SUPPLIER QUALITY DEVELOPMENT

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SUPPLIER QUALITY DEVELOPMENT
?
CONTINUOUS IMPROVEMENT
D
Q
S
evelopment
uality
upplier
?
BY WORKING TOGETHER
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• THE APPLICATION OF
• QUALITY TOOLS TECHNIQUES
• INTO NOKIA SUPPLIERS
• HOW HANDS-ON SUPPORT IS
• GIVEN FROM NOKIA SQD TEAM

Jason Foord Kulwant S Pawar SUPPLIER QUALITY
DEVELOPMENT PROGRAMME Nokia Networks, Finland
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WHAT FACTORS ARE IMPORTANT TO US WHEN WE BUY
PRODUCTS ?
Examples NEW CAR, VIDEO RECORDER, HI-FI SYSTEM,
etc.

• GOOD PRODUCT PERFORMANCE
• EASY TO USE
• GOOD BUILD QUALITY
• HIGH RELIABILITY
• LOW PURCHASE COST
• LOW MAINTENANCE COST

MOST OF THESE FACTORS ARE THE SAME FOR OUR
CUSTOMERS
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HOW CAN WE ENSURE GOOD PRODUCTS ?
1 - Strong PRODUCT DESIGN 2 - Robust
MANUFACTURING PROCESS
- TO ENSURE GOOD PRODUCT EVERY TIME !
NOTE THIS IS ESPECIALLY TRUE WHEN THE PRODUCT
HAS A HIGH DEGREE OF COMPLEXITY
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PRODUCTS FROM SUPPLIERS SUB-CONTRACTORS THAT
MAKE UP A NOKIA BASE STATION
FABRICATED METAL CABINET

FILTER UNITS

POPULATED PCB's


POWER MODULES

COOLING FANS

SUB-RACKS

CASTINGS

CABLES

NOKIA BASE STATION ( HIGH LEVEL OF COMPLEXITY )
CONNECTORS

TRANSMIT / RECEIVE MODULES
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PRODUCT QUALITY RELIABILITY
WOULD YOU WANT TO FLY IN A PLANE IF YOU
THOUGHT- - the wings might drop off during
take-off? - the engines might fail in
mid-flight? - the navigation system fails in a
rainstorm?
WOULD YOU BUY A NEW CAR IF YOU KNEW IT
WOULD- - break down frequently ? - fail to
start on cold wet mornings? - needed servicing
every 500 km?
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CUSTOMER EXPECTATIONS DEMANDS
IS IT THEREFORE UNREASONABLE THAT OUR CUSTOMERS
EXPECT- - good build quality ? - high
degree of reliability ? - low purchase cost
? - low maintenance costs ?
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GOOD QUALITY HIGH RELIABILITY CAN BE
SYSTEMATICALLY ENGINEERED INTOPRODUCTS FAILURE
MODES CAN BE PREVENTED or MINIMIZED !PREVENTIVE
TOOLS, TECHNIQUES METHODS CAN BE APPLIED
WITHIN THE PRODUCT DEVELOPMENT,
PRE-PRODUCTION MANUFACTURING PROCESSES
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DESIGN CONSIDERATIONS

• Product design meets customer requirements
• Surplus functionality avoided to save costs
• Product complexity reduced or minimized
• (More complexity higher risk of failure)
• Designed for ease of manufacture assembly
• (Choice of processes considered at design
  stage)
• Realistic design tolerances that can be achieved
  in manufacture
• Designed to achieve high level of reliability
• Design risks identified minimized

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MANUFACTURABILITY ISSUES

• Manufacturability proved before ramp-up
• Ability to support high volumes
• High yield productivity rates
• Opportunities for error identified minimized
• High levels of quality
• (low reject, rework or scrap)
• High levels of product reliability
• (High life-time without failure/low warranty
  costs)

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QUALITY ACTIVITIES BEING INTRODUCED INTO
SUPPLIERS TO ENSURE ROBUST DESIGN PROCESS
SUPPORTED BY NOKIA SQD TEAM

• Advanced product quality planning
• Quality function deployment
• Identify critical design features
• Design FMEA
• Statistical methods in design
• Process flow charting
• Process fmea
• Pre-production process capability study
• Production part approval process
• Production readiness review
• Statistical process control

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FMEA - AN EXAMPLE OF A QUALITY TOOL

• Systematic method of
• Identifying opportunities for
• Potential error, risk or failure

FAILURE MODE EFFECT ANALYSIS

• CAN BE USED TO IDENTIFY RISKS IN-
• SYSTEM
• DESIGN
• MANUFACTURING PROCESS
• MACHINERY EQUIPMENT

SIMPLE EASY TO USE / QUICK TO IMPLEMENT /
BENEFITS CAN BE IMMENSE
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THE MECHANICS OF THE FMEA TOOL

• Identify all known potential failure modes
  within multi-functional team
• Identify potential causes for failure
• Identify effects of failure
• Identify severity of failure
• Identify likelihood of occurrence
• How easy would failure be to detect
• i.e. is the failure likely to get to the
  customer?
• - particularly relevant if time or stress/load
  related !!

