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Automotive, Production, Manufacturing Core Tools Case Stuides

Automotive & Production Case Studies


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.

Mack Truck

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.

Philips Semiconductor (NXP Semiconductor)

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

Philips' Appreciation of Project

"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)

Semiconductor Assembly Council (SAC)

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

  • Productivity improvements 10% - 30%
  • Equipment
  • People
  • Yield improvement
  • Subcontractor yields improved to 99.6%
  • Performance to schedule improvement
  • Consistently sustaining 100%
  • Number of customer complaints decreased
  • Up to 15x reduction

TATA Motors, India

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

Boart Longyear Corporation

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 for correction.

The product launch proceeded flawlessly, with no quality or delivery issues or problems.

ST Microelectronics

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

TRW Automotive

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

Merck Pharmaceuticals

Omnex designed and co-developed an on-line, interactive E-Learning solution for teaching and deploying a company-specific approach to Lean Systems Implementation.

Cummins Engine Co., Inc

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.

U.S. Can Corporation (Now Ball Corp.)

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

Federal-Mogul Corporation

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

Letica Corporation

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 projects.

Reference: Jeff Devries, V.P of Operations

Saint-Gobain Glass India

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 Belt.

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


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Automotive / Production
Core Tools Attendee Comments

The course was useful in showing a standardized, comprehensive APQP. I now understand more clearly how each step interacts with the rest. more...

Automotive / Production
Core Tools Customers

AB Myr Industries
AC Delco