Operational Management Solutions-Informational consulting and training for automotive industry

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First tier supplier – from QMS improvement to IATF 16949 transition and beyond

2014-2015

From the beginning of 2014 OMS has started to work with the company team to improve the actual QMS system.

Project targets were:

  • reinforce the compatibility with ISO/TS 16949 requirements
  • simplification of documentation
  • reinforce core-tools deployment, especially APQP & Control Plan and FMEA, then links to 8D/Problem Solving
  • improve access to documentation by integration with SharePoint , utilization of hyperlinks and VBA for task automation as much as possible

For OMS team, thank you for all your help and support during integrated management system re-engineering project.  At the end of the project positive remarks such are the re-structuring of Integration Management System processes through a new process map, better process descriptions and follow up through utilization of new Excel –based infrastructure, the new online tool GAP – Global Action Plan (Database created for effective control of corrections/corrective-preventive actions) and, not at least an improved problem solving process were stated by our certification body.

Mrs. .., Integrated System Manager of the Company in Romania.
Topoloveni city, Arges County-RO,
EU, 2014-09-26

2018

In 2018 we restarted our collaboration with Bamesa for a new project: IATF 16949 transition preparation.

The project goal was to review actual QMS and implement new/updated requirements of IATF 16949.

Together with company management team, the following activities were performed:

  • Plan and perform necessary training for Bamesa management team
  • review existent documentation
  • analyse and implement CSR Renault revision 2017 in QMS
  • Develop product safety procedures and work instructions, forms
  • Develop and implement risks and opportunities control system, reinforce process approach
  • Assure support in develop and monitor planning for new equipment integration (Gant, risks identification and mitigation, progress follow..)
  • Update internal audit process
  • Implement other specific requirements and create templates and other documents
  • Perform internal audit and report the status to management team
  • Assure support to management review

2019

During the 2019 summer, we were involved in corrective action plan coordination following the IATF certification body surveillance audit.

As part of the action plan, we have initiated utilization of share point/ office 365 by:

  • establishing documentation structure and users access
  • perform training for Quality Department employees regarding utilization of share point/ office 365 tools – Planner and files/ folders management

2020

During first half of 2020 I have coordinated the preparation for IATF surveillance audit including the follow of corrective action plan. COVID-19 issue trigger a digital transformation wave who arrives also in customer plant.

Until the fall of 2020 we have developed and installed several digital tools, like for example:

  • Internal audit module: schedule and follow internal audit process
  • Technical Sheets portal: integration of product technical sheets into a digital portal

We have increased also the utilization of SharePoint/ Office 365 by developing a Quality System intranet site.

About our customer

This company is one of the international leaders in Steel Service Centers located in seven countries with a processing capacity of over 2.5 million tons per year of flat carbon steel, and production facilities covering a total area of more than 700,000 m2.



Contact


Alexandru TUDOSE

Phone: +40 724 349 179

E-mail:

alexandru.tudose@operationalmanagementsolutions.eu

Personal web site – qualifications:

https://alexandrutudose.ro/my-studies/

Linkedin: Alexandru TUDOSE

Despre (semi)esecul sistemelor de excelenta sau cum au aparut formele fara fond

Care este situatia in prezent?

Sistemele de excelenta au aparut, au promis sa ne conduca spre “excelenta industriala”, au disparut fiind inlocuite de altele, precum in moda. Initial vorbeam de standardizare, apoi TQM, am ajuns la 6Sigma, Lean… Tot aici intra si 9001/ TS 16949.

Formele fara fond apar in momentul in care aplicam ceva doar de dragul de a aplica, fara a intelege resorturile intime ale acelui proces. Cel mai bun exemplu este ISO 9001 (acum apare versiunea 2015) insa asta este alta discutie..). Cititind standardul actual (:2008) ii apreciem valoarea – vorbim despre “a pune ordine in activitati” dar daca auditam organizatiile “ISO 9001 proved” vedem ca sunt departe de abordarea bazata pe procese. In multe cazuri nu functioneaza lucruri de baza, precum 3S!

Trist este ca aceasta situatie s-a propagat inclusiv la organizatiile “automotive” certificate ISO TS 16949 – un standard de excelenta pentru industria auto.

De ce suntem in aceasta situatie?

