VPI PROCEDURE

VPI PROCEDURE

AgendaAbout Cummins IncStandard Operating ProcedureVPI Procedure

ABOUT CUMMINS INC1

$19.2 billionSkill set100%Total success!34Countries

132,000Thats a lot of money

Our Office

Products

Where all our Products Used?

Heavy-Duty TrucksMedium Duty Trucks & BusesConstruction and AgricultureLight Duty Automotive &RVMining,Marine,Oil and Gas,GovernmentStationary Power

STANDARD OPERATING PROCEDURE(SOP)2

What?

Documented instructions for a recurring process or an activity in an organisationSOPs addressa)Process identificationb)Controls and checksc)Potentially Hazardous Situation d)Waste Management

Importance of a Good SOPSaves time and helps in avoiding MistakesReducing Training costsEnsures consistent resultsEmpower the WorkforceSupport Quality goals

THE CUMMINS SOPVALUE PACKAGE INTRODUCTION3

OverviewTwo Technologies used in Developing a producta)Product Preceding Technology(PPT):validate new technologyb)Value Package Information(VPI):validate technology and incorporate into finished productBoth processes exit independently, but overlap to some extentBoth uses system of gates that define various stages of development process

What is VPI?

A set procedure for Designing,Developing and Introducing a new productCore part of the Cummins Operating System(COS)Guides the customer with the products usageThus fulfilling the vision of the companyTies together many processes and functional areas to ensure smoothe product introduction

Unleashing the Power of Cummins by making Peoples lives better

Why VPI is important?Customer SatisfactionRemain Competitive in the marketRobust DesignProvide quality parts and services to the end customers

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Cummins Product Preceding Technology

Audio

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Cummins VPI:OverviewAudio

Our process is easy

Technical ProfilePFMEAAppliactionGuideDFMEACPMInthis stage ,the clients demands are converted into technical specifications and based on this the design prototype is worked uponBased on the Hardware,Software and System Technical Profile,a document which helps the customer with the installation and functioning of the product is createdDesign-Fault Mode Effective Analysis capture the various modes of faults possible in design and the steps the engineers can cross check and accordingly implement corrective actionsCritical Parameter Method ranks all the critical inputs to the designProduct FMEA is similar to DFMEA. Its to the product as a whole .It also includes the Potentially Hazardous Situations Analysis

Identifying and Resolving Part FailuresIn case of failure,the parts need to be transported to point of failure to component Engineers for DiagnosisHowever,there had been instances of delay in this process means delay in rectification and delay in subsequent engine testingThe company then with Six Sigma came out with the solution and launched a VPI project and standardised the transportation issuesThe process helped in reducing time from 137 days to 22 days

ApplicationsProduct Safety

Corporate Product Safety Council has been set up to address product related safety issues that have a company wide impact and to make appropriate policy reccommendationsThe Council exists for each Business unit and has safety champions(Representatives) from different entities like HSE,Manufacturing,Marketing,Service,Quality,Purchase

Improvements made to the process

VPI deliverables are all well documentedHowever ambiguity on inputs required to draft these documents on some projects|Six Sigma Project(DMAIC) was taken up within the organisation to clearly mention: a)the stakeholders of the projectb)sources from which inputs to completion of the VPI deliverables can be obtainedc)RACI document (Responsible, Accountable, Consulted, Informed)

Contd..The DFMEA procedure was more explicitly defined. Clearly mentioning the failures modes in Hardware, Software and SystemFeedback and Diagnostic tests are also included

*The new VPI procedure was incorporated on all the new projects taken up in the first quarter of 2015.Whereas the old projects are slowly transiting to new process from the old one.

ConclusionImportant to reduce instances of failureReduce cycle time and costContinuous process improvementMeet all the project deliverables on timeMaintain the industrial standards, helps in quality check

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