b Product Audit Procedureb Product Audit Procedure
Static assessmentChecks on electricsBody and assembled parts
Checks within i t t Body- and assembled partsengine compartment
Bumpers / exterior trimCabling / hoses
Level of consumable liquids
Chassis number / stickers
Bumpers / exterior trim
Seats / carpeting / interior trimLights and instruments
Optional equipmentChassis number / stickers p q pDoors / boot and bonnet ...
b Product Audit Procedureb Product Audit Procedure
Customer-oriented assessment of faults in accordance with a check list and with quality gradequality grade
Input of dataG ti f Generation of a comprehensive vehicle-specific faultvehicle-specific fault report
b Product Audit Procedureb Product Audit Procedure
Presentation of vehicle to following
Quality grade = 2,8
groups– Manufacturing– Quality assurance– Quality assurance– Development
F lt l i Fault analysis
Di i f Discussion of remedial action
bb
and what has that all...and what has that all to do with SAS?to do with SAS?
bb"Everything in life can be traced
back to simple beginnings"
The History of IT SolutionsEventsEvents
b The History of IT Solutions for Product Auditsb for Product Audits
Prior to 1988» Product audits performed essentially by aProduct audits performed essentially by a
single central department (Quality Assurance)– ...we have a guy who can write programs in BASIC
1988 / 1990» Production plants wish to perform audits
themselves– ...there's a PC application available– ...let's give it a try and see if it works
b Hardware zoob Hardware zooApplication 2
Regensburg
Application 2
H d Offi
Munich Dingolfing
Head Office
Application 2
Application 1
Application 2
b The History of IT Solutions for Product Auditsb
1990:
for Product Audits 1990: Production plants increase the number of
monthly audited carsmonthly-audited cars-...where is the programmer, our PC is forever crashing
D i i t k b H d f Q lit Decision taken by Head of Quality-...this can't go on. We need a reliable, comprehensive
l tisolution.
Planning and initial implementation of d t dit li ti h t tproduct audit applications on host systems-...but we'll stick to our PC.
b Hardware zoob Hardware zooApplication 2
Regensburg
Application 2
Munich DingolfingHead Office
Application 2
Application 1
Application 2
b The History of IT Solutions for Product Auditsb for Product Audits
1991: Host-based audit applications now in actual 1991: Host based audit applications now in actual not trial use– ...but we still need the following functions...g
1992: Enhancement of host-based audit applications-... auditing is "in", but everyone is creating their own... auditing is in , but everyone is creating their own check lists. No uniform system and no way of comparing results !
1993: Development of PC-based audit applications– ...it needs to be flexible!
Enhancement of host-based audit applications– ...generation of master check lists
b Hardware zoob Hardware zoo
Regensburg
VM / CMSVM / CMS
Head Office
Munich Dingolfing
Head Office
b The History of IT Solutions for Product Auditsb for Product Audits
1994: 1994:» International deployment of PC-based audit
applicationsapplications– South Africa wants to use it, Spartanburg as well and
the CKD-countries as well– ...the poor, over-worked programmer and the need for
on-going support and maintenance
Inreased use for special tests– in some cases 100% deployment for dynamic testing
Pilot test for mobile data capture– ...we replace the long hard-copy check list with a
b Hardware zoob Hardware zoo
RegensburgSouth Africa U S A
VM / CMSMobile data
?
