Presentation of the QIP V2.0 M anufacturing P erformance A
ssessment May 2013 Slide 2 2 1 INTRODUCTION Contents 3 EVALUATION
WORKSHEET & SCORING MATRIX 4 EVALUATION PROCESS 2 REQUIREMENTS
OVERVIEW 5 EXAMPLES OF SCORING Slide 3 3 1 INTRODUCTION Slide 4
Assessment tools Present Situation 4 Enterprise Performance SOPSOP
Serial Phase Indus Phase ToolKickOffToolKickOff Design Phase
Selection Phase F2, F3 Audits F2, F3 Audits QIPQIPQIPQIP Checklist
& Process audit QSBQSB Sourcing Approval Matrix. (PSA / PCPA /
) PCPAPCPA Process Specific Audits One Single Common Referential
Slide 5 5 Main Specifications (1/2) The key principles One single
assessment referential 3 differents tools 92 Requirements 76 / 92
Requirements 59 / 92 Requirements 49 / 92 Requirements
Certification Slide 6 6 Main Specifications (2/2) Common
characteristics Versatile tools Versatile tools which can be used
on every manufacturing site & every process quality / logistics
/ Industrial efficiency Evaluation covers the entire manufacturing
scope (quality / logistics / Industrial efficiency) What is the
difference between ISO/TS and QIP V2.0 ? ISO/TS is the high level
review performed by an independent 3 rd party. QIP V2.0 is a much
closer look performed by the Customer. GM & PSA check on the
shop floor how systems are being used whereas ISO/TS checks that
there are Quality Systems in place. Slide 7 Part & Process
Project Manufacturing System Manufacturing System QIP V1.0 The new
tool to replace the QIP V1.0 Assessment Certificationimpact on
Supplier Scoring (BIDLIST) Certification associated with an impact
on Supplier Scoring (BIDLIST) A complete supplier plant Scope: A
complete supplier plant Purpose: overall robustness Evaluate the
overall robustness of processes on site: Manufacturing System
requirements are fully met and work effectively continous
improvement Drive the continous improvement (identification of weak
points & axes of improvement) Operational Requirements 2 days
Maximum duration of the evaluation on site: 2 days Self-assessment
Self-assessment can be done by supplier himself Updated continously
Updated continously to integrate the impact of the events in the
relationship 7 76 / 92 Requirements 76 / 76 Nb of Requirements 0 /
7 0 / 9 Slide 8 8 59 / 92 Requirements Diagnostic audit The new
tool to replace the Diagnostic audit A complete supplier plant
Scope: A complete supplier plant Purpose: manufacturing maturity of
a new supplier: Evaluate the manufacturing maturity of a new
supplier: Basics are in place effectiveness of operational launch
organization At the beginning of a project, evaluate the
effectiveness of operational launch organization on supplier site
Operational Requirements 1,5 2 days Maximum duration of the
evaluation on site: 1,5 2 days Optional Self-assessment by supplier
before evaluation: Optional 48 / 76 Nb of Requirements 7 / 7 4 / 9
Slide 9 Project 9 49 / 92 Requirements A complete process in a
supplier plant Scope: A complete process in a supplier plant
Purpose: Confirm the qualification status At the end of a project,
Confirm the qualification status of the process: Parts &
Process controls are in place to ensure final product quality
Diagnostic tool to identify weak points During mass production
phase after major issues, Diagnostic tool to identify weak points
Operational Requirements 1 days Maximum duration of the evaluation
on site: 1 days Optional Self-assessment by supplier before
evaluation: Optional 40 / 76 Nb of Requirements 0 / 7 9 / 9 Slide
10 10 One Single assessment referential Same questionnaire Same
questionnaire (same requirements) used for all the 3 types of audit
Continous assessment Continous assessment of suppliers
manufacturing system via audits All the audit results affect to
