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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 ...


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


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


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


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


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


Dingolfing 3 Series / 5 Series / 7 Series / 8 Series



3 Series / estate cars / convertibles / coupes / M3

Regensburg

Dingolfing 3 Series / 5 Series / 7 Series / 8 Series


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


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.....


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

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