CKD-PlantsVM / CMSMobile data
capture
Head Office
Munich Dingolfing
Head Office
Pentop
b The History of IT Solutions for Product Auditsb for Product Audits
Incorrect audit results Total reliance on the skills
of individual employees Decision to replace the
host-based system at the end of 1996
b The History of IT Solutions f P d A dib for Product Audits
Establishment of a special team for "project analysis of product audits"product audits"» Analysis of product audit
situation with regard tosituation with regard to specific aspect of product quality being tested and in terms of required informationterms of required information technology
» Proposal for a new world-wide paudit concept
b Strengths of the System in Use todayb Use today
High system availability of a host-based system
High level of securityHigh level of security for data on host
Flexibility in terms of Flexibility in terms of available data assessment functionassessment function on the PC-level
b Weaknesses of the System in Use todayb in Use today
Lack of data consistencyconsistency
Unreliable exchange of data between PCof data between PC and hostL k f l t l Lack of completely effective project managementmanagement
b Proposed Solutionb Proposed Solution
Implementation in the form of a client/server-application operating under pp p gSAS and ORACLE» Can be run on all hardware platformsCan be run on all hardware platforms» Software portability» Reusable modules» Reusable modules
b Objectives and Principlesb Objectives and Principles
Flexible evaluation functions on all hardeware platformsp
Distributed databases General licence for all hardware General licence for all hardware
platformsW ld id d l t di World-wide deployment on diverse platforms
b Client/Server Overviewb Client/Server OverviewCentral host with ORACLECe t a ost t O C
South Africa U S A
Munich CKD plants Dingolfing Regensburgp Dingolfing Regensburg
b Prototype Developmentb Prototype Development
Development under Windows/NT SAS Functioning prototype with the core Functioning prototype with the core
functions of the audit system Portability to PC MVS and UNIX Portability to PC,MVS and UNIX Client/Server testing under conditions
hi h l l i i t lwhich closely mimic actual use Evaluation function employing SAS/EIS Graphics and statistics
b Prototype Developmentb Prototype Development
Project team drawn from and responsible for all production plants
Co-ordinated system of deputising for absent colleaguesCl ll ti f Clear allocation of responsibilities for overall applicationapplication
b "Made in Bavaria""Made in Bavaria"b Made in BavariaMade in Bavaria
Munich
Regensburg
Dingolfing
b "Made by BMW""Made by BMW"b Made by BMWMade by BMW
bUniform, EnterpriseUniform, Enterprise--wide Information Technology for Product Auditswide Information Technology for Product AuditsbFFFFFromFrom
"M d i B i ""M d i B i "
FromFrom
"M d i B i ""M d i B i ""Made in Bavaria""Made in Bavaria"
toto
"Made in Bavaria""Made in Bavaria"
totoMunich
RegensburgDingolfing
toto
"Made by BMW""Made by BMW"
toto
"Made by BMW""Made by BMW"Made by BMWMade by BMWMade by BMWMade by BMWHelga van AnkenHelga van Anken
Ulrich Blank
BMW AG
SEUGI '96 Hamburg
b Production Plants in Germanyb Production Plants in Germany
Munich 3 Series limousines / compact cars
b Production Plants in Germanyb Production Plants in Germany
Dingolfing 3 Series / 5 Series / 7 Series / 8 Series
Munich 3 Series limousines / compact cars
b Production Plants in Germanyb Production Plants in Germany
3 Series / estate cars / convertibles / coupes / M3
Regensburg
Dingolfing 3 Series / 5 Series / 7 Series / 8 Series
Munich 3 Series limousines / compact cars
b Production Plants Abroadb Production Plants Abroad
Spartanburg (USA)
South Afrika
b Production Plants Abroadb Production Plants Abroad
CKD VietnamC et a
CKD Thailand
CKD MalaysiaCKD Mexico
CKD Malaysia
CKD Indonesia
b Procuction Plants Abroadb Procuction Plants Abroad
ROVERROVER
bb How do we make sure that the customer
gets consistent "made by BMW" quality g y q ywhen production is internationally structured ?
Quality system Checking the effectiveness of the Checking the effectiveness of the
quality systemE b f d t dit E.g. by means of product audits
b Product Auditsb Product Audits
Post-production checks on the conformance of products and modules to predetermined
ifi tispecifications
b Product Audit Objectivesb Product Audit Objectives
Fully objective assessment of the level of quality and the long-term development of q y g pquality in the product supplied to customers
Identification of product quality weaknesses Identification of product quality weaknesses Checks on the effectiveness of the quality
system on the basis of product qualitysystem on the basis of product quality
b Types of Product Auditb Types of Product Audit Vehicle as a whole Vehicle as a whole Audits of particular sectors,
e g in the follo ing areas ofe.g. in the following areas of production
M f t f th b d i hit– Manufacture of the body-in-white– Surface treatment and paintwork– Assembly of vehicle– Assembly of vehicle
Special AuditsDynamic testing of vehicle– Dynamic testing of vehicle
– Testing of water-proofness
b Product Audit Procedureb Product Audit Procedure
Dynamic Testing
60km
MotorwayUrban Roads
Recording of faults on vehicle-specific logUneven Roads
60km
Investigation of rattles / knocks
Chassis check (ayle alignment, handling, brakes)
Investigation of rattles / knocks
Drive-train test (Engine, transmission)
Heating / air conditioning.....
b Product Audit Procedureb Product Audit Procedure
Testing of waterproofnessTesting of vehicle in water-spray cabin
In the event of water ingress: Analysis of causes
Recording of faults on vehicle-specific log