Bidlist performance (supplier plant scoring) Manufacturing System
Project Part & Process 40 9 9 48 7 7 76 Bidlist (supplier plant
scoring) 4 4 Slide 11 11 BIDLIST Vision (Supplier Plant Scoring)
Details of impacts (implemented in 2014) Points deduction 0 pts
Certified (QIP v2.0 Green: Score > 85%) Waiver and Not
Applicable -10 pts Not Certified (not evaluated or QIP v2.0 Red:
Score < 75%) Certification expired (after 3 years) Temporary 0
pts Not Certified (QIP v2.0 Yellow: Score 75% - 85%) 90 days
Forecast: Supplier Self-assessment available & audit planned 6
months Slide 12 12 QIP V2.0 Life Cycle continuous Assessment with
the same Questionnnaire SOPSOP Mass Production Phase
ToolKickOffToolKickOff Design Phase SelectionPhaseSelectionPhase
Diagnosis of the supplier plant Indus Phase Confirmation of the
qualification status First self assessment Certification Audit
Annual Update by supplier Verification after Major issue BIDLIST
(Supplier Plant Scoring) Slide 13 QIP V2.0 Production Site
Assessment Structure of the questionnaire 15 Key Elements 92
Requirements 13 The referential is self-understandable For each
Requirement, a list of criteria describes precisely customer
expectations For each Requirement, a list of criteria describes
precisely customer expectations These criteria are used for the
scoring These criteria are used for the scoring Slide 14 14 2 QSB+
CERTIFICATION PROCESS Slide 15 Leadtime Process Complete self-
assessment Evaluation of self- assessment Training if needed
Complete action plan Certification audit Annual update Revoke
certification Certification granted for 3 years Major issue 15 15
days 10 days1 month max. 6 months 1.5 2 days yearly 10 days
Responsibility Supplier Customer PSA-GM Supplier Customer PSA-GM
Supplier Customer PSA-GM QSB+ Structural audit The main Steps QSB+
life cycle Monitor performance / PCPA Slide 16 16 QSB+ Structural
audit The Main Steps Supplier Self-Assessment Intent Supplier
awareness of requirements Gap analysis between requirements and
supplier current system Get status about readiness before customer
on-site assessment In case of revocation: identify why system fails
Process New Audit presentation (live conversation) Send audit
package 15 working days for complete self assessment Hint Highlight
that is a gap analysis: red result has no any negative affect but
help to identify weak points Obtain a full scoring with all
necessary comments (explanations of the supplier are as important
as the scoring) Slide 17 17 QSB+ Structural audit The Main Steps
Evaluation of Supplier Self-Assessment Intent Calibrate Suppliers
evaluation criteria Identify items where training is needed
Identify where action plans must be requested Process (2
possibilities) Theoretical calibration: self-assessment reviews
(meetings or conf-call) On-site Assessment Complete audit resulting
customer scoring Crosscheck requirements to validate supplier
evaluation Important: Supplier can be certified at this step if:
Self-certification has been verified on site by customer Final
score > 85% with no red key element Note: Self-assessment can be
refused if the scoring is not robust (important gap between
customer evaluation & supplier self-ass.) Slide 18 18 Training
Intent Understand Audit Requirements & expectations Review
& implement examples to supplier system Process Supplier
self-training based on QIP V2.0 material package Service provider
training (approved 3rd party) Available in 2014 Complete Action
Plan Intent Cover Gap between supplier current system & QIP
V2.0 requirements. Base for close follow up of implementation
Prepare supplier for Certification auditPrepare supplier for
Certification audit Process 6 monthsMaximum leadtime for full
implementation is 6 months In due dates it needs to be considered
