Fall 2001 Navigator

8/6/2019 Fall 2001 Navigator

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- 1 -

InsideFord

Launches

Re-vampedQ1 for

Service

iting the $2.5 billion dollar bottomline impact of poor quality in 2000,

Ford Global Facilities, Materials andServices Purchasing has begun the roll out of

a significantly revamped approach to Q1 forservice suppliers. Focused on customer

satisfaction, performance and continualimprovement, the new Q1 criteria, while basedon the previous version, incorporate signifi-cant changes.

Omnex has been participating in the roll outpresentations being given by Ford to the

targeted suppliers in each of the affectedcommodities. Omnex has provided Ford-approved training to over 5,000 companies

around the world, in every major automotivemarket and auto industry region, and has beenidentified by Ford as its preferred provider for

training and assistance to the service supplybase in this effort.

Targeted suppliers are being selected fromcommodity groups having the greatest impacton customer satisfaction and strategic assess-

ment. These include Machinery & Equip-ment, Services, Industrial Materials, Construc-

tion & Building Services, and Transportation.

C

Five Steps to

Transition from

QS-9000 to TS16949:2002by Chad Kymal, CEOOmnex

hat is the future of automotivesector-specific quality manage-ment system (QMS) require-

ments? And what should your organization

do to plan for the transition you need toseriously consider making in 2002? In

previous articles,we haveindicated thatTS 16949:2002

will align withISO 9001:2000.

Also, theInternational

AutomotiveTask Force(IATF) addi-tions to TS 16949, with only a few minor

edits, have been mapped directly to ISO9001:2000s structure. (Go to www.omnex.com/

news/news.html for more details.)Althoughchanges could still be made, the issueremains whether and when automotivesuppliers should consider making the switch

from the third edition of QS-9000 to TS16949:2002. There are 5 steps your organi-

zation can take to use ISO 9001:2000 andTS 16949:1999 and be ready for the future.

W

NavigatorNavigator

continued on page 2

continued on page 3

3Biggest

Challenge for

QS-9000

Companies in a

Nutshell

52001-2002 Training

Schedule

7Enterprise-wide

Quality Systems:

The Hitachi Cable

Story

B UILDING S UCCESS W ORLDWIDE F A L L 2 0 0 1

4Omnex News

OMNEXOMNEX

by Dave Watkins,PresidentOmnex


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Five Steps to Transition from QS-9000 to TS 16949:2002 (continued)

1. Create a Process Map and Understand Customer Require-

ments

Before you do anything, study your organizationfollow theproduct development process from product initiation to shippingand interview personnel in the process. Document the product

realization process in your process map. Identify all the supportprocesses that affect the development and delivery of your product.

Next, decidewhether theQuality Manage-ment System will

support onlycustomers or

whether it willsatisfy the

requirements ofall the interestedparties of your

organization. This may result in incorporating many more processes

to your process map. Lastly, check to see whether the process mapincludes every TS-16949:2002 process. (See Figure 1 Process Map

below.)

2. Conduct Gap Analysis of the Existing System

Now, examine the documentation structure behind your

organizations QMS. Do you have the seven procedures required byTS-16949:2002? Typically, QS-9000 compa-

nies will already have these procedures. Nextverify whether you have documents neededby the organization to ensure the effectiveplanning, operation, and control of its

processes and determine if both the

operation and control of these processes areeffective. The process map is a good placeto start evaluating your documentation

needs. Taking these steps should result inthe clarification of your organizationsdocumentation needs for satisfying custom-ers and/or interested parties. Once you have

taken the steps above, it is now time toconduct an audit or gap analysis to prepare

for revision of your QS-9000-registeredquality system to conform with TS16949:2002s draft requirements. Imple-

menting TS 16949 requires two methodolo-gies: Business Operating System (BOS)process, and the Process Review Methodol-

ogy (PRM).

3. Implement BOS

The first step in implementing BOS involvesidentifying customer and interested partyexpectations. In working with our clients,

our organization uses a process by which we list group and rate

expectations using Post-It notes. Through these groupings intoCustomer Expectations Categories, we are able to better align the

customers or interested parties expectations with processes andmetrics. Another key step in this methodology is the use ofalignment charts to link each expectation category to the keyprocesses and process measurables that need to be measured and

monitored. To effectively satisfy Subclause 5.4.1, PlanningQualityObjectives, of ISO 9001:2000, the organization should use

benchmarking to determine what its short- and long-term objec-tives should be. With BOS, the organization will be on its way to

achieving both enterprise improvement and breakthrough processimprovement.

