Post on 20-Feb-2023
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.1
LIMS, Key Performance Indicators and Productivity
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.2
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.3
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.4
• ETC = Engineering Technical Center
• More than 3,100 m2 of Labs
• Two Locations
• 60 Associates
• Competencies and Competence groups
• Throughput of approx. 3,000 single work requests per year
• Annual “billable work” for Bosch divisions + internal productive ETC work
approx. 7.5 Mio $
Brief Introduction of RBNA/ETC (1)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.5
• Competencies and Competence groups
- Environmental Testing
- Noise, Vibration & Harshness
- Machine Shop & Fixture Design
- Engineering Materials Laboratory
- Equipment Calibration & Metrology
- Test Equipment and Software Development
- Design for Environment, Document Control, Technical Process Support
- Test Program Management
Brief Introduction of RBNA/ETC (2)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.6
Engineering Technical Center – North America
Farmington Hills
Plymouth Technical Center
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.7
RBNA/ETC1
Center of Competence:
• Test Program Management
• Test Equipment Development
Process Champion:
• TLP – LIMS
• Electronic Laboratory
John McDonough
Manager
Test Program
Management
Cory Gira
Hector Gonzalez
Test Equipment
Development
Defang Meng
Dave Miller
Farahnaz Ashtiani
Jordan Smith
Robert Campbell
Todd Ellis
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.8
RBNA/ETC2
Center of Competence:
• Technical Support
• NVH
- Noise
- Vibration
Process Champion:
• Quality
• Mechatronic Laboratory
• ETC Web Site
Simon Price
Manager
Paul Potrzeba
Tom Smith
Kevin Welicki
Technical Support
NVH
Karen Kennedy
Tom Livingston
Richard Hahn
Sean McClure
Jacolbi Brooks
Steven Preiss
Steve
Essenmacher
Roger Narlock
Marc Shaver
Anthony Terminelli
Dushawn Williams
Ron Wolski
Robert Sullivan
Chris Luke
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.9
RBNA/ETC3
Center of Competence:
• Reliability Engineering
• Material Science
Process Champion:
• Reliability Engineering
John Haworth
Supervisor
Material Science
Reliability
Engineering
Kurt Enkeman
Dr. Frank Zhong
Erion Nikolla
Matt Wolfe
James Stachowski
Dr. Svetlana
Axakova
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.10
RBNA/ETC4
Center of Competence:
• Calibration
• Build
• Metrology
Process Champion:
• Preventive Maintenance
Pat Butler
Supervisor
Calibration/
Metrology
Build
Mohemmed Al-
Ansari
Sam Davis
Mike Edwards
Joseph Knecht
Steve Luckett
Brian Osborn
Robert Pendygraft
William Peppler
William Raikovich
Steve Santos
Keith Theil
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.11
RBNA/ETC5
Center of Competence:
• BES
• Process Development
Process Champion:
• Lean Development
• Process Development
• Policy Deployment
• Knowledge Management
• Sales & Marketing
• CTG
Mike Schwedt
Manager
Engineering
Documentation
Kim Howell
Diana Rochowiak
Deborah Valicento
Lean Engineering
TBD
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.12
RBNA/ETC6
Center of Competence:
• DRBFM
• PEP Process
• DFMEA
• DfE
Process Champion:
• 5S
• DSP
Mike McCuaig
Manager
DfE
Magda Cenusa
Margarete
Wasilewski
Marc Robling
Manager
DRBFM/
DFMEA
Paul Baird
Timothy o’Dell
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.13
Martin Boos
Director
John Haworth
Supervisor
Pat Butler
Supervisor Simon Price
Manager
Mike Schwedt
ManagerJohn McDonough
Manager
Mike McCuaig
Manager
Test Program
Management
Cory Gira
Paul Potrzeba
Hector Gonzalez
Tom Smith
Kevin Welicki
Test Equipment
Development
Defang Meng
Dave Miller
Farahnaz Ashtiani
Jordan Smith
Technical Support
NVH
DfE
Engineering
Documentation
Karen Kennedy
Tom Livingston
Richard Hahn
Sean McClure
Jacolbi Brooks
Steven Preiss
Magda Cenusa
Steve
Essenmacher
Kim Howell
Roger Narlock
Margarete
Wasilewski
Marc Robling
Manager
Diana Rochowiak
Marc Shaver
Anthony Terminelli
Deborah Valicento
Dushawn Williams
Ron Wolski
DRBFM/
DFMEA
Material Science
Reliability
Engineering
Paul Baird
Kurt Enkeman
Dr. Frank Zhong
Erion Nikolla
Matt Wolfe
Robert Sullivan
James Stachowski
Calibration/
Metrology
Build
Mohemmed Al-
Ansari
Robert Campbell