that system has to operate, not only implemented Hint Verify action
plan after receiving (actions definition, due dates are realistic)
Organize regular calls for checking completion of action plan and
guide supplier to right direction QSB+ Structural audit The Main
Steps Training & Action plan Slide 19 19 QSB+ Structural audit
The Main Steps Certification Audit Intent On-site customer
assessment to verify that all the Requirements are met Result in
Certified status for next 3 years Process only by customerno
exception even for strategic suppliers It can be done only by
customer auditor (no exception even for strategic suppliers)
Maximum 1.5 - 2 days assessment Result is reported out in the Audit
Sheet Slide 20 20 QSB+ Structural audit The Main Steps Supplier
Annual Update Intent To ensure that QIP v2.0 system works after
audit To ensure awareness of QIP v2.0 requirement in case of new
staff Process Supplier need to send self-assessment with associated
action plan Every 12 months Every 12 months after initial
certification, 60 days after any key management change 60 days
after any key management change (Plant manager, Quality Manager or
Operation Manager) or repeat Quality issue. If self-assessment is
missed to submit, certification can be revoked If PCPA meanwhile
performed, not necessarily need to submit self-assessment Slide 21
21 QSB+ Strcutural audit The Main Steps Revoke Certification Intent
To complete all certification process to ensure that QIP V2.0
system is operating and work effectively again Process In case of
major issue, repetitive failed PCPA or degradation of supplier
performance, SD site initiate revoke process with agreement of
management According to vision, audit result will have on-line link
with Bidlist Slide 22 22 3 EVALUATION WORKSHEET & SCORING
MATRIX Slide 23 Instructions Description of usage of QIP
questionnaire. QSB+ process Special instruction for QSB+
evaluation. Glossary Complete list of abbreviations used in audit
list. Header Input of basic information and selection of audit
scope. Summary Result of audit/self assessment calculated
automatically. Audit Common questionnaire list. Action plan
Supplier action plan to close gaps identified during self
assessment or audit. Change request Proposal for
changes/suggestions to be considered for next review 23 QIP V2.0
Production Site Assessment QIP Evaluation Worksheets Slide 24 24
QIP V2.0 Production Site Assessment An example of requirement
General Definition Summary of the intent of requirement Detailed
deployment of 'Requirement' in bullet points Supplier has to
operate a system to meet listed expectations Auditor hints and
techniques how and what need to be checked besides 'Criteria of
Requirement Two types of Criteria of the Requirement are
identified: Bold type (must have) basic criteria are identified
with Bold type, cover basic key requirements (must have)
(recommended best practice) additional criteria are identified with
unbold type, cover additional requirements (recommended best
practice). Furthermore it is used for collecting evidences and
setting up scoring ItemRequirementCriteria of RequirementLook for
Fast Response FR1 Daily leadership meeting held with
cross-functional, multilevel attendees to address significant
external and internal concerns. 1) There is a daily Fast Response
(FR) meeting with cross- functional attendees and led by
manufacturing. 2) The FR meeting is a communication meeting and a
precise timing is respected. 3) All the significant external and
internal issues are addressed. 4) Natural owners are assigned to
problems, next report out date is assigned. 5) Take into account
the production forecast and the quantity produced. 6) Safety and
near miss accident issues are reported out. Attend FR meeting.