4. Implement PRM

PRM is a method of documenting and controlling QMS processesIt takes the processes in the process map and your organizations

documentation and applies Process Flows (PFs), Process FailureMode and Effects Analyses (PFMEAs) and Control Plans toensure the documentation your organization has is effective andthat its QMS processes are under control. This document links the

BOS process measurables and the PRM approach.

5. Implement TS 16949:2002

One of the greatest challengesand benefitsof implementing

TS 16949:2002 is that it will require QS-9000-registered organiza-tions to become customer-focused as well as process-focused.

Becoming customer-focusedrequires an organization to

implement a methodology like theBOS process, however, it also

requires an organizational culture

change. Most important, imple-menting methodologies to becomecustomer-focused and process-

oriented do not require anystandards to initiate the process, so

you should start yourorganizations change to the newrequirements now, because theymake business sense in an increas-

ingly competitive marketplace.

An Alternative: The Minimalist

ApproachMake No Change: This is theapproach some organizations maytake. The inputs and outputsbetween two processes need to be

carefully defined..

Organizations and auditors needto be careful not to fall into the

continued on page 3

The issue remains

whether and when

automotive suppliers

should consider

making the switch...

Figure 1: Process Map


3/8

- 3 -

Transition (continued)

The Biggest Challenge for QS-9000

Organizations In a NutshellThe Final Draft International Standard (FDIS) of the ISO/TS16949:2002 is finally available. Thoughthe circulation is limited to a small circle, it is a sign that it will be released to the larger public. What is

still missing is the Customer-Specific document (GM, Ford and DaimlerChrysler) accompanying theISO/TS 16949:2002 standard.

In a nutshell, the ISO/TS-16949:2002 is more influenced by the ISO 9001:2000 Standard than any new

automotive-related change. For the most part, the ISO/TS 16949:1999 has now been faithfully mappedinto the ISO 9001:2000 to create the ISO/TS 16949:2002. Elements influenced by ISO 9001:2000

include 4.1 General Requirements, 5.2 Customer Focus, 5.4.1 Quality Objectives, 5.5.3 InternalCommunication, 5.6 Management Review, 6.1 Provision of Resources, 6.2 Human Resources, 6.2.2.3

Training on the Job, 6.2.2.4 Employee Motivation and Empowerment, 7.0 Product Realization, 8.2.1 Customer Satisfaction, 8.2.3 Monitoringand Measurement of Processes, and 8.4 Analysis of Data.(See the Omnex website for two articles on this topic which were published inThe Informed Outlook.)

The biggest challenge for QS-9000-registered companies is the customer focus and process focus represented by this standard. (See the

Omnex website or next months Informed Outlook for more information and a table on the subject.)

Changes

Among the more significant changes:

1. In the service supply base, only targeted suppliers in targetedcommodities will be eligible for consideration;

2. Defined categories of performance will be assessed on a

regular basis, with published performance ratings;3. Common performance metrics with defined minimum

acceptable performance standards are being established forongoing supplier performance assessment;

4. There is a defined evidence package;5. Q1 probation is eliminated;

6. There is revocation of Q1 for unsatisfactory performance ifnot rectified within a defined time period. Additionally, certain

defined events will trigger revocation.

Customer performance ratings will focus on Quality, Timing, Cost/Budget performance; Commercial assessment will focus on Costand Quality.

These changes and enhancements clearly target and requireperformance, continual improvement and customer satisfaction,

rather than just achieving conformance to system requirements.

Ford Q1 (continued)Basic Requirements

The basic requirements for Q1, while similar to the prior criteria,

incorporate significant differences:

1. 3rd Party Certification to ISO-9001 (automatically to ISO-9001:2000 for those not currently registered);

2. An effective QOS, with QOS metrics;

3. Performance above minimum acceptance standards;4. Certification to ISO 14001 by 2005

5. Customer Endorsements from up to 5 Ford customers

Dave Watkins is President of Omnex, Inc. and a senior trainer/consultant. He has a wide range of international experience focused onenhancing his clients ability to create value for customers and stockhold-

ers and integrating quality and manufacturing systems to enhanceperformance.

Look at the Training Schedule in this newsletter and contact us for

information on training and consulting services available to help your

company achieve Q1 and a competitive advantage that leads to greater

growth and profitability.

See the full article on the Omnex website at

www.omnex.com/news/news.html.

trap of the minimalist approach. In effect, no improvement will be

evident in such a system. More important, the organization will notmake any movement forward in becoming customer- or process-

focused, which could be detrimental in the long term.