Sam Davis
Mike Edwards
Joseph Knecht
Steve Luckett
Chris Luke
Brian Osborn
Robert Pendygraft
William Peppler
William Raikovich
Steve Santos
Keith Theil
Lean Engineering
Todd Ellis
Dr. Svetlana
Axakova
Timothy o’Dell
TBD
Overall RBNA/ETC Organization
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.14
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.15
Reasons for LIMS and dacore
Goal: Communized Laboratory Information Management System (LIMS)
Increasing organization, work load and complexity (within RBNA/ETC)
To many separate systems in place, lack of data integrity (RBNA/ETC)
Streamlining existing processes and eliminate duplication
dacore was selected as supplier and Bosch TLP established as the
replacement for current or upcoming LIMS systems for all Bosch
laboratories
dacore´s project based and not license based business model
GS/ETC already gained experience with a dacore system (since 2005)
and purchased a more comprehensive one in late 2008
This comprehensive system was a good starting point for RBNA/ETC
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.16
Approach with dacore
RBNA/ETC needed some additional features and customization
Specification Process Dec 2008 – Feb 2009
Project released to start on Oct 2009
Target to switch use for RBNA/ETC in April/May 2010.
Bosch TLP development process:
TLP will be jointly developed by CI/NE2, GS/ETC, RBNA/ETC & GS/EAT-NA.
CI/NE2 to provide coordination of efforts by Bosch and dacore.
Development will be done via rapid prototyping of the software requirements.
Software development was separated into 4 work packages
Improves resource leveling for dacore
Allows software development test/teams to better focus their
testing/refinement efforts.
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.17
Timeline and Project TrackingS= Start X= other action item
Q= Questionnaire D= Delivery
F= Feedback P= Prototype (Feedback in between)
R=Ready for usage
CW 49
SW-Development RBNA-ETC 1
Group 1
1. Interface ETT S Q F X (Test-Environment provided ETC)P P
2. Test Sequences and Val. Plan S Q F P P
3. Booking & Tracking of Overtime S Q F P P
Group 2
1. Invoicing and related Reports S Q F P
2. Budget Data for ETC Labs S Q F P
3. Material costs and tasks to order material S Q F P
Group 3
1. Single Sign-On P (started in June 09) Q F
2. Scheduling within Machine Shops S Q F
3. Sample Management S Q F P (3xLIMS and 3xPDA)
Group 4
1. Key Metrics, Reports and Key Process Indicators (KPI) S Q F
2. Flexible Work Flows and Check Lists S Q F P
SW-Development GS/ETC-Willwand
Multilingual User-Interface with English Texts D F (Feedback by RBNA) R
PDA-Integration D
Changes discussed for Web-Interface D
Step by step migration of data and functions from old to new system S (end of 08)
Delivery of SW-Releases
Version 0.3
Version 0.4 D
Version 0.5 D
Version 0.6 D
Version 0.7 D
Version 0.8
Version 0.9
Version 0.10
Consulting and Ramp Up Packages RBNA-ETC 1
Setting up structures, content, overall process
Processes and Details per Lab Field
Reports and KPI
Finalization and Acceptance
Other activities
WebEx - Meetings
Final Training RBNA-ETC 1
CW 40 CW 41 CW 42 CW 43 CW 44 CW 45 CW 46 CW 47 CW 48 CW 50 CW 51 CW 52 CW 53 CW 01 CW 02 CW 03 CW 04
Oct-09 Nov-09 Dec-09 Jan-10
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.18
Switch over to productive Usage: Step 1
From May 2010
All new requests with new system
All old work requests with end date May not transferred
All others newly set up in TLP
Interface to Bosch-Project-System in use but still in test environment
60 people were trained
Depending on test/work request booking of labor and capital in new old
and new system
Approximately 60% of the existing features used from the very beginning
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.19
Switch over to productive Usage: Step 2
From June 2010
All work requests transferred to TLP
All labor and capital booked in new system
Switch over of reports for Key Performance Indicators and Policy
Deployment
Starting to use Test Report Generation, Scheduling and Planning,
Scanner
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.20
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.21
Overview LIMS Functionality
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.22
Web Interface for customer orders.
