1. IET 419 – TOTAL QUALITY IMPROVEMENT Dr. Hans Chapman Group 3 Andrew Abbott Jacob Brewer Vickie Pennington Jeffrey Sebastian -Team Leader

2. SRG Global Mission Statement We strive to provide quality products ensuring the highest level of customer satisfaction

3. The SRG Way is defined through Ten Guiding Principles  RESPECT PEOPLE  TEAM FIRST  EMPOWER AND DEVELOP TALENT  BE PASSIONATE  CREATE AND INNOVATE  ADD VALUE EVERYDAY  EMBRACE GLOBAL PRESENCE  SERVE A GREATER PURPOSE  WIN  CELEBRATE SUCCESS

4.  Ford Q1 Award  Ford Total Quality Excellence Award  Chrysler God Award - Superior Supplier Performance  Chrysler Pentastar Award  Nissan L2 and L1 Award  Ford Q1 Award  Ford Total Quality Excellence Award  Chrysler God Award - Superior Supplier Performance  Chrysler Pentastar Award  Nissan L2 and L1 Award QUALITY SYSTEMS AND AWARDS

5.  Implementing Just-In-Time on the floor  Kaizen performed in groups  Implementing Just-In-Time on the floor  Kaizen performed in groups Kaizen/Kanban Systems Both Kaizen and Just-In-Time are positive for the plants; The Challenges are applying lessons learned from this practices.

6.  5-Why method  Global 8D method  Pareto Carts  Cause-and-Effect Diagrams  Gantt Charts  5-Why method  Global 8D method  Pareto Carts  Cause-and-Effect Diagrams  Gantt Charts PROBLEM SOLVING TOOLS

7. Meet requirement for PPAP approvalMeet requirement for PPAP approval 1 Department’s develop PFMEADepartment’s develop PFMEA 2 APQP software to standardizeAPQP software to standardize 3 Failure Modes and Effects Analysis (FMEA) Utilization

8. Statistical Process Control (SPC) SPC – set of statistical tools used to analyze the quality aspects In control – process values are evenly distributed about the mean value and between 3 sigma values on either side of mean value Capable – process values measured fall within set range.

9. Statistical Process Control (SPC) con’t Control Chart – time ordered plot of individual measurements plotted in order of occurrence. LCL – Lower control limit. UCL – Upper control limit. R Chart – time-ordered plot of sample ranges X Chart – plot of sample averages.

10. CHARTS AND DATA XLT/FX2 GRILLE DIAGRAM

11. CHARTS AND DATA Capability Charts C pk > 1 C pk > 1 C pm < 63 per million C pm < 63 per million Both SC1 and SC2 are Both SC1 and SC2 are capable since C pk > 1 capable since C pk > 1 Data Analysis Recommendation: To adjust their process to make the parts slightly smaller to ensure their size is centered around target specification and falls within tolerances to meet 6 sigma standards.

12. CHARTS AND DATA Capability Charts C pk > 1 C pk > 1 C pm < 1 per 2 million C pm < 1 per 2 million Both SC3 and SC4 are Both SC3 and SC4 are capable since C pk > 1 capable since C pk > 1 Data Analysis Recommendation: To adjust their process to make the parts slightly smaller to ensure their size is centered around target specification and falls within tolerances to meet 6 sigma standards.

13. CHARTS AND DATA X-bar and R Charts No points outside control limits No points outside control limits Signs of potential process change Signs of potential process change Data Analysis Recommendation: Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Look for preventable reason why points close to control limit lines.

14. CHARTS AND DATA X-bar and R Charts No points outside control limits No points outside control limits Signs of potential process change Signs of potential process change Data Analysis Recommendation: Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Look for preventable reason why points close to control limit lines.

15. CHARTS AND DATA X-bar and R Charts No points outside control limits No points outside control limits Signs of potential process change Signs of potential process change R chart suggest that may be breaking the four-of-five rule R chart suggest that may be breaking the four-of-five rule Data Analysis Recommendation: Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Look for preventable reasons why points are close to control limit lines Look for preventable reasons why points are close to control limit lines. Look for possible process change. Look for possible process change.

16. CHARTS AND DATA X-bar and R Charts No points outside control limits No points outside control limits Signs of potential process change Signs of potential process change R chart suggest that may be breaking the four-of-five rule R chart suggest that may be breaking the four-of-five rule Data Analysis Recommendation: Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Utilize 30 subgroups of 5 instead of 15 subgroups of 2. Look for preventable reason why points close to control limit lines Look for preventable reason why points close to control limit lines. Look for downward trend. Look for downward trend.

17. CONCLUSION Cpk capability index processes are capable. Cpm Capability indices examined processes were not capable. Not enough measurements for accurate X- bar and R charts. At risk of breaking six-point-trend-rule and the four-of-five-rule. Good capable process but needs some minor fixes to remain within 6 sigma standards.

18. Resources Websites: Admin.SRG 2012-03-27. SRG Global’s Covington Plant adds “Flash” to vehicles with trim and accessories. SRGglobal.com Admin.SRG 2011-01-06. SRG Global Receives Top Honors From Ford Motor Company. SRGglobal.com Textbooks: Aikens, C.H. (2011). Quality Inspired Management: The Key to Sustainability. Upper Saddle River, New Jersey, United States of America: Prentice Hall Aikens, C.H. (2011). Quality Inspired Management: The Key to Sustainability. Boston: Prentice Hall

19. Resources Personal: Tony Miller, SRG Engineering, Morehead, Kentucky. Chris Breeze, SRG Quality Engineer, Morehead, Kentucky.