Chad Kymal is CEO of Omnex, Inc., and a much sought-after interna-

tional consultant and trainer. He was on the Malcolm Baldrige Board of

Examiners and has a BSME from General Motors Institute and an MS

degree in Industrial Operations Engineering and MBA from the Universityof Michigan.

For the complete article, go to

www.omnex.com/news/news.html


4/8

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News from Asia

India

TELCO, Indias biggest OE manufacturer of heavy vehicles, hasselected Omnex for a large supplier training initiative. Omnex will be

training around 300 suppliers of TELCO. Omnex India recentlypartnered with Visteon India for their Six Sigma initiatives. ZF Steering

Gear has purchased and implemented the EwQMS Omnex SystemsSuite through Omnex India. Also, the India office is working with ZFSteering Gear India and Asian PPG Industries Ltd. for TS 16949:2002

(Second Edition) implementation. Omnex and TUV Rheinland Indiahave announced joint training programs on quality improvement to the

Indian industry.

Thailand

Our Thailand office has recently signed two consulting projects for

ISO/TS 16949:2002 (Second Edition). It also completed its first ISO17025 implementation and an ISO 9001:2000 implementation forBASFs regional chemical operations.

Ford Asks Omnex to Present on Ford Q1Omnex has been asked to participate in a series of Q1 for Service roll-out presentations sponsored by the Ford Global Facilities, Materials andServices Purchasing group. Participants include targeted suppliers fromthe Transportation, Construction, Machinery & Equipment, Industrial

Materials, and Service industries.

Omnex News

New Software Releases from Omnex SystemsOmnex Systems recently released new versions of Audit Pro and Docu-

ment Pro. In addition, the industry has taken notice of the full Enterprise-wide Quality Management System (EwQMSTM). Omnex Systems has

implemented several suites in the US and abroad. Already, the suite thatdoes it all is doing it worldwide. (See below, and the article about the EwQMS Suiteon page 7.)

AQuA was written up in the October issue ofQuality Digestin theNewsoftware section. A screenshot was shown, and a description toldabout how it links with the rest of the EwQMS Suite.

Omnex to Provide Training at National

Manufacturing Week ConferenceFor the first time, National Manufacturing World will partner with Omnexto provide public training seminars. The conference takes place at

McCormick Place, Chicago, March 18-22, 2002. Omnexs courses duringthe 5 day conference will include Understanding the ISO-9001:2000International QMS Standard, Six Sigma: An Executive Overview and

Understanding the ISO-14001 International EMS Standard.

Online TrainingOmnex is offering its first online courses in collaboration with a leader in

webconferencing, Virtual WorkshopsTM. Currently Omnex is teaching the

Understanding ISO 9001:2000 course found in our Training curriculum.


5/8

- 5 -

Training Schedule is subject to course load requirements; dates may vary. Please contact Omnex forthe most current information and a copy of our catalog, outlining our full course offering.

ISO/TS 16949

2 0 0 1 - 2 0 0 2 S C H E D U L E 734.761.4940 WWW.OMNEX.COM

Understanding,

Documentation and

Implementation of

ISO/TS 16949:2002

(Second Edition)January 14-16, 2002

February 6-8, 2002

March 4-6, 2002

April 3-6, 2002

May 6-8, 2002

June 5-7, 2002July 8-10, 2002

ISO/TS 16949:2002 fully integrates ISO 9001:2000 and will bethe automotive standard of the future.

OMNEXOMNEX

Ford Q1

OverviewThis one day

course for Fordsuppliers will provide a

three hour overview of thenew Ford Q1 and an in-depth

4 hour look at the 15 partManufacturing Assessment

Tool. For Ford Q1 Training forService, call Omnex.

November 21, 2001

December 10, 2001

January 9, 2002

February 6, 2002

March 6, 2002

April 3, 2002

May 8, 2002

June 5, 2002

July 10, 2002

TrainingTrainingRISO/TS 16949:2002

(Second Edition) Lead

Auditor Training forAutomotiveJan 28-Feb 1, 2002

February 18-22,2002

March 18-22, 2002

April 15-19, 2002

May 20-24, 2002

June 24-28, 2002

July 22-26, 2002

ISO/TS 16949:2002

(Second Edition) Inter-

nal Auditor Training forAutomotiveJanuary 21-23, 2002

February 11-13, 2002

March 13-15, 2002

April 8-10, 2002

May 15-17, 2002

June 17-19, 2002

July 15-17, 2002

ISO/TS 16949:2002

(Second Edition) Transi-

tion Training for Audi-

tors of AutomotiveJanuary 17-18, 2002


March 14-15, 2002

April 11-12, 2002

May 16-17, 2002

June 13-14, 2002July 18-19, 2002

FMEA

FMEA based onAIAG and Ford Q1

Requirements

January 7-8, 2002

February 4-5, 2002

March 11-12, 2002

April 1-2, 2002

May 13-14, 2002

June 3-4, 2002

July 11-12, 2002Study linkages between

concept, system, design, and

Process FMEAs.