Submit Orders
Review Open Orders
Retrieve Reports
Work order routing.
Work is routed to responsible lab personnel for processing.
Quotation development tools.
Able to quote single tests or complete validation test plans.
The ability to handle both single tests and complete validation plans.
Graphical interface for the ordering and linking of tests.
Resource management and scheduling.
Manage physical resources by class (vibration equipment,
environmental chambers, dynamometer, test benches, etc.)
Manage engineering human resources.
Overview LIMS Key Features (1)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.23
Automated report generation.
Inserts pre-defined data into Microsoft Word templates.
Policy deployment report generation.
On-time delivery
First pass yield
Quoted cost adherence
Equipment Utilization by equipment class
Integrated WIFI Bar Code scanners
1-D & 2-D barcode scanner capability
Used in all facets of test performance
Scan Device Under Test (DUT), test equipment, interface
equipment (harnesses, fixturing, other tooling, etc.)
Integrated 2MP camera for recording test setups.
Greatly reduces errors caused by manual entries.
Overview LIMS Key Features (2)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.24
BGN
DUT*
Wire
Harness /
Fixturing
Associates
Work
OrdersGeneral
Test
Equipment
Specialty
Test
Equipment
Built-in
Camera
* DUT = Device under Test
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.25
Main Features to be added to existing Solution (1)
Interface to ETT: Bosch TLP will act as RBNA/ETC‟s primary
tracking tool. All associate time will be transferred from TLP to ETT.
Test Sequence and Validation Planning: Extends the functionality
of Bosch TLP to cover DV/PV test planning consisting of multiple
tests grouped in test legs.
Booking and Tracking of Overtime: Add the ability to track
standard overtime, work on Sundays and work on holidays to Bosch
TLP. Also adds report tools for management to review overtime
usage.
Invoice and Related Reports: Enhances the built in invoicing
capability of TLP and adds summary invoices for Product Lines.
Material costs and Tasks to Order Material: Allows for a higher
level of manual control of material orders than currently
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.26
Main Features to be added to existing Solution (2)
Single Sign-On: Automatic sign-on of associates to the web interface
based on their Active Directory information to Bosch TLP.
Existing Hand-Scanner Features of GS/ETC to be implemented in new
Hand Scanner Hardware
Sample Management: Comprehensive „cradle-to-grave‟ sample
management for tests. Allows for the assigning of individual samples to
different tests and the scanning of bar codes for assigning samples to
specific tests.
Key Process Indicators: Added functionality to automatically created
KPI reports already used by RBNA/ETC.
Flexible Work Flows and Checklists: Work flows will be added to Bosch
TLP to support both internal and customer sign-offs of quotations and
invoices. Checklists will be added to TBD internal processes for improved
quality control
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.27
• RBNA/ETC is reviewing further upgrades of RBW LIMS
• Enhancements to the bar code scanner capabilities
• Improved data mining capability
• Improved resource management
• Productivity data gathering
• Improved web interface
• Improved automation of internal software processes.