Observe: - lead by manufacturing with cross -functional attendees,
- how leader controls the FR meeting (keep timing max 10-20
minutes, focus on subject, not going to the details...), -
environment is suitable (everyone can hear and see the meeting), -
how issues reported out. - Problem Solving report format is used
for report out and document the status of the issue. Slide 25
StandardizeStrictly apply Axiom #1: Standardize all your activities
& Strictly apply your standards Measure improve Axiom #2:
Measure your real effectiveness to achieve customer expectations
& improve it 25 QIP V2.0 Production Site Assessment The Scoring
Principles Slide 26 QIP V2.0 PRODUCTION SITE ASSESSMENT Scoring
Definition 26 Quality manuals Procedures Work Instructions Guides
flowchart PrinciplesCriteria Main processes Organization
OperationalStandards Requirements QIPQIP suppliersupplier
suppliersupplier Implementation scoring Effectiveness scoring
Process Metrics Result Metrics To evaluate standardization and
implementation of requirement To evaluate real effectiveness to
achieve customer expectation and continous improvement Slide 27 27
Key Element #1 Key Element #2 Implementation scoring of each
individual requirement Effectiveness scoring at the end of each key
element QIP V2.0 Production Site Assessment Scoring Structure &
application Slide 28 IMPLEMENTATION SCORING For Each Requirement 28
PrinciplesCriteria Main processes Organization OperationalStandards
Implementation scoring Each Requirement is scored from 0 to 4
according to the following scoring matrix: Each Requirement is
scored from 0 to 4 according to the following scoring matrix:
PtsElement Scoring 0 No criteria are in place. 1 Several basic
criteria are not in place. 2 A majority of basic criteria are in
place and followed. At least one basic criteria is not followed. Or
basic criteria are not in place or followed at all areas of
company. 3 All basic criteria are in place and followed. Some
additional criteria are not in place. Or basic criteria are not
followed at each job or all the time. 4 All criteria are in place
and followed and most additional criteria are followed at each job
or all the time. NR Not Reviewed: Requirement not audited at this
time (Not part of audit scope, Training Required, Follow-Up
Required). Plan to review in future. Give future review date in
Comment box. NA Not Applicable: Question does not apply and not
calculated to overall result. Note to explain why question is not
applicable is needed in Comment box. Audit Failed Slide 29 Is
system working well when ? Fast Response fully implemented, but
there are several long lasting customer complaints, Non-conforming
materials are controlled, but operating with high scrap rate
without any improvement activities, LPA is performed in all level
according to schedule, concerns documented and action defined, but
there are lots of repetitive finding on LPA System is in place, but
not working effectively! 29 EFFECTIVENESS SCORING Introduction
Slide 30 EFFECTIVENESS SCORING FOR A COMPLETE SECTION 30 the Key
notions The customer (internal or external) The measurement of
satisfaction Metrics shared with customer (target & management)
Effectiveness is evaluated through a specific requirement at the
end of each section A list of relevant metrics related to the
evaluated process PrinciplesCriteria Main processes Organization
OperationalStandards Effectiveness scoring Example of requirement
LPA effectiveness are continuously monitored and analysed via LPA
results 1) Tracking of audit results with visualization to share
status on affected area (nb of non conformances per LPA, pareto of
non conformances, repetitive findings, nb of customer issues caused
by non respect of standardized work - it should have been found by
LPA). 2) Tracking of keeping audit schedule & effectiveness of
action plan implementation(average time to treat
deviations/effectiveness). PtsEffectiveness Scoring 0 No metrics
are in place to evaluate topic effectiveness 1 Some metrics are in
place but basic metrics are not defined 2 Basic metrics are in
place and followed with targets however deviations from targets are
not managed 3 Basic Metrics are followed and deviations are managed
by action plans but most additional metrics are not defined 4
Continuous improvement for key metrics are in place or majority of
additional metrics are managed. Slide 31 31 SCORING Thresholds for
result calculation Red / Yellow / Green visualization applied
Thresholds are defined on 2 levels Overall result goes Red
Conditions to be certified No Red item (Key Element or Requirement)
85% Overall result 85% Slide 32 32 SCORING Equivalencies QIP V2.0
QIP V1.0 QIP V2.0 Requirements QIP V1.0 Requirements QIP V1.0
Requirements QIP V2.0 Requirements Old Scoring New Scoring Slide 33