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HOW SQD TEAM SUPPORTS SUPPLIER
SUPPLIER TRANSFERS KNOWLEDGE SKILLS FROM 1st
PROGRAM INTO FUTURE PROGRAMS
QUALITY TOOLS TRAINING
QUALITY TOOLS TRAINING
QUALITY TOOLS TRAINING
Program 1
HANDS-ON SQD SUPPORT
Program 2
HANDS-ON SQD SUPPORT
Program 3
HANDS-ON SQD SUPPORT
SQD SUPPORT ON 1st PROGRAM IS HEAVY AS SUPPLIER
LEARNS HOW TO USE QUALITY TOOLS TECHNIQUES
HOWEVER, SUPPORT FROM SQD REDUCES ON FUTURE
PROGRAMS AS SUPPLIER BECOMES MORE COMPETENT IN
QUALITY TOOLS TECHNIQUES
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CONTENTS OF QUALITY TOOLS TRAINING GIVEN TO
SUPPLIERS

• WEEK 3
• Advanced product quality plan (APQP)
• Quality function deployment (QFD)
• Nokia 7 step problem solving
• Special techniques

• WEEK 1
• Nature of variation
• Quality systems
• Process control (SPC)
• Statistical thinking
• Process capability
• Statistical tolerances
• Control charts
• Measurement system analysis

• WEEK 2
• 7 Quality tools
• - Pareto
• - Flow charts
• - Cause effect
• - Scatter diagrams etc.
• Fault tree
• Analysis
• FMEA

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IMPROVING EFFICIENCIES WITHIN THE MANUFACTURING
SUPPLY CHAIN
DESIGN, DEVELOPMENT, MANUFACTURE, ASSEMBLY, TEST
DELIVERY
Strategic Suppliers
NOKIA
2nd Tier Suppliers
NETWORK PROVIDERS
Other 1st Tier Suppliers
Improve efficiencies by Nokia Suppliers working
together - facilitated by Supplier Development
NETWORKUSERS BUSINESS PERSONAL USERS
- PRODUCE BETTER PRODUCTS - REDUCE COSTS -
IMPROVE QUALITY RELIABILITY - IMPROVE
DELIVERY
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WORKING TOGETHER TO SOLVE TASKS
RD RELIABILITY
MANUFACTURING ENGINEERING
1st Level SUPPLIER
2nd Level SUPPLIER
PROJECT MANAGEMENT
PURCHASING / LOGISTICS
SUPPLIER QUALITY DEVELOPMENT
NOKIA
SUPPLIER
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Traditional Approach to a Project - ACTIVITIES
PERFORMED SEQUENTIALLY - LITTLE OR NO SUPPLIER
DEVELOPMENT
?
?
unexpected problems requiring high levels of
effort support to fix
RAMP-UP
Work with Suppliers is slow at start, but
increases just before / during volume ramp-up
EFFORT
high level of effort to support production
volumes
EXTRA EFFORT REQUIRED BECAUSE DESIGN PROCESS
ARE NOT ROBUST
PRODUCTION PHASE
DESIGN / DEVELOPMENT PHASE
PROCESS DOESN'T ACTUALLY START TO STABILISE UNTIL
HERE
STABILITY SHOULD HAVE STARTED HERE
TIME
LOST OPPORTUNITY
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CONCURRENT ENGINEERING Approach on
Project with SUPPLIER DEVELOPMENT
- ACTIVITIES PERFORMED CONCURRENTLY - HIGH
INVOLVEMENT OF SUPPLIERS
?
?
RAMP-UP
EFFORT
Virtually no problems during ramp-up and
requiring very little effort
Project heavily front-loaded and work with
Suppliers starts at very early stage
Little / no effort to support production, even
at high volumes
Potential problems are addressed early by Design
FMEA and Process FMEA
PRODUCTION PHASE
DESIGN / DEVELOPMENT PHASE
NO SLIPPAGE IN PRODUCTION RAMP-UP
ROBUST DESIGN PROCESS ACHIEVED WELL BEFORE
RAMP-UP
TIME
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BENEFITS OF SQD WORK

• Better communications sharing of information
• Better product designs (combining best
  technologies?)
• Higher yields / lower product costs
• Savings in logistics / administration
• more effective use of resources
• Higher profitability (to all involved)
• Faster time to market
• Competitive edge in market
• Longer-term relationships
• Better security lower risk (safer to plan /
  invest)