• Other RBW laboratories looking to transition to RBW LIMS in 2011.
• GS/ETC
• GS/ETC-NA
• DGS?
• AE?
LIMS Future
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.28
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.29
Policy Deployment
ETC Policy Deployment – a strategic planning and management tool that
incorporates Plan-Do-Check-Act (PDCA) to create goals for the group,
set measurable targets, and link our daily laboratory activities to Bosch‟s
vision and strategy
You can‟t change / improve what you don‟t track
Key Performance Indicators (KPI‟s) (P)
Align / focus the work carried out on a daily basis (D)
Goals / results are tracked, then commutated to all working levels (C)
ETC groups are held accountable for achieving set goals
If goals are not met, then act (A)
Understand why (reaction summary)
Develop counter measures
Repeat the cycle, PDCA
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.30
Preparation of Policy Deployment
Management drove Policy Deployment Implementation
Weekly “Lean Testing” meeting established
Research and study different methods, papers, articles, and books
Bosch Production System (BPS)
Visteon SAE paper
Wayne State University Thesis
Getting the Right Things Done
Toyota Way
Benchmarking was conducted (Sbd (AF), ChP, Visteon, Denso, GS/EAT)
Value Stream Map (VSM) was conducted- April 2008
KPI‟s were identified
Gaps were found in tracking methods
Direction was set for future improvement (3 strategic categories each
with their own KPI‟s)
Training / knowledge transfer
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.31
KPIs implemented: Customer Satisfaction
1.1 Work Contract on Time (OTD)
Owner – John McDonough
Report out – monthly
1.2 Customer Satisfaction
Owner – John McDonough / Erion Nikolla
Report out – bi-yearly
1.3 Quoted Cost Adherence
Owner – Simon Price
Report out – monthly
1.4 First Pass Yield (FPY)
Owner – John McDonough
Report out – monthly
From lists manually
maintained to automated
data reports using TLP
From lists manually
maintained to tick off list
in TLP
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.32
KPIs implemented: Associate Satisfaction
2.1 CIP Lean Suggestions
Owner – Kim Howell
Report out – quarterly
2.2 5S
Owner – Marc Robling
Report out – monthly
2.3 Associate Satisfaction- HR survey
Owner – HR
Report out – Yearly
2.4 Audit Performance
Owner –Marcus McCauley
Report out – semi-annually
2.5 Training
Owner –Mike Schwedt
Report out – monthly
All not kept measured with
TLP
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.33
KPIs implemented: Business Success
3.1 Machine Utilization /
Overall Equipment Effectiveness
3.1.1 Vibration Equipment
3.1.2 Environmental Chambers
3.1.3 Corrosion Chambers
Owner – Simon Price
Report out – monthly
3.2 Administrative Overhead
Owner –Mike Schwedt
Report out – monthly
3.3 Overtime => TLP
Owner – Mike Schwedt
Report out – monthly
3.4 Budget => Partly TLP
Owner –Mike Schwedt
Report out – monthly
From lists manually
maintained or gathered from
other systems to automated
data reports using TLP
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.34
4. Other
4.1 Performance Review on Time
Owner – All ETC management
Report out – semi-annually
4.2 Lab Tour
Owner –Mike Schwedt
Report out – quarterly
4.3 Storage
Owner – Kim Howell
Report out – monthly
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.35
On Time Delivery (OTD)
Dec-07 Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Rolling YTD
Work Contracts Due 175 177 212 173 273 231 259 188 179 230 206 180 2483
Wk Contracts On Time 170 175 206 171 257 216 248 172 172 217 198 173 2375
% Complete 97% 99% 97% 99% 94% 94% 96% 91% 96% 94% 96% 96% 96%
Wk Contracts Complete 187 203 233 200 306 253 292 222 219 264 252 204 283595 95 95 95 95 95 95 95 95 95 95 95
Work Contracts Open 168 253 263 273 325 443 491 484 486 439 442 469 1599
Past Due 5 2 6 2 16 15 11 16 7 13 8 7 108
Tech or Engineering Capacity 5 0 6 0 14 13 9 12 5 1 1 2 68
Internal Scheduling Problem 0 1 0 1 1 0 0 0 1 3 0 0 7
Equipment Capacity Issue 0 0 0 0 0 0 0 0 0 0 0 0 0