Understanding andImplementing ISO/TS16949:2002 (SecondEdition)

November 19-20, 2001December 17-18, 2001

If you want to be current on allof the changes in the new ISO/

TS16949, Omnex is the place

to go for training!

QOS

Implementation

and Improvement

for Manufacturing/

ServiceNovember 8-9, 2001

January 10-11, 2002

February 7-8, 2002March 7-8, 2002

April 4-5, 2002

May 9-10, 2002

June 6-7, 2002

July 11-12, 2002

Omnex Systems offers

training in its popular APQPprocess management and

quality documentation soft-ware.

AQuA 3 Basic TrainingNovember 12, 2001

December 3 & 10, 2001

February 18, 2002

April 15, 2002

June 10, 2002

AQuA 3 WorkshopNovember 13-14, 2001

December 11-12, 2001

February 19, 2002

April 16, 2002

June 11, 2002

AQuA

APQP Implementation

and ImprovementJanuary 21-25, 2002

April 29-May3, 2002

July 29-Aug 2, 2002

APQP

RNew!

New!

Ford-Approved Automotive

Training

RNew!

ISO/TS 16949:2002 (Second Edition) with ISO 9001:2000


6/8

- 6 -

ISO 14000

ISO 9001:2000

ISO 9001:2000

Lead AuditorNovember 26-30, 2001

December 10-14, 2001

Feb 25-March 1, 2002

April 22-26, 2002June 17-21, 2002

ISO 9001:2000

Internal AuditorDecember 5-7, 2001


April 8-10, 2002

June 10-12, 2002

NOW RAB-ACCREDITED!Transition TrainingRAB-APPROVED!

Taught by a Master Black

Belt who led Allied Signal

Safety Systems in their Six

Sigma implementation. The

Omnex Six Sigma training

instructor will show you the

hands-on techniques used in

the successful deployment of

Six Sigma from an insiders

view.

With our Black Belt training,

youll be able to save

$500,000 - $750,000 per

Black Belt. And sign up

today for Omnexs Cham-

pion Training in Six Sigma!

Call Omnex for more infor-

mation on our Six Sigma

Open Enrollment and

onsite training being of-

fered now.

OMNEXOMNEX

ISO 14000 Lead AuditorNovember 12-16, 2001

Jan 28-Feb 1, 2002

March 18-22, 2002

May 20-24, 2002

July 22-26, 2002

ISO 14000 InternalAuditorJanuary 14-16, 2002

March 11-13, 2002

May 13-15, 2002July 15-17, 2002

Understanding,

Documenting and

Implementing ISO

14000January 7-9, 2002

March 4-6, 2002

May 6-8, 2002

July 8-10, 2002

TrainingTraining2 0 0 1 - 2 0 0 2 S C H E D U L E 734.761.4940 WWW.OMNEX.COM

Six Sigma

An intensive two day auditortransition training course for

auditors who have passed aninternal or lead auditor course

This two day course will teach

ISO 9001:2000 audit trailsscope selection, and audi

planning. Breakouts an

graded exercises will test yourskills in the new ISO 9001:2000

requirements for documentation, management review and

customer expectations, etc.

November 15-16, 2001

December 3-4, 2001


May 9-10, 2002

ISO/IEC 17025

This new standard

replaces lessons learnedfrom implementation of

the ISO/IEC Guide25:1990 and EN 45001:

1989 and contains all therequirements that testing

and calibration laborato-ries should have.

Laboratory Quality

SystemsFebruary 14-15,2002

April 11-12, 2002

June 20-21, 2002

Understanding and Implementing ISO 9001:2000December 3-4, 2001

February 4-5, 2002

Omnex is offering courses

on the West Coast. Many ofthe courses you see here are

also offered with the Semi-conductor Supplement

included. Call Jim Hooper at408-683-2710 or visit

www.omnex.com to obtain a

schedule for San Jose.

