Omnex helped AMD, Philips Semiconductor (now NXP) and many other Semiconductor manufacturers
design and develop their New Product Development Phase Gate approach. We helped
them design the process and provided in depth training so that the team could be
successful. We helped them understand DFMEA, DVP&R, Process Flow, PFMEA, and Control
Plans as they applied to their specific industry and company.
For Philips Semiconductor we worked with 14 Business Lines to standardize their
launch process. The details of the checklists for each phase could vary, but the
overall phases for launch were standardized. A major feat for this independent organization
that served many industries from computers, cell phones to Automotive.
Omnex helped Mack Truck take their New Product Launch process and improve it with
Defect Prevention Tools including Risk Analysis, DFMEA, DVP&R, Process Flow, PFMEA,
Control Plans, and PPAP. Omnex integrated this process with their parent company's
process in France. Not only did we roll this out for two major launches in Mack
Truck, we rolled it out to all the suppliers.
In 2001-2002, Omnex implemented ISO/TS 16949:2009 Quality Management System for
Philips Semiconductor, which included 3 Wafer Fabs (manufacturing), 3 testing facilities
and 14 Business Lines (product groups), encompassing over 4,000 employees.
Working with Philips, Omnex improved quality systems, teamwork, documentation, auditing
and Top Management involvement. The entire project took less than 18 months to complete
and achieved certification on the first try.
Reference: Ray Suen, Director, Quality & Technical Services
"Using OMNEX helped shorten the learning curve for our complex site organizations:
Expert training on ISO/TS standard
Expert pre-audit gap analysis
Provided a facilitated roadmap for deployment
Aggressive 1:1 consultation and follow-up with organization's issues/progress
Facilitated and performed internal audits of our organizations
Assisted in the creation of many procedures"*
"...what (the Business Excellence Leader) and the engineering team accomplished
in this implementation has been remarkable and is now a real business process around
control plans, FMEAs and significant characteristics" - (Manufacturing Manager)
Between 1998 and 2004, Omnex developed and delivered a comprehensive battery of
custom training courses for SAC, conducted for all members that are suppliers to
the automotive OEMs and semiconductor manufacturers.
At the time, over 90% of semiconductors world-wide were produced by SAC members.
The training was usually accompanied by consulting, mentoring and auditing services
to improve performance. Based on objective performance data, SAC believes this process
transformed mediocre suppliers to world-class performers.
Reference: Ron Ramos, Board of SAC (Ret'd)
SAC Supplier Development Performance Impact
Supplier Development program involving approximately 225 suppliers over a period
of three years. Omnex conducted assessments of all critical and major suppliers,
creating a comprehensive training and development program.
Initial training included APQP, Process Review, PPAP, SPC and MSA, followed by Internal
Auditing and TPS/Global 8D, and finally Advanced SPC in a third phase. Omnex delivered
training and conducted PPAP development workshops, engaging all 225 suppliers.
TATA SQI Group evaluated the program effectiveness based on flawless launch criteria
for the launch of the Indica car program - the first entirely designed, developed
and launched in India
Reference: SR Inamdar, SQI Group Manager
Omnex supported a major product launch of 200 parts. Omnex audited the suppliers,
then trained the suppliers in the First Article process and subsequently worked
with Engineering and the suppliers to iron out issues with the FA process.
Omnex conducted the First Article assessments for Boart Longyear, approving or rejecting
The product launch proceeded flawlessly, with no quality or delivery issues or problems.
Developed and deployed, two major, sustained global training programs, starting
with a 5-day battery of Quality concepts and management system integration. Receiving
the highest participant evaluation scores, Omnex continues to update and deliver
this training in Europe, U.S., Morocco and Singapore.
Developed and deployed STM DMAIC (customized 6б) training & project facilitation
in U.S., Europe and Singapore. Through two flights of training, client has verified
through internal calculation savings of over $1MM per project.
Reference: Mr. Meempat Murali
Omnex developed and delivered a battery of courses in support of the deployment
of the TRW Global Business Operating System (over 270 facilities world-wide), incorporating
requirements of ISO/TS 16949, QOS, Lean & Six б CI, and APQP.
Training continues to be delivered at, to date, over 35 sites in the U.S., Latin
America, U.K., India and China
Ref: Mr. Tom Bundy, Quality Systems Mgr., Western Hemisphere
Omnex designed and co-developed an on-line, interactive E-Learning solution for
teaching and deploying a company-specific approach to Lean Systems Implementation.
Working with Cummins and their JV partner in China, Omnex developed and provided
the entire range of supplier development training and consulting services for 2nd
& 3rd tier suppliers to DFM, the largest Chinese truck manufacturer at the time.
Omnex designed and developed a company-specific approach to QOS/BOS and then delivered
custom training and consulting in the U.S., Germany, U.K., France, Italy & Spain
Working with Corporate Quality and each of several divisions, Omnex developed 6
versions of custom, product group-specific training courses combining the F-M New
Product Development Process and APQP. This training was delivered at over 20 sites
in the U.S., Mexico and Western Europe (U.K., France, Germany, Italy & Spain).
Reference: Graham Dobson, Program Launch Mgr., Europe
Omnex has provided Executive, Champion and Green Belt training in Lean & 6б
to this major container company with 16 plants in the U.S.
The first phase of the program is in the process of completing 18 projects with
anticipated operational savings of at least $2.3 MM.
The second phase will involve a new flight of Green Belts and the development of
a group of Black Belts from the original cadre, and will initiate another 16-18
Reference: Jeff Devries, V.P of Operations
Omnex has trained and facilitated projects with over 60 Green Belts and 20 Black
Belts for Saint-Gobain India, including Saint-Gobain Sekurit Automotive Glass.
Omnex works on an on-going basis with the champions and Top Management in sustaining
the Lean Six Sigma culture and deployment. Saint-Gobain to date has saved hundreds
of thousands of dollars through the Lean Six Sigma projects - both Green and Black
Based on the success of this initial phase, Omnex is currently providing Lean Six
Sigma services to other Saint-Gobain factories in India, China and Thailand.
Reference: Satish Gupta, Head-Business Excellence
Training and Workshops
Omnex Webinar: Effective Program Management to Achieve Rapid Product Development & Launch without Surprises (11.5 MB Webex file)
Omnex Systems Webinar - Knowledge Management: Back to Basics (5.5 MB Webex file)
Omnex Webinar - Product Development FMEAs for Design Engineers March 15, 2006 (16 MB Webex file)
Omnex Systems Webinar, "How Broke Is My Process?" April 20, 2005 (10MB Webex file)
The course was useful in showing a standardized, comprehensive APQP. I now understand
more clearly how each step interacts with the rest.
AB Myr Industries
Algorithm Failure Modes and Effects Analysis (AFMEA) Case Study
Machinery Failure Modes and Effects Analysis (MFMEA) Case Study
Automotive Case Studies Around the World
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