Outside Labs Issue 0 0 0 0 0 0 0 0 0 1 0 1 2
Equipment Down 0 0 0 1 0 0 1 0 0 0 1 0 3
Customer Prioritization Change 0 1 0 0 1 1 1 3 1 1 2 0 11
Customer Information Issue 0 0 0 0 0 0 0 1 0 5 2 3 11
Task Scope Creep 0 0 0 0 0 1 0 0 0 2 2 1 6
Parts not available 0 0 0 0 0 0 0 0 0 0 0 0 0
Total ETC Issues 5 1 6 2 15 13 10 12 6 5 2 3 80
% ETC Issues 3% 1% 3% 1% 5% 6% 4% 6% 3% 2% 1% 2% 3%
Total Customer Issues 0 1 0 0 1 2 1 4 1 8 6 4 28
% Customer Issues 0% 1% 0% 0% 0% 1% 0% 2% 1% 3% 3% 2% 1%
Total Overall Issues 5 2 6 2 16 15 11 16 7 13 8 7 108
Percent of Scheduled Testing On-Time
60%
65%
70%
75%
80%
85%
90%
95%
100%
Dec-
07
Jan-
08
Feb-
08
Mar-
08
Apr-
08
May-
08
Jun-
08
Jul-08 Aug-
08
Sep-
08
Oct-
08
Nov-
08
Per
cen
t O
n T
ime
0
50
100
150
200
250
300
350
Nu
mb
er O
f W
ork
Co
ntr
acts
% Complete % ETC Issues % Customer IssuesWk Contracts Complete Past Due Target
Top Reasons for Being Late
0 10 20 30 40 50 60 70 80
Tech or Engineering Capacity
Internal Scheduling Problem
Equipment Capacity Issue
Outside Labs Issue
Equipment Down
Customer Prioritization Change
Customer Information Issue
Task Scope Creep
Parts not available
YTD Monthly
Using TLP:
• Run a monthly report either for tests or orders
• Filter for “tests closed this month”
• Compare planned end date vs. date “technically closed”
• Can be combined with FPY (First Pass Yield) data
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.36
Quoted Cost Adherence (QCA)
Using TLP:
• Set up an run a monthly report either on test, orders
or test plan level
• Filter for “tests closed month “x””
• Compare planned costs vs. actual bookings either
on test, orders or test plan level
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.37
Equipment Utilization
Right now two parallel Reports
• One created manually with indicators for “not in use”
• The one built in TLP using the bookings
• Will be merged soon
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.38
First Pass Yield (FPY)
Using TLP:1) We use new feature “flexible work flow”2) Implemented a predefined check list to be ticked off3) Linked this list to the action “closing tests”4) So whenever a test is closed the questions have to be ticked off5) Set up und run a monthly report to analyze answers given6) Export this to MS-Excel and summarize the data
1
2
5
6
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.39
Administrative Overhead and Overtime
Using TLP:
1) In general two options to book time: Not billable (admin, training,
vacation, sick, ….)and billable means to book time against certain tests
2) Month end run a report and compare billable vs. non billable
3) Next step: to extend report so that kind of non billable can be
analyzed
1
2
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.40
Cost Transparency
On (Bosch internal) customer level:
1)Monthly summary and invoice of all costs per e.g. Product line
but also break down of labor, capital, material and external
2)Export of all data on all levels to MS-Excel
3)Same details available on Project Level, Order Level and Test Level
4)Inbuilt process to transfer cost data to ERP/Project System
1
2
2
3
4
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.41
Future Steps / Continuous Improvement
Accuracy of incoming data
Automated data gathering- LIMS
2nd level of tracking- dig deeper into the data for root cause
Raise the bar / target level
Training & awareness – take part in board review
Group members
Customer groups
Add additional KPI‟s for individual groups (productivity measures,
calibration back log, equipment usage, etc…)
Gain knowledge and continue to benchmark
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.42
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.43
Productivity Project
Two main goals:
Measurable improvement of overall Lab Productivity
More reliable Cost Estimation & Quotation Process
Project will use proven PDCA cycle: Plan – Do – Check – Act
Project is therefore going to have four Work Packages
WP 1: Plan => Definition of Base Line (Apr. – Aug.)
