vision by helping companies realize the benefits of their
investment in technology, and the extended value of their
product definition data by:
• Developing guidelines and best practices to educate and
prepare the Automotive Industry
• Working with the industry software providers.
For more information on AIAG’s Quality Initiatives please contact:
Scott Gray: sgray@aiag.org or Karen Krutsch: kkrutsch@aiag.org
Now Available: MBE Wallchart
The AIAG MBE Roadmap Wallchart
provides companies; their partners
and suppliers a visual means to
assess current capabilities and
measure their progress from a Level
1- 2D drawing centric environment
towards a comprehensive Level 4 -
“Model Based Enterprise”.
The Wall Chart identifies the key
aspects of drawing/model usage to
determine your current MBE level,
and highlights where to focus to
make the transition to the next level. Achieving the transition to
full MBE performance will enable the industry to realize greater
product compliance AND much leaner operations, initially through
drawing elimination and ultimately through reuse and delivery of
complete, in-context product definition to critical operations and
processes.
For more information on the MBE Wallchart, please visit
www.aiag.org.
If you are interested in this Initiative or have new
ideas to improve this area, please contact us at
quality@aiag.org.