Optimizing Global Quality Audits on Mobile Devices

About GKN Driveline

• “GKN Driveline is the leading automotive driveline

technology and systems engineer.”
• 29,000+ Employees
• 49 Manufacturing Locations
• £4.62 Billion / $6.02 Billion in Sales
Background: GKN Driveline Quality Program

• Various AIAG / VGA / OEM requirements and bespoke in

house Leadership Standards of Work (LSW) along with
robust product development.
• Model cells to show what good should look like and
regular management engagement in the non-production
areas as well as the production areas of the business as
well as a quality first culture.
• Stronger GKN AQE leadership team focused on systems
and processes to deliver program quality
Why Change? GKN Driveline

• Lessons learnt from previous OEM launches

• Importance of built in / designed in quality and the
ability to have a positive effect on new launches through
managing the quality in the program development
instead of having a product that the plants don’t get
involved with until it is time to industrialize the product.
• Get rid of Excel!
Goals of Project at GKN

• Improve the time taken to complete the audit

• Standardized responses
• Ease of audit
• The ability to assign direct actions during the
audit that can be tracked and managed.
• Trend analysis on issues and target training to
improve business
Quality Auditing in the 21st century

• Implement a global quality auditing

system with a fraction of the typical
resources
• Standardize audit procedures across 20
countries, multiple languages, and
cultures
• Keep OEM requirements up to date
across 53 facilities
Quality Mobile Auditing in the 21st Century

1. Manage audit schedules around the world

2. Tie employee bonuses to audit performance and
schedule adherence
3. Track data across multiple locations
4. Conduct audits on mobile devices
5. Assign responsibilities for non-conformities and
tracking follow-up
6. Ensure non-conformities are re-assessed for
effective root cause within 1 year of the issue
1- Audit Schedules: Multiple and Changing

• Jurisdiction specific
requirements (safety) – Delay
of 9 months due to changed
requirements not incorporated
into audit schedule
• Industry standards (AIAG…)
• OEM Requirements (Ford,
GM,…) - with no clear change
management
1 – Standard Audit Scheduling

• 15 step process!
• Illegible due to number of
steps
• Too many areas for human
error, delays and
miscommunication –
especially with paper, word,
excel, email…
Quality Auditing in the 21st century

• Global Operations
• Multi-Lingual
• Multi-cultural
• Training, Training, Training
• Visibility across operations and
suppliers
1- Audit Schedules: Visibility is the Key

• 1200 Suppliers to Tier 1 Supplier

Company
• Spread over 25 countries
• Many suppliers were getting audited
multiple times by the Tier 1 Supplier as
different divisions and factories were
auditing the same supplier
2- Employee Alignment Around Audit Program

• Staff must:
• Perform audits on time
• Issue audit reports and corrective
actions on time
• Close corrective actions on time
• Various enforcement tactics are used
3 - Tracking Data: GKN Tracking Non-Conformities

• If a Non-Conformity is Found, Corrective

Action must be closed within three weeks
or it impacts bonus
• Tracked through one central weekly report
that is automatically generated
3 - Tracking Data: Tracking Non-Conformities
4 – Audit on Mobile Devices

• GKN was using a mix of PDF, Word and

paper
• Centralize all the audits in one location
with reference material
• Centrally manage the reference material
• Mobile devices can work offline and online
and sync automatically
• Multiple people can audit together
4 – Audit on Mobile Devices
4 – Audit on Mobile Devices
4 – Operational Effectiveness

• Reduce the human element

• Standardize the procedure
• Remove subjectivity and bias
• Your plan is only as good as your people’s
training and skills
4 – Operational Effectiveness
5 – Corrective Actions

• Assign to a person or Function

• Clear due date tied to level of non-
conformity
• Clear action to take
• Evidence non-conformity, annotated photo
5 – Annotated Photos Make Big Difference
5 – Assigning Corrective Action Responsibility
5 – Complete Corrective Action

• Complete Corrective Action with:

• Date, GPS and Time Stamp
automatically
• Note explaining Completion
• Attach evidence – Photos,
Documents…
• Manager approves/rejects action notes
5 – Complete Corrective Action Report
6 – Effectiveness Assessments

• Used in Aviation and Military

• Return to non-conformity after a set time
– 6 months to a year
• Determine if the non-conformity was
permanently solved with the corrective
action
• If not effective, conduct further analysis
6 – Prioritize Effectiveness Assessments

• Generate Problematic Items Report to

see:
• Items that appear across audits by
supplier, OEM, product line or other
metrics
• By audit type ; IATF 16949, VDA 6.0…
6 – Recurring Non-Compliances
Three Biggest Challenges at GKN

• Language
• Training time
• Governance of standard of the audit
Three Biggest Challenges at GKN
Language Barriers at GKN

• Even though the business language is English

we still see some interpretation of certain
requirements but this we manage through
governance and training.
• Translated in to some local languages for key
audiences China/Mexico for example.
Next Steps in Auditing Process

• More Automation
• More Context for Auditors to understand IATF
Requirements
• Framework already in place for GKN transition
to PSSO IATF 16949
Lessons Learned at GKN

Key Elements:
– Ease of use
– Tracking of open issues
– Quick turnaround on modifying the audit questions to
meet new requirements
– Power of the reporting and ability to capture shop
floor issues immediately on camera in phone and link
them directly to the audit questions.
Lessons Learned at GKN

“Ability to attach standards to the questions is

absolutely immeasurable, especially when they
can be referenced or reviewed on the shop
floor.”
Summary

• Key Points
• Select EASY to use software with
global support
• Have auditor test the software
• Focus on data, not dashboards
• Focus on performance bonuses and
motivators to stick to the system
• Start small and grow!
Contact

Thank you and good luck!

Jonathan Brun
jbrun@nimonik.com
+1-514-712-0637