WP 2: Do => Analysis of Pilot Lab Processes & Areas and
Improvement of selected Processes (May – Sep)
WP 3: Check => Measure again (Sep)
WP 4: Act => Deployment to other Lab Processes & Areas (from Sep.)
Duration 9 months, from Apr. 2010 – Dec. 2010
Clearly defined set of tools and clearly defined Project Organization
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.44
Planned Work Packages of Productivity Project (1)
“Plan” (Work Package 1):
TLP to look at “standardized” Lab Processes & Areas
(Methods/Requirements & Lab Fields)
Define Matrix for deployment
“Do” (Work Package 2):
Measure booked hours and reports on process step level (set up,
execution, tear down
Analyze: Involve process stakeholders and identify potential areas for
improvement
(see separate slides)
Analyze with Mathematical tools (see separate slide)
Improve processes identified (apply CIP to selected areas)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.45
Planned Work Packages of Productivity Project (2)
“Check” (Work Package 3):
Measure and Analyze again: See if same processes measured under
“Do” have improved
“Act” (Work Package 4)
Deploy but first decide if to deploy using same or different approach
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.46
Identification of Focus for Productivity Project
Identification of applicable
requirements per Lab Field:
x= as linked in TLP
m= indicate for missing links
green = pilot ares for productivity
project
red = identify areas for
prodcutivity improvements within
you lab field(s) LAB FIELDS DR
Tasks (Test Requirements)
AIF - Air Flow AST - Asset
Tracking
CAL -
Calibration
COR -
Corrosion
DAS -
Documents
and Standards
DFE - Design
for
Environment
DRB -
DRBFM_DFME
A
EDS -
Electronics
Development
& Support
MAL -
Materials Lab
MAS -
Machine Shop
MET -
Metrology
NVH - Noise
Vibration &
Harshness
OCS -
Occupant
Development
Support
PDE - Product
Development
Engineering
Support
Purchasing REL -
Reliability
Engineering
SAO - Sample
Ordering
STA - Starters
& Alternators
SWD -
Software
Development
& Support
TSD - Test
System
Development
& Support
VEH - Vehicle
Instrumentatio
n
VET -
Validation
and
Environmental
Testing
VIB - Vibration WIP - Wipers
Simon Price,
Kevin Welicki
Howell Butler Price Schwedt Robling McCuaig McDonough Haworth Butler Butler Price Price Price ? Haworth Schwedt McDonough McDonough McDonough McDonough Price Price McDonough
Data Analysis x x x x x x x x x x x x x x x x x x x x
Document Management x x x x x x x x x x x x x x x x x x x x
Estimation x x x x x x x x x x x x x x x x x x x x
General admimistrative Activities x x x x x x x x x x x x x x x x x x x x
Materials Processing/Procurement x x x x x x x x x x x x x x x x x x x x
Program Management x x x x x x x x x x x x x x x x x x x x
Review Documents, Requirements, and
Specifications x x x x x x x x x x x x x x x x x x x x
Sample Ordering x x x x x x x x x x x x x x x x x x x x
Supplier Management x x x x x x x x x x x x x x x x x x x x
Travel x x x x x x x x x x x x x x x x x x x x
Electrical x x x x x x x x x x
Mechanical x x x x x x x x x x
Software x x x x x x x x x x
Fabrication x x x x x x x x x x x x x x x
Machining x x x x x x x x x x x x x x x
Programming x x x x x x x x x x x x x x x
Technical Support x x x x x x x x x x x x x x x
Data Management x x x x x x x x x x x x x x x x
Documentation x x x x x x x x x x x x x x x x
Photography x x x x x x x x x x x x x x x x
Report Generation x x x x x x x x x x x x x x x x
Calibration x x x x x x x x x x x x x x
Repair & Maintenance x x x x x x x x x x x x x x
Application Assessment x x
Customer Negotiation x x
Specification Assessment x x
Test Definition (DV/PV/QZ) x x
Vehicle Assessment x x
Failure Analysis x x x x x x x x
Inspection x x x x x x x x
Measurement x x x x x x x x
Specimen Preparation x x x x x x x x
Test Execution x x x x x x x x x x x x
Test Setup x x x x x x x x x x x x
Test Teardown x x x x x x x x x x x x
Debug x x x x x 40
Verification/Validation x x x x x
No
methods
assigned
up to now
(05-05-10)
Te
st M
eth
od
s
Valid
atio
nD
esig
nD
evelo
pm
en
tE
qu
ip
m.
