Quality Systems Education Partnership (QSEP)

Overview of QSEP – What is it? EEducational partnership LLocal company & Bowling Green State University EEmployees from multiple facilities UUndergraduate and graduate degree programs QQuality systems technology FFocus on Lean and Six Sigma systems TTeam based structure WWork on actual projects in plant instead of “case-studies” OOn-line learning environment WWin-Win-Win solution

Production Management Philosophy derived from Toyota Production System Elimination of Waste Replacement of batch and queue with flow manufacturing systems Optimal production efficiency achieved by:Just-in-time product deliveryUtilizes Team organizational systems What is “Lean”? Quality Systems Education Partnership (QSEP)

What is “Six-Sigma”? The term "Six Sigma" refers to the ability of highly capable processes to produce output within specification. In particular, processes that operate with six sigma quality produce at defect levels below 3.4 defects per (one) million opportunities 1,000,000 units of Raw Materials 3.4Rejects 999,996.6 units of Good Products Quality Systems Education Partnership (QSEP)

What is “Six-Sigma”? Six-Sigma is a collection of statistical, engineering based quality and process evaluation and improvement tools and practices. The foundational convictions of Six-Sigma are: Continuous efforts to reduce variation in process outputs is key to business success Manufacturing and business processes can be measured, analyzed, improved and controlled Succeeding at achieving sustained quality improvement requires commitment from the entire organization, particularly from top-level management Quality Systems Education Partnership (QSEP)

Six-Sigma Includes TQM DMAIC DMADV Design of products and processes using DMADV – Define, Measure, Analyze, Design, Verify Improvement of existing products and processes using DMIAC – Define, Measure, Analyze, Improve, Control Sustaining improvements from DMADV and DMAIC through Total Quality Maintenance Quality Systems Education Partnership (QSEP)

One of only a few such partnerships between a company and an educational organization in the country Combines graduate and undergraduate students in the same courses to teach leadership skills to the graduate level students while providing a performance model for undergrad students. Utilizes self-directed team structure, with faculty oversight, to teach students/employees the skills needed to work successfully in teams in their workplace. System characteristics that make QSEP unique Quality Systems Education Partnership (QSEP)

Strategic Advantages of QSEP Builds a “culture of change for improvement” in existing employee base Demonstrates corporate commitment to employee education and development No wasted effort - Students apply Six-Sigma and Lean tools to solve actual problems in their workplace rather than “canned” case Provides cutting edge technology resources to companies to improve all-around competitiveness Quality Systems Education Partnership (QSEP)

How is QSEP a Win/Win/Win? BGSU Strengthens Center of Technology programs and enrollment Student/Employees Gain higher education in cutting edge quality systems Company Gains problem solutions while building quality culture Quality Systems Education Partnership (QSEP)

Results from the Spring 2008 class – QS370/616 Project statement: develop and encourage a Quality Systems Educational Partnership (QSEP) between Bowling Green State University (BGSU), the United Autoworkers (UAW) and Chrysler LLC that is robust and provides a modern workforce capable of eliminating waste and delivering cost improvements through the use of Lean and Six Sigma tools while providing higher education opportunities to employees. Quality Systems Education Partnership (QSEP)

Results from first class – QS370/616 Example of some of the tools used to complete this project Project tasks and assignments tracked using Plan-Do-Check- Act (PDCA) tool Project Plan Value Analysis (PPVA) and Project Earned Value Analysis (PEVA) tools Quality Systems Education Partnership (QSEP)

Results from first class – QS370/616 Example of some of the tools used to complete this project Process Layout Flow tool Cost Analysis tools Quality Systems Education Partnership (QSEP)

Results from first class – QS370/616 Example of some of the tools applied in this project Quality Function Deployment (QFD) Benchmarking Process Failure Mode & Effects Analysis (PFMEA) Survey tools Detailed Operator Instructions Quality Systems Education Partnership (QSEP)

What’s needed to really make QSEP work? From the employee survey – assistance with costs related to working toward a degree (tuition, books, and other expenses) was a top concern. The QFD process revealed, among other things, the need for better marketing of the QSEP concept and process to perspective students and management. The PFMEA tool highlighted the need for improved instructions for students for the process of registering for classes.

Quality Systems Education Partnership (QSEP)