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2003 Righ first time produciton release_thesis.pdf

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2003 RIGH FIRST TIME PRODUCITON RELEASE_THESIS
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Right First Time Production Releases. Paul A. Cash. Thesis submitted in fulfilment of the requirements for the degree of Master of Science under the Ford Engineering Quality Improvement Program. University of Bradford. 2003 2 Abstract Name: Paul Anthony Cash Title of Thesis: Right First Time Production Releases This Thesis is a study from within an automotive design and manufacturing organisation on their ability to deliver 'Right First Time Production Release'. Within any vehicle manufacturing company the main function of the Product Development (PD) organisation is to engineer products, which downstream divisions can procure and make parts that will assemble together to make a vehicle. The information on the product is communicated from PD to the downstream activities via the Production Release. In the ideal world once the Production Release is issued there should be no further changes required. However, in reality there are a number of re- release actions required between the initial Production Release and the first production vehicle being available for sale. The aim of this research was to understand the issues relating to the Production Release and associated processes. The thesis therefore studies the number of times parts are typically re-released during the PD cycle. A case study approach was adopted, followed by an in-depth analysis concentrating on part of the PD cycle. The data was analysed in a number of different ways looking for trends and root causes. A benchmarking study of similar organisations was conducted to compare various aspects of the release process and overall release performance. Through the case study approach the aim of the research was met. The discussion and conclusions generated from the case study and benchmarking analysis suggest there are a number of opportunities available to the company to improve their release performance. These include improvements to the quality of data within the Production Release and revisions to the process steps, which support the subsequent verification and tooling time spans. The research identifies shortfalls with the design verification process due to the number re-release actions. Keywords: Right First Time, Engineering Change, Project Management, Benchmarking, Simultaneous Engineering, Systems Engineering, Engineering Process, Design Evolution. 1 Acknowledgements I would like to thank the following people for their contribution to this MSc research project on 'Right First Time Production Releases': To Professor Andrew Day and Dr. Felician Campean from Bradford University and Malcolm Thomas and Jim McDonald from Ford Motor Company for their support and guidance throughout this research project. To Graeme Harris and Cliff Brunt for their assistance in obtaining the release data, and Vince Gower for his help with the data analysis. To my colleagues Andy Charalambous and Rachel Cowley for their superior I.T. skills during the write up phase of the project. Special thanks to Yamashita-san and Yagi-san from Mazda Corporation for their help and support during the Benchmarking exercise. Finally to my family, Alison, Ruth and Victoria for their patience during the last 18 months whilst I have worked on this research. 5 Table of Contents Page No. Abstract 1 Table of Contents 2 Acknowledgements 5 G l o s s a r y o f t e r m s 6 Chapter 1. INTRODUCTION 7 1.1 Background 7 1.2 Research Topic 8 1.3 Research Aims and Objectives 8 1.4 Thesis Content 9 Chapter 2. LITERATURE REVIEW 10 2.1 Project Management 10 2.1.1. Definition 10 2.1.2 Organisation for Project Management Teams 12 2.1.3 Work Breakdown Structure 13 2.1.4 Planning / Scheduling (CPA and Pert) 14 2.1.5 Milestones two automotive companies, one from Europe and one from Japan, are compared in terms of their respective processes leading up to and after the Production Release. Comparisons of the various processes are made and recommendations for improvement actions are discussed. Chapter 6 discusses the approach and methodology used for the research, reviews in detail the findings of the research including Quality of the Production Release, Design Verification, Competitive analysis, Process Performance Metrics and Causal Factors. Finally there is a discussion on solutions for releasing and FPDS process improvements. Chapter 7 summarises the research and its findings, draws conclusions and lists out recommendations and improvement actions. Chapter 2 Chapter 2 Literature Review 2.1 Project Management 2.1.1 Definition Project Management is a process used to manage projects. This could be a simple DIY project of decorating a room or a much larger project like constructing the Channel Tunnel. The purpose of initiating a project would be to achieve an end goal as in the examples above of either a fresh appearance to a room or the completion of a route from England to France. The British Standard for Project Management BS6079-1 (2000) defined project management as: “The planning, monitoring and control of all aspects of a project and the motivation of all those involved in it to achieve the project objectives on time and to the specified cost, quality and performance“ This definition is also supported by the Cost, Time and Quality triangle, (Atkinson, 1999), often referred to as the Iron Triangle which is used to measure the success or failure of projects. The Iron Triangle is the symbol of the Project Management task of balancing the 3 corners of the triangle, (Lamers, 2002). Figure 2.1 illustrates the Iron Triangle with the three measures of Cost, Time & Quality. These three measures (Cost, Time & Quality) could be used to assess the level of success in the two examples of Projects given above, of the decorated room and the channel tunnel. Oisen, (1971) referenced Project Management as the application of tools and techniques to accomplish unique, complex and one-time tasks within time, cost and quality constraints. Cost Quality Timing Figure 2.1 – Showing the Iron Triangle of Cost, Time & Quality, (Atkinson, 1999). 10
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