Su
pp
ort
Do
cu
men
tatio
nR
eliab
ility
Sam
ple A
nalysis
To Do =>
Testin
gA
dm
in
istrative W
ork
Lab Processes
=
Test Methods +
Requirements
as set up in TLP
Areas = Lab Fields as set up in TLP
Pilot Areas = Lab Fields: • Vibration• Validation• Enviro. Testing• Materials Lab• Calibration• Air Flow• Corrosion• DFE• Starters & Alternators
Pilot Lab Processes:• Test Set up, Test
Execution,Test Tear Down
• Program Management (TPM)
• All Sample Analysis• Calibration• Data Analysis• Document
Management• Review Documents
Matrix shows how the
various lab processes (methods & requirements)
are used in the lab fields!
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.47
Productivity
Kind of data to be collected:
Time estimated/planned per single process (method/requirement=> set up,
execution, tear down)
Actual time needed per single process that was finished
How to collect:
Per test finished
Per lab field
Per period of time
Of all associates that booked against one and the same lab process
Data derived :
Distribution and mean of planned time within a lab field
Distribution and mean of actual time within a lab field
Distribution and mean (%) of planned vs. actual needed within a lab field
How to use Data? (see separate slide)
Discussion and Decision on statistical/mathematical methods to be used
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.48
Productivity Project Data Analysis Approach
t (planned)
frequency
t (actual)
frequency
Data derived from TLP reports Planning process:
e.g. t (planned) – t (actual) => planning accuracy
Mean = 0 => Average planning process good
Standard deviation => reliability of estimation process
Review influencing factors
Set up action items
Continuous measurement and improvement
Productivity
Mean and distribution of t (actual) e.g.
Shift mean to left => improve overall productivity
Improve standard deviation => improve repeatability
Depending on shape to discuss and decide if to focus
on runaway values (tests) or set up generic
improvement steps
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.49
Overall data:
• Number of tests in the system by Aug 13´th: 1350
• Number of tests “technically closed” by Aug 13´th: 425
• Number of lab fields in TLP 28
• Number of lab fields that have tests “technically closed” 19
Usage of methods and requirements in tests “technically closed”
• Total number of line items in test plans in tests performed: 2110
• Average number of line items (method/requirements) per test performed (technically closed): 5
• “not used” at all (not planned and not booked): 956 (45%)
• “planned but not booked”: 318 (15%)
• “booked but not planed”: 138 (7%)
• “planned and booked: 698 (33%)
Intermediate Results: 3,5 Months using TLP(all ETC)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.50
VET
7
23
12
10 10
8
34
32 2
1 12 2 2
1 1 1
1312
7 7
34
34
21 1 1 1
10
2
0
5
10
15
20
25
0 1 2 3 4 5 6 7 8 9 10 11 12 14 17 23 24 52 0 1 2 3 4 5 6 7 8 9 13 14 17 18 1 2
Test Execution Test Setup Test
Teardow n
VET
Seitenfelder hierher ziehen
Anzahl von Rounded Hours(h) -Actual Labour
Requirement Rounded Hours(h) -Actual Labour
Lab Field
Test Execution
• 94 bookings for Execution
• 10 bookings > 10 hours
• Average = 4.9 h
• Stand. Dev. = 7.0 h
Set up
• 60 bookings for Set up
• 4 bookings > 10 hours
• Average = 4.2 h
• Stand. Dev. = 3.8 h
Tier down
• 12 bookings for Teardown
• No booking > 10 hours
• Average = 1.0 h
• Stand. Dev. = 0.3 h
Intermediate Results: Distribution of Labour booked(within one Area of the Lab)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.51
In total methods and requirements are not
used the way they should be (planned and
booked).
