QC Story - Registration to TS16949

I. Purpose: V. Future Image

Timely compliance / registration of each TG Group company Kaizen Quality System Improvement Plan VII. Recommendation
1. Presidents to agree on approach
II. Background GAP 1 1.1 'Single/Unified Process
A. Control – Cust. Exp. -> Product Real. -> Cust. Satisf.
1. Automotive Market Demands In
B. Team Work / Unity
1.1 1980 -1990 - Domestic OEMs loose significant market share TS16949 GAP Analysis process
S 2. Establish one corporate system/process
1.2 1994 - QS9000 Manual released T
E GAP 3 Corporate 2.1 TS looks for 'single' process
1.3 1999 - TS16949 released Process
Process P A. Centralized business planning
1.4 2002 - DaimlerChrysler first to mandate registration by 7/2004 Design 3
Design
Verification & TS16949 Establish Process + PDCA + Integration B. Focus on Customer Satisfaction
1.5 2003 - Nissan requiring compliance by 1/2004 Satisfaction Output S
Validation 2 2.2 Only one registration per company
1.6 2003 - Honda requiring compliance to ISO9001:2000 by 1/2004 T
GAP 2 0 A. No more site registration
2. TGNA Do Check E Corporate Done

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P 0
B. No more exclusions (4.6, 4.7, 4.8, 4.9, etc.)
2.1 1997 - TGNA Registered to QS9000 2 4
Manufacturing QS9000 Establish Method Target (2002) 2.3 Structure for future growth
2.2 1998 - TGNA Quality System Re-written and Improved S
Plants 2 3. Targets
2.3 2000 - TGTC and TGNA Quality Systems were combined T
0 Current Sept 02
E GAP 1 TGNA 3.1 Compliance by all NA TG Group companies by 12/2003
2.4 2001 - Gap Analysis of TGNA Quality System Plan Act P 0
2 3.2 Registration required by DCX – 7/2004
3. NAMC 1

Ø Ý
Process Process
QS9000 Quality System Standard Minimum
3.1 1997 - WTG Registered to QS9000 through KPMG Design Design
Input Review
3.2 1997 - TGMO Registered to QS9000 through UL
3.3 1997 - TGFSUS Registered to QS9000 through Entella
VIII. Strong Points
Info

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3.4 2001 - TGKY Registered to QS9000 through UL Product No Quality System
3.5 2002 - TGNA Evolving as NA Business Center
Customer Continuous 1. TS16949 Brings Standardization
Realization y Globalization Effort
Improvement
Process y Initial Stage Control
y Strong Policy Deployment
III. Current Situation TS16494 Specification y Standardization Policy (Sales & Technical)
1. Automotive Market Demands Design
Design y Manufacturing can follow best practices
1.1 Better Continuous Improvement Verification &
Output
Validation Continual Improvement of 2. NA TG Companies Learned Process Approach
1.2 More Effective Quality Systems y TG way is process oriented (Job Flow)
The Quality Management System

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1.3 Better Customer Focus Do Check y TG way is PDCA
1.4 Better Cost Reduction Efforts y TG way is Kaizen
2. TGNA TGNA
Management ª
2.1 Established Continuous Improvement as a core value Plan Act

ª
Responsibility
2.2 Established a Corporate Quality Function (Cost Sharing, Warranty) IX. Main Concerns
2.3 Taking 'Step 1' to improve TGNA Quality System Expectations Design Design Plan & Act
Input Review
2.4 Established Corporate Planning Office for better corporate Customer 1. Achieving Strong Customer Focus
integration and Customer Focus Output Measurement
y Lack of Top Management involvement
2.5 Natsume-san of TGJ advises TGNA to investigate TS16949 Input Customer
Resource
Management
, Analysis & Satisfaction y QS mindset
3. NAMC improvement y No strong Business Process
3.1 Basic APQP process established Act Check y Poor Communication between companies

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3.2 Manufacturing Companies have established Visual Control
3.3 TGNA working with Manufacturing Companies to establish a Do 2. Achieving 'Single/Unified Process'
Warranty and Cost Sharing process Product y Lack of teamwork
Requirements Product
3.4 Initial Stage Control being implemented for improved product launch, Realization
customer satisfaction, and cost control. 3. Establishing Good Kaizen
y Ineffective process ownership
Information Flow Value-adding y Poor PDCA (objectives & measureables)
IV. Analysis
TS16949 incorporates basically the same requirements as QS9000 but
attempts to fix some of the QS9000 failures ( see Detail TS/QS Gap VI. Key Goals of TS16949 X. Action Plan
Analysis)
1. Continuous Improvement
1.1 PDCA + Process Approach makes for best Kaizen
1.2 Audits to focus on proven results - including evidence of Kaizen
1.3 Supplier Development - a key to Kaizen
TS QS
2. Quality System y Strong Customer Focus ~ |
2.1 Based on ISO9001:2000
2.2 Process audits- definition of inputs, outputs, and measureables y 'Single/Unified Process Approach' ~ X
2.3 Focus on process effectiveness rather than documentation
2.4 Elimination of 75% of QS registrars - due to infeffective auditing y Process Centered (defined Inputs & Outputs) ~ X
2.5 QS9000 failed to monitor effectiveness of interaction between depts.
2.6 Focus is on evidence of execution - a QS9000 failure
y Built-in Continuous Improvement (by PDCA) ~ ∆
2.7 Executive ownership of processes is required y Product Realization(APQP + ISC) - main process ~ |
3. Customer Expectations/Satisfaction
3.1 Product Realization is main process for customer satisfaction y Strong PDCA (Good Objectives & Measureables) ~ ∆
3.2 Process flow - expectation -> product realization -> satisfaction
3.2 Customer oriented processes will be main focus of audits y Good Communication & Data Flow ~ ∆
3.3 Objectives and measurerables througout the Quality System
4. Cost Reduction Efforts
4.1 Supplier Development - more specific requirements/involvement
4.2 The Process Approach - each step is measured for 'value added'
4.3 Reduction of waste - one of main objectives of process audit

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