Personnel Development
and Continuous Improvement –
Utilizing AIAG Core Tool Products
David Kneisler
VP, Global Quality
Dana Holding Corporation
Dana Overview
Dana Snapshot
• Founded in 1904
• Based in Maumee, Ohio, USA
• 2014 sales: $6.6 billion – Fortune ranking: 385
• Global operations and customers – 90 major facilities
– 25 countries on six continents
– 4,000 customers in more than 125 countries
• 15 R&D centers
• Approx. 23,000 people
2
Dana Global Markets
Sales by Market and Region
50% Light
Vehicles
30% Heavy
Vehicles
2014 Sales by Market 2014 Sales by Region
20% Asia Pacific*
43% North America
25% Europe
20% Off-Highway
Markets
47% North America
30% Europe
12% South
America
11% Asia Pacific
Dana Core Technology Expertise
Sealing – Oil Consumption and Emissions
Gaskets and seals, molded cover and pan
modules, fuel-cell plates
Brand: Victor Reinz® (since 1909)
Thermal Management – Manage the Heat
Heat shields, transmission and engine oil
cooling, battery cooling, charge air cooling,
active warm-up, fuel-cell products
Brand: Long® (since 1903)
Driveline – Torque Management
Axles, driveshafts, off-highway transmissions,
tire management systems
Brand: Spicer® (since 1904)
Dana Products
Light Vehicle Products
• Cylinder Head Gaskets
• Thermal Acoustical Protective
Shielding
• Active Warm-up Units
• Engine Oil Coolers
Axles
Driveshafts
Sealing
Thermal
• Water-Cooled Charge Air Coolers
• Thermoplastic Oil Pans
• Cylinder Head Cover Modules
• Secondary Gaskets
• High-Temperature Gaskets
• Valve Stem Seals
• Transmission Oil Coolers
• Fuel Coolers
• Battery Cooling
Transmissions • VariGlide™ CVP Variator
• Transmission Valve Body
Separator Plates
Quality in Today’s Automotive
Environment
• Quality doesn’t “sell”!
• Expectations:
– Safety
– Reliability
– No Issues / Hassle Free
• To achieve expectations, automotive people need to know the “rules” and “tools”
– OEM’s, Tier 1 – Tier “N”
AIAG Quality Core Tools
• The AIAG Core Tools are the “building blocks” for Quality knowledge and performance expectations in the automotive industry
• Utilized / required by many OEM’s and Tier 1 supplier in the automotive industry
– Third party auditors required to be certified so they can effectively audit these Core Tools
AIAG Quality Core Tools
APQP / Control Plan
Automotive Quality
Core Tools
FMEA PPAP
SPC MSA
AIAG Quality Core Tools
• Advanced Product Quality Planning/Control Plan (APQP/CP)
– Guideline for quality planning for new product development
• Failure Modes & Effects Analysis (FMEA)
– Reference manual for product and process risk assessment
• Production Part Approval Process (PPAP)
– Requirements for confirmation of supplier product/process capability prior to serial production launch
• Measurement Systems Analysis (MSA)
– Guideline to evaluate capability of inspection/test equipment
• Statistical Process Control (SPC)
– Guideline for application of statistical methods in production
AIAG Core Tool Self-Assessment
• FREE, on-line Self-Assessment
– Available in English, Spanish, Korean, Chinese, Russian
• Purpose:
– Measure basic understanding of the core tools
– Identify where more education / training may be useful
– Feedback on effectiveness of prior training investments
• Timed, open book assessment
– Questions based on Body of Knowledge from the Core Tool certification courses
– Seasoned quality professionals should be able to score 90+ in their prime competencies, 80+ in all areas
AIAG Core Tool eLearning
• Two Overview Courses
– Core Tools Overview
– Quality Core Tools - Connect the Dots
• Four Detailed Courses
– Implementing APQP, Control Plan and PPAP
– Implementing Failure Mode Effects Analysis
– Implementing Statistical Process Control
– Measurement System Analysis with Applications
Dana’s Core Tool Scope and Vision
• Dana has an excellent, professional Quality staff.
– Varied industry backgrounds
– Business specific training focus
– Quality Career Path knowledge base differences
• Recognized that we had an opportunity to leverage AIAG’s core tool products to benefit all Dana employees.
– “Level up” to common knowledge set
Initial Desired Outcomes
• Deploy AIAG Core Tool Products across Dana globally.
• Develop a Dana Core Tools Certification based on AIAG Core Tools.
• Focus on Quality professionals: e.g. Managers and Engineers
• Link demonstrated Core Tool knowledge to the Dana Quality Career Path
Dana Core Tools Certification
• Utilize AIAG’s Core Tool Self-Assessment as the basis for Dana’s Core Tool Certification.
• “Passing” scores set at >= 80% on all four scoring categories in a single test session.
• Initiated the program late Q1 2015.
Knowledge Deployment supporting
Certification Efforts
• Goals:
– Global access with local language support
– E-Training focus
– Access to Technical Experts as needed
Knowledge Deployment supporting
Certification Efforts (continued)
• AIAG Core Tool and CQI Documents available to Dana employees via Dana Intranet
• AIAG Core Tool E-Training communicated globally
• Dana “expert” access established
Initial Core Tool Self Assessment
Framework
• Requested Quality professionals to take the self-assessment without preparation or study.
• Emphasized that scores do not need to be shared with anyone unless applying for the Dana Certification.
• Communicated expectations:
– Take the self-assessment within 90 days from roll-out.
– If needed, study and re-take the self-assessment as needed to achieve the Dana Certification.
First Round Results
• No one “passed” on the first attempt!
– Do not be surprised if this happens to you!
• Initial Score Results (averages):
– APQP/PPAP: 73
– FMEA: 74
– MSA: 72
– SPC: 69
– Overall: 72
First Round Results
• Dana scores were consistent with AIAG’s baseline industry results.
• No significant differences noted between populations:
– Business Unit
– Region
– Corporate / Tech Center / Plants
First Round Results
• Key feedback from Dana personnel:
– Universally positive! (worth the time)
– In many cases a single category or two required additional study.
– Great appreciation for online access to AIAG documents (via Dana Intranet) and AIAG e-learning (via AIAG website)
– Desire for certification and associated recognition
Learning Progression
• Clear positive trend in scores on subsequent self-assessments
• In many cases only self-study of AIAG material was needed to achieve desired score targets
• Although a few certifications were achieved fairly quickly, significant progress was not seen for six months
– Study time vs. workload
Current Certification Status
• 63 Quality Professionals Certified
– Average score = 86%
• 14 points above the initial baseline scores
– Largest improvements seen in MSA and SPC
• Certifications now happening weekly
• Significant support from Operational leaders
2016 Deployment Expectations and
Plans
• Most Quality Professionals are expected to be certified in 2016
• Expanding certification efforts to Applications Engineering, and some Process Engineering positions
• Adding the Dana Core Tools Certification to our Quality Career Path requirements for Quality Manager and Quality Engineer positions
Deployment Lessons Learned
• Key success factors:
– Initial communication
• Employee and customer benefits
• Desired outcomes
• Score anonymity
– Access to documents and e-learning
– Access to subject matter experts
– Leadership support (all levels)
• Especially Plant Managers
– Employee Recognition
Questions?
Thank you!