. . 2556

16-18 2556

ISO/ TS16949

A Design Of Product Development Process For New Product Model Certified

With ISO/ TS16949

1* 2 1,2

E-mail: theerawa @ buu.ac.th*

Theerawat Somsirikarnjanakoon1* Anawat Booncharoen2

1,2Department of Industrial Engineering, Faculty of Engineering, Burapha University

E-mail: theerawa @ buu.ac.th *

ISO/ TS16949

(EGR Pipe) : Ø25.4x220Lx5N

PERT

2

28 ISO/ TS 16949 25

3 10.71%

ISO/ TS16949

Abstract

The objective of this research is to design the product development process for the new product model

corresponding to the ISO/ TS16949 certification. This study also aims to control the duration of the product development project as required by the customers. The new process proposed in the research

was designed with emphasis on the reduction of product cost and non-value added activities, while the

product qualities were maintained. In addition, the new process was flexible to the product changed by the customer order and the requisition for annual price reduction. This study designed the product

development process for the exhaust gas recirculation pipe modeled EGR Pipe: Ø 25.4x220Lx5N. The project tasks were studied and controlled to finish the project on time as required by the customers

or the co

applied inwas 28 w

25 weeks

Keyword

1.

(Cost D

(Lead t

ISO/TS16

TS 16949

ompany finish

n this study. Tweeks, where

s. In other wo

ds: Product D

Down)

ime)

6949 ISO

9

hing time targ

The results ofas the duratio

ords, 10.71% t

Development,

(N

ISO/ TS 1

9001

ISO/ TS

(EGR

(

get of 25 day

f the study shon of the proj

time reduction

Process, New

ew Model)

16949

1 6 9 4 9

R Pipe)

(New Mode

ys. Project ma

howed that duject for the ne

n was accom

w Product Mo

l) ISO/

2.

TS

3.

3.1

anagement te

uration of the ew process c

plished.

odel, Certifica

(EGR Pipe

16949

: Ø25

1 2

1

2

16-1

echnique inclu

project beforeertified with IS

tion of ISO/ T

e)

5.4x220Lx5N

Ø25.4x220Lx

18 2556

uding PERT

e the improveSO/ TS16949

TS 16949

ISO/ T (EGR

(EGR Pip

x5N

. . 2556

was

ement 9 was

ISO/

TS 16949 R Pipe)

pe) :

ISO/ TS

. . 2556

16-18 2556

16949 7-8 7

1 3

1 (New Model)

ISO/ TS 16949

( )

A

1 -

B 1 A

C* 2 B

D** Dummy 0 C

E* / , ,

, , ,

2 B

F

1 D(C),E

G 2 F

7

3

ISO/ TS 16949

PERT

(EGR Pipe) : Ø25.4x220Lx5N 2

3

2

(New Model) ISO

A

B

C*

D* (APQP Plan)

E** Dummy

F / , , ,

G

H*

I*

J** Dummy

K PPAP

L (Sign Off)

3

( )

a m b t

A - 1 1 1 1 0.00

B A 1 1 1 1 0.00

C* B 1 1 1 1 0.00

D* B 1 1 1 1 0.00

E** C 0 0 0 0 0.00

F D,E 2 3 4 3 0.11

G F 2 3 4 3 0.11

H* G 8 12 16 12 1.78

I* G 8 12 16 12 1.78

J** I 0 0 0 0 0.00

K H,J 1 1 1 1 0.00

L K 1 2 3 2 0.11

: C,D H,I

(*), E J Dummy (**)

(Critical Path)

4

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16-18 2556

4

(Critical Path) 4

1) A 1-2-3-4-5-6-7-9-10-11= 24

2) B 1-2-3-5-6-7-8-9-10-11 = 24

3) C 1-2-3-5-6-7-9-10-11 = 24

4) D 1-2-3-4-5-6-7-8-9-10-11= 24

24

6

= 2.112

24 50% 25

75.49% 26 91.62%

25 F /

, , , , , / , ,

/ 3 4

3.2

(EGR Pipe) ISO/TS 16949

1. (1

) 1.

(2 ) 2.

(4 ) 3. (2 )

2 1 4

4

Plan Actual

2. (Feasibility New Model, 1 ) 1.

(2 ) 2.

(2 ) 3.

(3 ) 4.

(2 )

1.

2. , , ,

(Gauge Check)

. . 2556

16-18 2556

,

3.

5

5

3. (1 )

1. Process Flow Chart Control Plan (7 ) 2. FMEA

(7 ) 3.

Drawing (3 ) 4. Drawing Drawing

(4 ) 5. (WI) (7 ) 6.

(Check Sheet) (7 ) 7.

(Inspection Standard) (7 ) 8. (Packing Standard) (7

) 9. (7 )

4. (APQP

Plan) (1 ) 1.

, (5 ) 2. (APQP Plan)

(2 ) 1

1 5

5 (APQP Plan)

5. / , , , , , (4 ) 1.

(4 ) 2.

(7 ) 3. , , , , ( ) (5 ) 4.

(21 ) 5. / ,

, , , (21 ) 6. / , , , (7 ) 6

6 / , ,

INABA (THAILAND) CO.,LTD.

