Robust Production Process

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Product Manufacturing and Delivery - Robust Production Process, Pre-requisites, Standards, Controlling, Examples,
1st edition November 2007, English edition published in Dec. 2011

Short description to VDA Volume “Robust Production Process”

 

Industry in Germany and Europe, especially the automotive industry, is currently experiencing great changes. Market globalization continues to progress and the industry is now exposed to international competition. The number of different automobile brands, which had been decreasing in recent decades, has expanded in the last few years to include Asian competitors who are now also internationally active. Their products are taking an ever-larger market share due to the extensive fitment of products as standard and a good ratio of price to performance.

In addition, the OEMs are faced with ever-greater product complexity and ever-shorter development and test lead-times.

 

The percentage of electronic components involving complex software will continue to increase and this will lead to additional challenges in terms of essential validation and verification to achieve the high reliability and quality levels required.

At the same time cost pressures are enormous. By any international comparison, production and manufacturing costs are clearly higher in Europe and especially in Germany. These disadvantages can be countered only by greater innovation and technology, as well as features which will catch the customer's imagination.

The customer expects not only a vehicle providing excellent performance at a reasonable price: he also expects an innovative, safe, premium-quality, reliable vehicle. These expectations apply to the end-product – that is, the vehicle with all its components. In addition, a defect-free supply chain for manufacturing and production, servicing and the supply of replacement parts must be guaranteed.

This present volume, Robust Production Processes, provides assistance with the following topics:

  • How are Robust Production Processes implemented?
  • How are Robust Production Processes evaluated or measured?
  • How are influencing factors and failures dealt with?
  • How can existing production processes be improved?

Contents

1

Introduction

1.1

The initial situation

1.2

Objectives

1.3

Influencing factors

1.3.1

Complexity and Innovation

1.3.2

The human factor: management and employees

1.3.3

Resources

1.3.4

Planned and unplanned changes

1.4

Definition / “guide rails” of a Robust Production Process

2

Overview of the complete concept

2.1

Comments on navigation

2.2

The four control loops of the Robust Production Process

2.3

Links with VDA standard Maturity Level Assurance for New Parts

2.3.1

Classification using the "traffic lights" system

2.4

Illustrations, check-lists and examples

3

Pre-requisites for a Robust Production Process

3.1

Corporate culture

3.1.1

Culture of trust, handling successes and failures

3.1.2

Process orientation and increased quality

3.1.3

Failure prevention / avoidance

3.1.4

Sustainability

3.1.5

Continuous Improvement

3.2

Product development and planning process

3.2.1

New parts

3.2.2

Parts from a new manufacturing location

3.2.3

Carry-over parts

3.3

Minimum requirements for the quality functions of a production location

3.4

Logistics concept

3.5

Risk management – preventive failure management

4

Check-point

5

Standards for Robust Production Processes

5.1

Basic standards for internal production processes

5.2

Supplier management

5.2.1

Supplier selection

5.2.2

Contract validation, quality assurance & logistics agreement

5.2.3

Involvement of new suppliers

5.2.4

Monitoring the quality of deliveries

5.2.5

Escalation management

5.2.6

Communication and cooperation

5.2.7

Transfer to the complete supply chain

5.3

Monitoring & controlling

5.3.1

Key data cockpit

5.3.2

Communicaiton, display, reporting

5.3.3

Control loops

5.3.4

Requalification

5.4

Failure management

5.4.1

Preventive failure management / risk management

5.4.2

Reactive failure management

6

Road map covering standards, guidelines and methods

6.1

Methods and guidelines road map for the VDA Volume

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