Continuous Improvement with Broad-Based Engagement
AIAG's Quality initiatives span the wide array of product development, manufacturing, service, and customer experience improvement activities challenging our members companies in today's ever changing automotive industry.
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, click here.
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. For more information,click here.
Model Based Enterprise
As more of the automotive industry makes the transition to 3D, virtual models offer an opportunity to significantly promote reuse, improve design efficiency, reduce cost and improve quality across the extended enterprise. Success, however, requires that business practices are transformed to leverage the enormous potential of the virtual model. The inclusion of complete definition of the product into the 3D design is called Model Based Definition (MBD), and the use of these models throughout the extended enterprise is called Model Based Enterprise (MBE). For more information, click here.
Heat Treat Assessment
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 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. For more information, click here.
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. For more information, click here.
Plating & Coating Assessments
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. For more information, click here.
Risk Based Audit Project
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. With the revision of ISO/TS underway by the IATF, there is an opportunity to propose a modification to the Rules, so that risk, performance, and maturity factors are considered in the audit day’s determination. 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. For more information, click here.
Problem Solving Work Group
One of the team’s first steps was to survey the industry and further investigate why almost two-thirds of respondents in the Quality 2020 study felt their organizations are, at best, only moderately capable at problem solving. The purpose of the survey was to gather more precise information about the characteristics of ineffective problem solving. Overall, the committee’s industry survey pointed to the need for a well-defined problem statement, more guidance on how to enhance the "up-front" steps of the problem solving process, and how to close, verify and measure the effectiveness to ensure the problem is not repeated. For more information, click here.
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.
Special Process Assessments