Quality operating system

• US 6,901,372 B1
• Filed: 04/05/2000
• Issued: 05/31/2005
• Est. Priority Date: 04/05/2000
• Status: Expired due to Term

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Helzerman, Thomas Henry
• Primary Examiner(s): MEINECKE DIAZ, SUSANNA M
• Application Number:
  US09/543,227
• Time in Patent Office: 1,882 Days
• Field of Search: 705/1, 705 7- 10
• US Class Current: 705/7.14
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/063112 Skill-based matching of a person or a group to a task
• CPC Class Codes: G06Q 10/0633 Workflow analysis
• CPC Class Codes: G06Q 10/0635 Risk analysis of enterprise or organisation activities
• CPC Class Codes: G06Q 10/06375 Prediction of business process outcome or impact based on a proposed change
• CPC Class Codes: G06Q 10/06395 Quality analysis or management
• CPC Class Codes: G06Q 10/06398 Performance of employee with respect to a job function
• CPC Class Codes: G06Q 10/10 Office automation; Time management
• CPC Class Codes: G06Q 10/1095 Meeting or appointment

Abstract

A quality operation system or method 10 for performing manufacturing projects 12. The method 10 efficiently organizes the project into five phases including a concept proposal phase 24, a concept feasibility phase 26, a manufacturing concept ready phase 28, a manufacturing implementation ready phase 30, and a replication phase 32.

Claims

1. A method for developing and performing a manufacturing project comprising the steps of:

providing a communication mechanism for a plurality of users associated with the manufacturing project to efficiently communicate with each other;

providing a plurality of electronic concept proposal worksheet files, wherein each of the plurality of electronic concept worksheet proposal files defines a selected concept proposal, and wherein each of the concept proposals formed initially from a non-implemented preliminary concept used to develop at least one of a manufacturing technology, a process and a methodology;

selectively communicating the plurality of electronic concept worksheet proposal files to a plurality of users of the communication mechanism;

modifying the electronic concept worksheet proposal files;

entering the modified electronic concept worksheet proposal files into a proposal database;

using the proposal database to generate at least one complete project proposal;

performing a manufacturing concept ready procedure, effective to verify that said certain technology is capable of manufacturing said desired product under simulated conditions;

performing a manufacturing implementation procedure, effective to verify that said certain technology is functionally sound and meets certain quality and cost criteria;

developing a replication plan wherein the replication plan comprises the substeps of

identifying a plurality of replication sites,

developing a replication plan using the identified replication sites,

establishing a replication team consisting of key technology developers and representatives from each of the replication sites, said replication team being led by an appropriate operating activity within an advanced manufacturing technology development (AMTD) department, wherein a plurality of AMTD departments roles and responsibilities are defined on a case by case basis,

reviewing pilot application with potential replication customers,

developing a generic non-site specific workplan,

revising the generic non-site specific workplan to include unique requirements for each replication site wherein said unique requirements for each replication site are selected from projected intellectual property rights and regulatory requirements,

estimating human resources and skills required to replicate technology,

developing directional estimates of other resources required for replication, and

agreeing on roles and responsibilities between operations and manufacturing departments including project closure requirements;

prioritizing replication sites in accordance with a confirmed replication plan; and

performing a replication procedure in accordance with the confirmed replication plan.

2. The method of claim 1 further comprising the step of:

assembling a workforce for performing said project.

3. The method of claim 2 further comprising the steps of:

providing orientation and communication processes for said workforce;

providing career development that advances the workforce along career paths to become technical specialists and training processes for said workforce; and

providing reward and recognition processes for said workforce, wherein the step of providing reward and recognition processes for said workforce further comprises

recognizing technical and non-technical contributions by the team, wherein said awards are selected from at least one of technology awards, technical achievement awards, operational excellence awards, and patent incentive awards.

4. The method of claim 3 further comprising the step of:

performing a procedure to establish logistic metrics pertaining to project performance and budgeting.

5. The method of claim 4 further comprising the step of:

forming manufacturing technology committees; and

convening said committees on a regular basis to define effective strategies to advance global manufacturing competitiveness.

6. The method of claim 5 wherein said project is related to the manufacture of an automotive vehicle.

7. The method of claim 1, wherein the substep of developing a replication plan using the identified replication site further comprises the steps of:

recommending the sequence of replicating within the identified replication sites;

describing unique local requirements for each identified replication site, wherein said unique requirements for each replication site are selected from projected intellectual property rights and regulatory requirements; and

establishing an issues deck to document new data that would be useful for replication planning.