33 4 REQUIREMENTS OVERVIEW Slide 34 34 QIP V2.0 Production Site
Assessment 15 Key Elements Slide 35 Detection & Tracking of the
internal/external major issues Daily production meeting Fast
response Board Problem solving standardize methodology Used for all
type of concerns 6 steps: define, contain, root cause id,
correction, validation, institutionalization System to manage
lessons learned Organization Procedure / forms 35 QIP V2.0
Production Site Assessment Detailed Content #1: Fast Response (FR)
Slide 36 Traceability Compliance to specific customer requirements
Equipments & Organization associated FIFO Management
Identification mode of the non-conforming or suspect material Alert
issue Upstream: Tier N Downstream: Customer Containment process
Rework process Management of the deviations (customer derogations)
36 QIP V2.0 Production Site Assessment Detailed Content #2: Control
of Non-conforming Product (CNC) Slide 37 Final Checking
Organization Standards Alarm system Thresholds definition
Escalation process Error proofing systems Management of the EPS
Management of the malfunctionning / failures 37 QIP V2.0 Production
Site Assessment Detailed Content #3: Verification Station &
Error Proof Verification (VS) Slide 38 Workplace organization
Standardize Layout 5S management Ergonomics & Painfulness
concerns Rules related to ergonomics Assessment of the workstation
Operator involvement Working instructions (production process
operations & logistics) Standards Procedure to validate start
of production Visual & appearance items (boundary samples)
Procedure Management of the boundary samples Control devices
Calibration & Capability Management of the devices
(identification) Capability & Calibration 38 QIP V2.0
Production Site Assessment Detailed Content #4: Standardized Work
(SW) Slide 39 Training organization Needs identification /
Organization Infrastructures & skills for training activity
Training material Safety Policy Safety handbook Training on safety
Employees Qualification / Flexibility Chart Qualification process /
follow up qualification status Calibration process for the quality
control activity Training refreshment Motivation of Staff Process
of motivation Individual interviews 39 QIP V2.0 Production Site
Assessment Detailed Content #5: Training (TR) Slide 40 Generic
layered process audit Procedure and working standards Auditors
training LPA on operational activities (under manufacturing dep.
responsability) Master planning Complete coverage with relevant
frequency Involvement of the different level of management LPA
results follow-up Deviations record Action plans associated
Countermeasures sheet Continuous improvement 40 QIP V2.0 Production
Site Assessment Detailed Content #6: Layered Process Audit (LPA)
Slide 41 PFMEA management Periodical reviews Cross-functional
approach Management of the highest risk items Identification &
analysis Action plans follow-up Reverse PFMEA Real and effective
risks verification at the workstation Findings taken into account
to improve process General Risks management to guarantee
manufacturing activity Natural risks (floods, fire,) Supply chain
risks (loss of energy, loss of supply ) 41 QIP V2.0 Production Site
Assessment Detailed Content #7: Risk Reduction (RR) Slide 42 Main
topic: cleanliness of the process Risk analysis on the complete
shopfloor Compliance to customer specifications when needed
Management of the sensible areas (clean rooms, paintshop,)
Management of the foreign material in parts Management of the dirts
in parts or paint 42 QIP V2.0 Production Site Assessment Detailed
Content #8: Contamination Control (CC) Slide 43 Management of the
Tier N suppliers Procedures to evaluate & select supplier
Cascading of the customer requirements to the Tier N CSE tranfer
Traceability requirements Product change management Escalation
process Management of the single issues Audit policy Target
definition and performance review Bidlist and business hold
Incoming inspection process Components Control plan Sampling rules
records 43 QIP V2.0 Production Site Assessment Detailed Content #9:
Supply Chain Management (SCM) Slide 44 All type of changes (planned
& unexpected) Procedure for monitoring product/process changes
Project management Communication with the customer Management of
the deliverables (documents) Risk analysis before any change
Production Trial Run (PTR) process Banking process Planning Stock
build-up Management of the long term storage Alternative processes
/ Bypass processes Identified alternative processes Authorizing
process Specific countermeasures 44 QIP V2.0 Production Site
Assessment Detailed Content #10: Managing Changes (MC) Slide 45
Maintenance organization & strategy Perimeter covered Available
ressources & facilities Communication with manufacturing dep.