: Yarnapund (Public) Co.,Ltd. : 06-Jun-2011

: Bellow Pipe "EGR Pipe" : SUS 304 (0.8 x 78.1)

: Ø25.4x220Lx5N (1582A151-01) Model : MMT-031-01

( )

1) , ,

(Spec New Model)

2) (Capacity)

3) (

)

4) Material

( Supply , )

5)

( )

6) / ( )

( Process)

8) Tooling Supports

(Jig & Fixture)

9) Plant Lay Out

( )

(Mold)

New Model 15-20 1-2

Supplier Stock

Order Order

/ Factory Manager / 6-Jun-2011 / PC Manager / 6-Jun-2011

/ Quality Control Manager / 6-Jun-2011 / Supervisor / 6-Jun-2011

/ Supervisor / 6-Jun-2011 / Supervisor / 6-Jun-2011

/ /

/ /

/ /

/ /

/ /

/ /

. . 2556

16-18 2556

1 1

6.

(3 ) 1. (3 ) 2.

(3 ) 3. (3 ) 4. , ,

, , (3 ) 5. (3 )

6. (3 ) 7. (3 ) 8. (15 )

9. Ppk

(15 ) 10. /

(15 ) 11. (Sample Product) (3 ) 12.

(21 ) (Trial

New Model)

30-50 (100%)

/ Ppk

Ppk 1.67 ISO/

TS16949 Ppk 7

(Sample Product)

(Inspection Data)

7. (12 ) 1.

(14 ) 2. (14 ) 3.

7 Ppk

, , , (14 ) 4.

(14 ) 5. (7 ) 6. (Mass

Production) (12 ) 7. Cpk (12 ) 8. /

(12 ) 9. 100% (12 ) 10.

MSA, FMEA, SPC, QC 7 Tools (12 ) 8

8

. . 2556

16-18 2556

1 4

2554

2554 (100%) 3

(First Stage Control) (Customer Complain) /

(Customer Claim)

Cpk ( 1.33) 9

(%NG)

2554 10

8. (12 ) 1. Process Flow Chart, Control

Plan (7 ) 2. FMEA (8 )

3. (14 ) 4. MSA (14 ) 5.

(14 ) 6. PPAP (14 )

9 Cpk

( Cpk)

1 3 Pipe

O.D

Ø25.4

+ 0.2

1.39 1.35 1.36

2 4 Bellow

O.D

Ø34.1

+ 0.5

1.35 1.34 1.35

3 6 Pitch

Dimen

sion

Ø 26.4

+ 1.0

1.43 1.57 1.59

4 9 Total

Length

220.0

+ 3.0

2.29 2.27 2.62

5

10 (%NG)

- 2554

3%

1 Pipe Forming

& Cutting 1.5% 0.57 0.69 0.55

2 Bellows

Forming 1.5% 1.20 1.13 0.60

3 3.0% 1.77 1.82 1.14

9. PPAP (1 )

1. PPAP (5 ) 2. PPAP

(2 )

10. (Sign Off) (2 ) 1. (

1-2 ) (2 ) 2.

(2 ) 11

11 (Sign Off)

4.

(New Model) ISO/TS 16949 (EGR

Pipe) : Ø25.4x220Lx5N 2

1

(New Model) ISO/ TS 16949

. . 2556

16-18 2556

2 (EGR Pipe) : Ø25.4x220Lx5N

1

ISO/TS 16949 28

ISO/ TS 16949 25

(New Model)

(EGR Pipe) : Ø25.4x220Lx5N

25 3 ( 10.71%)

2 (Pipe Forming & Cutting)

,

(Grinding)

() 12

12

1.

28 25 3

( 10.71%)

2.

7 5

2

3.

7 5 2

12

( )

4.

7 5 2

5.

690 250 440

( % 63.77%)

6.

- Pipe

Forming &

Cutting

700 900 200

( 28.57%)

- Pipe

Chamfer 700 700 -

- Bellows

Forming 700 700 -

- Leak

Test 1,400 1,400 -

7.

(Scrap)

Pipe Cutting

to Size

(1 30

mm; 1 70

; 2,100

mm)(1 mm.

= 0.48 g;

2,100 x 0.48

= 1.0 Kg)

-

2,100 mm.

(1 Kg.) (Scrap)

2,100 mm.

(1 Kg.) (

25

25 Kg.

8.

(NG)

3.0%

3.0% 1.77%,

1.82%,

1.14%

(

, ,

.54)

. . 2556

16-18 2556

2555 1 1 0 / 2 5 5 5

[1] , (MSA), ( -

), 19 - 113 [2] ,

2, ( -

), 261 � 290, 367 - 407 [3] ,

, ( - ), 135 � 173, 249 �

252 [4] ,

ISO/TS 16949:2009, 34 � 229, 2553. [5] , ,

[6] , , , 274 � 284

[7] ,

, 2551.

[8] ,

, 2552

[9] Kachen Impro Consultant, (APQP),

ISO/TS16949:2009, 2553. [10] Kachen Impro Consultant,

(FMEA),

ISO/TS16949:2009 [11] Kachen Impro Consultant,

(MSA),

ISO/TS16949:2009, 2553. [12] Kachen Impro Consultant,

(SPC),

ISO/TS16949:2009, 2553. Physical Review Letters, 82: 4671-4674.