8. The method of claim 1, further comprising the step of confirming a replication plan, wherein the step of confirming a replication plan further comprises the steps of:

confirming a business case, conditions and economic constraints;

calculating a proposed project'"'"'s plan tryout “

time adjusted rate of return”

(“

TARR”

);

comparing the TARR to the manufacturer'"'"'s TARR requirements;

confirming effect of local requirements at each proposed replication site;

identifying any economic constraints;

estimating the effects of identified economic constraints upon the proposed replication plan; and

summarizing the business case in terms of investment and total expected savings by a cost labor category and a materials category.

9. The method of claim 1, wherein the step of prioritizing replication sites in accordance with a confirmed replication plan further comprises the step of:

developing a prioritized listing of replication sites using business conditions, cycle plans, and available vendor resources.

10. The method of claim 1, wherein the step of modifying the electronic concept worksheet proposal files further comprises the steps of:

finalizing project workplan information; and

refining estimate information for required resources and project benefits.

11. The method of claim 1, wherein the step of using the proposal database to generate at least one complete project proposal further comprises the step of:

submitting the modified electronic concept worksheet proposal files to an activity coordinator; and

comparing the modified electronic concept worksheet proposal files with timing rules, guidelines, and standards to ensure that the modified electronic concept worksheet proposal files meet associated timing rules, guidelines, and standards.

12. The method of claim 1 further comprising the steps of:

determining a plurality of potential failure modes of said replication plan, wherein the step of determining includes documenting said failure mode analysis based on long term performance criteria, wherein said long term performance criteria is selected from at least one of process potential, process potential with customer concurrence, a mean time between failures, and a mean time to repair;

determining a corresponding plurality of safeguards needed for protection against each of said plurality of potential failure modes for said replication plan; and

developing a plurality of production procedures to adjust to each of said plurality of potential failure modes.

13. A method for developing and performing a manufacturing project comprising the steps of:

providing a communication mechanism for a plurality of users associated with the manufacturing project to efficiently communicate with each other;

providing a plurality of concept proposals, wherein each of the concept proposals formed initially from a non-implemented preliminary concept used to develop at least one of a manufacturing technology, a process and a methodology;

providing a plurality of electronic concept proposal worksheet files, wherein each of the plurality of electronic concept worksheet proposal files defines a selected concept proposal;

selectively communicating the plurality of electronic concept worksheet proposal files to a plurality of users of the communication mechanism;

modifying the electronic concept worksheet proposal files;

entering the modified electronic concept worksheet proposal files into a proposal database;

using the proposal database to generate at least one complete project proposal; and

implementing multiple applications of said technology in manufacturing operations by performing the substeps of

identifying a plurality of replication sites,

developing a replication plan using the identified replication sites,

developing a generic non-site specific workplan;

revising the generic non-site specific workplan to include unique requirements for each replication site,

confirming a replication plan, wherein the step of confirming a replication plan further comprises the steps of;

confirming a business case, conditions and economic constraints;

calculating a proposed project'"'"'s plan tryout “

time adjusted rate of return”

(“

TARR”

);

comparing the TARR to the manufacturer'"'"'s TARR requirements;

confirming effect of local requirements at each proposed replication site;

identifying any economic constraints;

estimating the effects of identified economic constraints upon the proposed replication plan; and

summarizing the business case in terms of investment and total expected savings by a cost labor category and a material category;

prioritizing replication sites in accordance with a confirmed replication plan, and

performing a replication procedure in accordance with the confirmed replication plan.

14. The method of claim 13 further comprising the step of performing a milestone review meeting to insure that certain project issues have been accomplished after each step.

15. The method of claim 13 further comprising the step of:

reviewing technology, wherein said step of reviewing technology includes the substeps of

identifying a best in class technology, wherein the best in class technology is an existing product or process that represents superior value to a customer relative to all similar products or processes, and

identifying a state-of-the-art technology.

16. The method of claim 15 further comprising the step of:

convening committees on a regular basis to assess best in class technologies and state-of-the-art technologies.

17. The method of claim 16 further comprising the step of:

establishing logistic metrics relating to project performance and budgeting by manufacturing wants.

18. The method of claim 17 further comprising the step of:

conducting time and data management meetings.

19. The method of claim 18 wherein said manufacturing project relates to the production of an automotive vehicle.

20. The method of claim 13 wherein the previously non-implemented preliminary concept is created in response to a customer need.