TPM strategy & implementation / Standardization Policy
Maintenance activities (planning & tracking) Preventive
maintenance master planning / Corrective maintenance activities
Working standards & technical documentation Maintenance records
(equipments diary) L1 Maintenance management Definition of L1
maintenance operations Planning & follow-up Spare parts
management Critical spare parts Stock management & storage
conditions Management of the customer specific tools Tools
identification Diary sheet and operation records Storage &
handling conditions 45 QIP V2.0 Production Site Assessment Detailed
Content #11: Maintenance (MAI) Slide 46 Manufacturing scheduling
Business Planning (=> fix the capacity) Master production
schedule (MPS => manage the ressources) Daily manufacturing
program Constraints management (Bottlenecks) Identification updated
in real time Equipment level of load permanently followed Product
Packaging Storage areas & handling conditions Supply of
workstations Supply organization Improvement Process 46 QIP V2.0
Production Site Assessment Detailed Content #12: Manufacturing
& Material Flow Management (MMFM) Slide 47 Supply process
Master schedule of deliveries Logistic protocol with TIER N Service
rate of the TIER N Supplier Securization of the supplies
Identification of the risky supplies Securing plans Safety Stocks
management Shipping process Shipping planning Preparation process
Bogus truck EDI & logistic Electronic Protocol 47 QIP V2.0
Production Site Assessment Detailed Content #13: External Logistic
(ELG) Slide 48 Used only for new supplier or for a new project
Industrial Strategy & Vision (=> 5 yrs) Site organization
& human ressources management Site Involvment during project
Quality organization Job desciptions New equipments validation
process Qualification process Project milestones Deliverables
management Spare parts production Specific process End of life
management PR storage Packaging design 48 QIP V2.0 Production Site
Assessment Detailed Content #14: Strategy / Project Management
(SPM) => NSA Slide 49 Management of the documents Identification
of the KPC (CSE) Process flow diagram and link with PFMEA Process
control plan SPC and records management Product audits Customer
contractual Safety Stocks (Optional requirement) 49 QIP V2.0
Production Site Assessment Detailed Content #15: Part & Process
Control (PPC) => NSA & PCPA Slide 50 50 5 EXAMPLES OF
SCORING Slide 51 LPA1 Implementation 1/2 LPA1 Example Of Scoring 51
0 - No LPA Procedure / No check sheet defined. 1 - Generic check
sheet defined but not covering items related to safety,
manufacturing or quality 2 - Generic check sheet established but
theres no auditor training or some key items for safety, quality
and manufacturing are not covered 3 - Few auditors are not trained
or check sheet not defined for supporting areas 4 Check sheet
covering all items. Evidence that all auditors were trained. Check
sheet defined for supporting areas Slide 52 Example Of Scoring 52 0
- No LPA scheduled and performed 1 - LPA not performed but
scheduled according to action plan or audits performed occasionally
but no shcedule available 2 - LPA conducted in all shifts but no
scheduled for all levels following an established frequency 3 - LPA
missed for few workstations. Minor concerns related to
documentation (e.g.: readability, dates, issues fix immediately are
not documented) 4 - LPA conducted according to schedule by all
level (all shifts/workstations) and documented properly LPA2
Implementation 2/2 LPA2 Slide 53 53 Example Of Scoring LPA Key
Element Effectiveness 1/2 LPA Key Element 0: No metric in place.
Supplier has no global vision of the LPA implementation and LPA
results (Eg: number of late LPA,) 1: Supplier is tracking LPA
planning. He is able to know if he is late or not. There are no
metric to track results (Eg: mean nb of deviation by LPA, pareto of
deviations,) 2: Supplier is tracking LPA planning and LPA results.
Some metrics are not correctly managed (no target, heterogeneous
situation from a line to another,). Team leader is free to do or
not Slide 54 54 Example Of Scoring LPA Key Element Effectiveness
2/2 LPA Key Element 3: Supplier is tracking LPA planning and LPA
results. Metrics are well managed (target defined, metrics
standardized, action plan to reach the target). Target not reached
on some line & several road blocks (customer issues, repetitive
deviation, late action plans,) 4: Same situation Cross check
activites on the different metrics (Eg: Gap analysis between
product line, between hierarchical level,) Stabilize Metrics &
No open issue.