April 1-2, 2002

June 3-4, 2002

How to Audit ISO

9001:2000

An Auditors Guide

This is your last chance to

order the best techniques forvalue-added implementation,

interpretation, and docu-

mentation of ISO

9001:2000 from Omnex.

Chad Kymals book is

going to be printed by

Paton Press. But you can

order one of the few copies Omnex has left.

Contact us today to order at a cost of $50.

734.761.4940 [email protected]

OMNEX...A world

ofKnowledge

California

Training


7/8

- 7 -

The Hitachi Cable Storynterprise-wide software solutions are just starting to come

out on the market. The Omnex Systems EwQMSTM Suitemay be the answer to what companies are looking for

one package for all of their quality management needs. Compa-nies today are tired of addressing their documentation, auditing

and measurement systems analysis needs by stringing several

packages together.. And organizations who have locationsaround the world are looking for Internet-based solutions likeEwQMSTM.

The EwQMSTM solutionallows the organiza-

tional entity and thesupply chain to act as acohesive whole. Howdoes this work? Read

the Hitachi Cable Storybelow. Though this

implementation is

in its infancy, thepotential is huge.

Savings with AQuA

Hitachi worked withOmnex because of the

large savings they gotwhile using Omnex

Systems AQuAsoftware. Hitachi Cablehad been using AQuA software since May, 2000. Greg Walts,Quality Manager at HCI, found AQuA user friendly and

powerful to use. By the end of 2000, Greg had documentedover $200,000 in savings using AQuA. (Go to

www.omnexsystems.com to download a presentation from

HCI on the savings it got from AQuA.)

Hitachi QMS Strategy

Hitachi Cable Indiana along with other Hitachi Cable companieswere looking for a system to 1) bring standardization to theirquality systems worldwide, 2) allow communications between

companies concerning quality matters by using the Internet, and3) help information travel more easily. Also, 4) Hitachi manage-

ment was seeking an efficient means of obtaining critical

performance measurements for each operating unit.

Due to their experience with AQuA, it seemed natural for HCIto expand their involvement with Omnex Systems by implement-ing its EwQMS software. What surprised them was the relativeease with which Omnex Systems got their implementation going.

While most of the time it takes weeks or months to install newsoftware and convert existing systems, Omnex Systems told

Greg that the web installation would take one day and that AuditPro and Document Pro would take a day each to get up and

running. So in a matter of three days the core of the EwQMSsuite would be functional.

Omnex Systems purchased the server and configured the systemfor Hitachi. Next we carried the software and hardware to

Hitachi and installed it that day. In two more days, we uploadedthe existing documentation to Document Pro and got Audit Proup and running.

Omnex delivered on its promise. Greg says, We found the

software to be very user friendly, with no so-called bugs in thesoftware. The software required very little additional program-ming to meet our companys specific requirements. Basically, the

software can beloaded off theshelf and itbecomes functiona

immediately.

Chad Kymal,

Omnex SystemsPresident, says, W

run against compettors that give quote

where the set-upand implementation

costs for thesoftware are much

larger than thequote for thesoftware itself. Onthe other hand,

Omnex Systems catypically get a company up and running and the documents

converted in a day. On top of that, we dont need to customizethe programs. Why? Quality and quality systems are Omnexsbusiness already. The flexibility is built in to accommodate mostorganizationss quality systems. We not only accomplished it at

HCI, we just did it again in a Lear Seating plant last week.

At HCI Omnexs web-based solution has been a major boon.

Greg Walts says, Document Pro and Audit Pro are both web-based software packages. Our desire to use the Internet for glob

communications will make it much easier to achieve our inter-company goals. We envision an audit program that will be used

by all of the satellite companies at one time. HCI is still in theprocess of implementing Doc Pro, Audit Pro, and BOSS to their

fullest potential. Their implementation of the AQuA softwarehelped them to realize a savings of $225,000. The initial estima-

tion of the savings for the suite will definitely be at least that

much, if not more.

E

Enterprise-wide Quality Systems

For the complete text of Greg Walts interview, go to

www.omnexsystems.com/news/news.html.

Take a guided tour of Document Pro and Audit Pro

online, right at your desk. Call 734.761.4940.

Figure 1: EwQMSTMSuite


8/8

- 8 -

PRSRT STD

U.S. Postage

PAID

Ann Arbor, MI

Permit No. 502

3025 Boardwalk

Suite 120Ann Arbor, MI 48108

Phone: 734.761.4940Fax: 734.761.4966Email: [email protected]

Web: www.omnex.com

Fall 2001 Navigator

Documents

Transcript of Fall 2001 Navigator