Some lab fields use them properly others
do not.
The proper usage is a precondition to
- Derive & analyze productivity data
- Reach a much better QCA
In principle 40% of all line items in test
plans have bookings and can be used for
productivity data analysis
Only 33% of all line items in test plans can
be used for productivity data analysis and
QCA analysis
The approach on how to analyze data has
been proven (easy to get distribution
curves, mean, deviations, runaways, …
Status Quo To Do: Improve TLP-Usage
Review applicability of methods/requirements
that were set up and linked to lab fields
=> tendency “less is more”
Review Test Plan Templates available
Set up rules for planning and booking
Improve common understanding of line items
planned
Train proper usage of booking (especially set
up/execution/tear down)
Improve communication between those that
plan and others that book, especially TPMs
(Test Program Manager) and lab field
associates
Set up approach for estimation/quoting
introducing and using “influencing factors”
Ongoing!
Ongoing!
Ongoing!
Ongoing!
Intermediate Results: Action Plan (1)(based on data analysis)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.52
Intermediate Results: Action Plan (2)(based on personal interviews with lead technicians per lab field/lab area )
• General comuniaction, notification and planning concept for tests and orders:
- Responsibility
- Assignments
- Perform/execution
- Notification of changes
- Resource planning
- Estimation
- ….
• Review OTD focus and target groups
• TP-Project-rules or processes
• No other “big” limitations as e.g. working environment or logistic barriers mentioned
Not TLP related TLP related
• Equivalent messaging, assigning and planning in TLP (partly covered by Gen II and ongoing discussions concerning planning)
- Compare concept (see left) to features available
- Specify D if there is one or work around
- Implement in TLP
• May be run two OTD reports
- Order OTD => address customers
- Test OTD => address internally
• Improve booking features (see Gen II)
• Transfer equipment utilization reports from manual lists to TLP (needs some add ons)
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.53
Productivity Project: Next Steps
• Establish an enhanced Reporting on KPIs
• Monthly follow up on ETC and on Lab Field Level
• Monitor if Improvements and Action Items identified have impact
• Monitor the estimation process and compare estimates to actual total for tests closed
• Focus on identified main lab fields and test plan “activities” identified
• Evaluate data in January 2011
• Decide if and how to apply to other areas and test plan activities
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.54
• Brief introduction of RBNA/ETC
• The approach with dacore
• Existing system features and those to be added
• Policy Deployment and Key Performance Indicators (KPIs)
• Productivity measurements and productivity improvement
• Summary
Agenda
Robert Bosch North America
RBNA/ETC | 10/26/2010 | © 2010 Robert Bosch LLC and affiliates. All rights reserved.55
The Approach with dacore
• A lot of effort spent to make a big step in a short amount of time
• Well supported by dacore
Existing System Features and those to be added
• Comprehensive System in use
• Additional features on the wish list
• Potential identified to improve the existing software
Policy Deployment and Key Performance Indicators (KPIs)
• Most of the data are in the system n
• More detailed level creates a different kind of quality and awareness concerning data
Productivity Measurements and Productivity Improvement
• Promising Approach
• Tools in place to measure (in a way we could not have done before)
• Potential identified to improve
Summary