Aditi Sharma

29th June 2016

Public

1. Design for Zero Defect Product2. Supplier Quality Improvements3. Plant Quality Improvements4. Product Quality & Reliability Improvements5. Service Quality Excellence6. Quality Functional Excellence & Quality Systems7. Continuously Improve using 6 Sigma & COS

AMaZe Methodology – Example HHP

Projects & Initiatives –Action Tracker

KJ Analysis S Curve

Quality Function Strategic Initiatives

VOC/VOB

3

Quality Framework

3

Quality Functional Excellence – Processes, Tools & People

Change

Management

IQA Process

VPI/VPC Process

ESW Process

(Product/Application)

FIRG Process

Reliability Standard

Work

System integration

Supplier non –

conformance Mgmt.

APQP / PPAP

SIP – Supplier

Improvement Plans

SPC & Process

Capabilities (PPCM)

Design Quality Review

MQV

Conformance of

Production (COP)

Statistical Process

Control (SPC)

EASE

Control of Non –

confirming material

Purchased Parts

Inspection

Manufacturing PPAP

Product Problem

Solving (PPS)

Warranty Analytics

BIS Process

PQC - Product

Quality Committee

Global Problem

Reoccurrence

Prevention (GPRP)

Communication

Flow

Parts Availability -

Repair Event Cycle

Time

Technical

Capability

Infant Care

NEPI Compliance

Calibration, Measurement & Test Support services , Standards Laboratory & Materials Laboratory (NABL Accreditation)

Audits – Process Audits, Product Audits, Dock Audits, Layered Process Audits, COP Audits

Database – Metric Stream CQMS - CAR, SCAR, MNC/PNC, QSi Document Control, GPS

Continuous Improvement - Six Sigma (DMAIC, DFSS & TDFSS)

Capable People – Certified ASQ Engineers, Lead Auditors, Six Sigma MBB, BB & GBs, SME’s

Quality Management Systems – ISO 9001:2008 , TS 16949: 2009

Cummins Operating System

Plant Product ServiceSupplier Design

4 Cummins Confidential

Area Leader

AMaZe Program Nitin Deshpande

Design Quality Kavita Kaushik

Supplier Quality Sanjay Tamhankar

Plant Quality Siva G

Product Quality &

Reliability

Rohan Mengale

Service Quality Sundaram Babu

Sponsors Sandeep Sinha &

Aditi Sharma

AMaZe (Accelerated Move towards Zero-defects) is a company wide Quality Function initiative launched to accelerate improvements in five

crucial areas - Design Quality, Supplier Quality, Plant Quality, Product Quality & Reliability, and Service Quality.

This initiative is expected to play a significant role in bringing dependable products and services to the marketplace on a sustained basis.

This initiative is expected to play a significant role in bringing dependable

products & services to the marketplace on a sustained basis

Accelerated Move towards Zero-defects

5

Pillars Critical Processes / Tools

Design 1. VPCR Execution Process

2. IQA Process

3. Customer Engineering Approval Process

Supplier 1. Source Release & PPAP for new & VPI parts

2. Supplier Improvement Program

3. Supplier Non-Conformance Management

Plant 1. Statistical Process Control (SPC)

2. Conformance of Production (COP)

3. EASE implementation

Product 1. PPS Database

2. Warranty Data Analytics

3. BIS Process

Service 1. Communication Flow from Business to Field

Personnel from Distribution Business

2. Parts Availability – Repair Event Cycle Time

3. Technical Capability

keeping the entire

product life cycle in mind

all bought out, semi-finished

and finished products

product to deliver performance

before and after-in-service

all manufacturing processes

ensuring Right First Time

through enhanced

responsiveness to

service events

6

AMaZe Review Mechanism

Deployment started from April 2015 post AMaZe launch in March 2015

Convened by Quality Champion

Attendees: Quality Leaders, BU AMaZe

Program Leaders

Convened by AMaZe Leader

Attendees: Quality Leaders & CF Team

Convened byCMD & COO

Attendees: SLT, OLT members & CF Team

Convened byCOO & Quality Champion

Attendees:OLT members, Quality Leaders

& CF Team

Convened by BU Leader & Quality Leader

Attendees: Quality Champion, Quality

Leaders, BU HOD & CF Team

Convened by AMaZe Leader

Attendees: Quality Leaders, HOD & CF Team

Function Business

Leadership

Launch AMaZe program in Q1’’15 across all business units in India ABO.

100% participation from Leadership.

Structured review mechanism.

Synergize across business units.

Journey and Key Learnings

Q2’ 14 – Q4’ 14

2015

Q4’ 13 – Q1’ 14

Focus on Engine Business

(EBU) and Power Generation

Business (PGBU)

Best Practice – HHP and

HMLD

DBU and Components – out

of scope

Best Practice – HHP

Challenges – Sustained

leadership engagement and

reviews within HMLD and

PGBU

Launch AMaZe across India ABO

Leadership engagement

Structured review mechanism

Synergize across business units

Sharing best practices

7

Supplier Partner’s increased collaboration on AMaZe

8

Design Quality:

Earlier engagement in design

Change Management

IQA process

VPI/VPC process

Supplier Quality:

Supplier non-conformance mangement

APQP / PPAP

SIP – Supplier improvement Plans

Product Quality:

PPS Database

Warranty Data Analytics

BIS Process

Cummins’ Support

Benefits

Reduction in supplier, BIS, ELF,

testing PPM

Improvement in STU

Less product failures at customer

end

More satisfied customers

We are looking for your collaboration on the front of design quality and supplier quality

9Insert Data Classification