Sunt multe moduri/ cauze care au condus la aparitia formelor fara fond, insa, in esenta putem sa le sintetizam in cateva categorii:

  1. Diferentele culturale – intre popoarele care au dezvoltat metode, cerinte si cei care le aplica in prezent
  2. Neimplicarea personalului din managementul de varf/ mediu
  3. Neintelegerea cerintelor standardului (standardelor) in special a beneficiilor pe care le putem obtine implementand anumite cerinte corect
  4. Delegarea implementarilor catre personal fara putere de decizie

Sa le discutam pe scurt:

Diferentele culturale – intre popoarele care au dezvoltat metode, cerinte si cei care le aplica in prezent

Daca vorbim de ISO 9001, TS, s.a.m.d. vs. diferentele culturale trebuie sa intelegem originea acestor practici/ standarde. In general ele provin din tari anglo-saxone (vezi ISO 9001 – UK) sau asiatice (Japonia). Aceste tari au ca trasatura comuna un respect al angajatilor fata de munca prestata ceea ce ii face sa se implice in procesele pe care le controleaza, implicare care apare la toate nivele organizationale. Mai simplu spus, operatorul de la masina de injectie va fi constiincios si va genera inclusiv idei de a ameliora propria sa activitate.

ISO 9001/ TS se aplica insa si in Romania, Bulgaria unde nu exista acest mod de a privi lucrurile. In majoritatea fabricilor (si ma refer aici in special la cele din josul lantului de aprovizionare – producatorii de furtune, cuie, tabla, profile…) care nu au legaturi directe cu constructorii auto, nu au o cultura axata pe ameliorare continuua. Aici operatorii sunt platiti aproape de salariul minim pe economie si nu sunt cointeresati in buna functionare a proceselor lor, cu atat mai mult in ameliorarea acestora.

Practic, pentru a elimina aceasta diferenta si a reusi implementarea macar la nivelul de a controla procesul de fabricatie va trebui sa “fortam” operatorul – trebuie sa ne luam gandul de la “people empowerment” si alte concepte care au venit (si functionat) din (in) civilizatiile anglo-saxone. Aici e mult de povestit, mai ales despre ce posibilitati avem in a “forta” operatorul (si nu numai, acelasi lucru va trebui sa il facem personalului din middle-management), voi reveni intr-o postare separata.

Neimplicarea personalului din managementul de varf/ mediu/
Neintelegerea cerintelor standardului (standardelor) in special a beneficiilor pe care le putem obtine implementand anumite cerinte corect

Aceasta neimplicare o gasim in special tot in companiile din josul lantului de aprovizionare – in general porneste de la managerul general, director de fabrica,.. s.a.m.d. care nu cunoaste cerintele/ avantajele unei aplicari corecte. Necunoscand aceste avantaje nu va aloca resurse personalului din managementul mediu – si nu ma refer doar la aspectul financiar, ma refer la timp – timpul dedicat studiului/ aplicarii acestor metode/ cerinte. Practic, sistemul de management (calitate, mediu, integrat…) va fi perceput doar ca o obligatie de a completa niste hartii pe care oricum nu le va utiliza nimeni.

Multe organisme de certificare se vor complace in aceasta situatie, totul devenind o afacere: tu platesti, eu te auditez (daca te mai auditez, exista cazuri chiar daca pare greu de crezut), iti dau hartia (certificatul), si lumea e fericita.

Delegarea implementarilor catre personal fara putere de decizie

Legat de (2), delegarea se face de sus in jos: directorul de fabrica e ocupat cu necesitatea de a gasi noi clienti, cum platim noi taxe, salarii, … etc. Directorul de calitate “stinge” o criza (reclamatie) dupa alta deoarece, in lipsa implicarii, nimeni nu va dori sa solutioneze problema – mergem pe solutii temporare, ca doar suntem in criza, nu !? :-), si astfel sistemul (implementarea, actualizarea) ajunge in mana unei persoane (gen responsabil Asigurare Calitate, ca sa folosim o denumire veche insa des intalnita) , persoana care in general nu are putere de decizie si nu poseda suficiente cunsotinte, date pentru a intelege problemele (tehnice dar nu numai).

Astfel sistemul devine un dosar frumos stocat langa certificatul ISO 9001/ TS…