1. Large Automotive OEM – FMEA Managed Service
Case Study
Large Automotive OEM – FMEA Managed Service

2. Failure Mode & Effects Methodology
Process Flow
Block Diagram
Customer Requirements
Design Inputs
Process
FMEA
System
FMEA
Control Plans
Shop Floor Checklists
© 2010 Omnex Inc

3. Automotive OEM – FMEA Managed Service
Design Failure Mode and Effects Analysis
-- Distribution of Recommended Actions
Before AQP
After AQP
© 2010 Omnex Inc

4. Initial Quality of U.S. and Import Brands
Note: Import Brands Include Europe and Asia

5. Large Aerospace Engine Manufacturer
Case Study
Large Aerospace Engine Manufacturer

6. New Product Introduction & PPV
Program Start
Experimental
Production
Product & Process Planning
PPV Activities Consolidation
Planning
Product Design and Dev.
Ongoing Part & Process Control
Process Design and Development
Industrialization
Product and Process Validation
Production
Corrective Action Board activity
Plan & Define Program
Product Design & Development Verification
Process Design & Development Verification
Product & Process Validation
CAB Activity
© 2010 Omnex Inc

7. Large Aerospace Engine Manufacturer
Conducting PPV (Product and Process Validation including FAI) training and facilitation for internal resources and 200 suppliers
Rollout PPV to ensure product and process conformance for all new products
Currently in initial stages – 10% to 30% improvement expected in RCNs

8. Truck – System Supplier
Case Study
Truck – System Supplier

9. Operations Excellence
MANUFACTURING
Materials
Purchasing
FUNCTIONAL
EXCELLENCE
Quality
6S/VISUAL WORKPLACE
We are all material handlers, expeditors,production planners.
We all produce something, some service. We require metrics to measure our progress, we need feedback on regular basis.
We have customers
We have problems
We are not as organized as we could be
We are all support people
Team Skills
Global 8D
FOUNDATIONAL
EXCELLENCE
QOS
TS16949/APQP/PPAP
© 2010 Omnex Inc

10. Truck Industry Large Sub System Provider
187 DPM
Improvement
Before
After
Comments
Quality
Rejects measured in percentages
3 Years – 187 PPM
Implementation of APQP and PPAP internally and with Supply Base

11. Semiconductor Industry Transition
Semiconductor Assembly Council – Representing 95% of Chip Industry Outside Japan

12. Semiconductor Industry Methodology
Customer Involvement Similar to Aerospace Industry
MSA, SPC, and Process Control
ISO TS plus APQP and PPAP
© 2010 Omnex Inc

13. Customer Driven Changes: 1998 to 2004
Productivity improvements: 10% – 30%
Equipment
People
Yield improvement
Subcontractor yields improved to 99.6%
Performance to schedule improvement
Consistently sustaining 100%
Number of customer complaints decreased
Up to 15x reduction
PPM improved by over 100 times to under 30 PPM
© 2010 Omnex Inc