CQI- 35 Bruno Mendoza Issamendi • Is a Mechanical, Electrical, and Industrial Engineer, graduating from the National Autonomous University of Mexico (UNAM). • He has pursued academic stays in the United States at Brigham Young University, the University of California, and Rose-Hulman Institute of Technology. He holds a postgraduate degree in Materials Science Engineering from the Kingdom of Saudi Arabia and a doctorate in Business Administration and Management. • With 13 years of experience in the automotive industry, focusing on quality and supply chain management, and 12 years specifically at Ford Motor Company Mexico, Bruno currently leads the supply chain for Ford Motor Company in Mexico. He directs electrification efforts for the automotive industry, leading a team of 400 engineers from North America.
2 Irving Rodriguez Bautista • Irving Rodríguez is a highly qualified and experienced engineer with a strong commitment to sustainability and innovation. His diverse educational background and extensive experience in the automotive industry make him a valuable asset to Ford Motor Company (8 years). • He is well-positioned to continue leading and contributing to the future of the automotive industry. • Is a Mechatronics Engineer with masters in Energy and PhD in Management Science.
3 José Gonzalez • Is an Electronic Engineer, graduating from Instituto Tecnologico de Aguascalientes, Mexico (ITA). • With almost 17 years of experience focusing on manufacturing & Quality industry (TI, Xerox, Flex, Sensata Technologies, Altia Group) supply chain management, SQE / AME/ Buyer / SQE Medical lead. • 11 years specifically at Stellatis, QPS, RE for Water & BSR, Jose currently leads the Supplier Quality Electrical Wire Harness in USA.
4 WHY THIS MATTERS? • Electrical Distribution Systems (EDS): Are becoming increasingly important in the automotive context, especially with the rise of electric vehicles (EVs) and Advanced Driver- Assistance Systems (ADAS). 5 PROBLEM STATEMENT • The automotive industry faces significant challenges in maintaining consistent quality and reliability in wiring systems, leading to increased warranty costs, customer dissatisfaction, and potential safety hazards. • Existing wiring quality processes are often reactive, focused on identifying defects after production, rather than proactive prevention. • Variability in manufacturing processes and supplier performance leads to inconsistent wiring quality. • Lack of standardized metrics and data collection makes it difficult to track trends and identify root causes of defects. • The complexity of modern wiring systems, with increasing integration of electronics, poses additional challenges to quality assurance. FRAMEWORK Mexico's Harness Manufacturing: Leading the Way with Standardization • Mexico is a leading force in harness manufacturing, attracting global attention with its competitive production costs. To further enhance this industry, a groundbreaking initiative is underway to standardize manufacturing processes among suppliers. This project aims to: • Reduce Variation: Minimize inconsistencies in harness production, ensuring consistent quality and performance. • Enhance Quality Control: Implement robust quality control measures, leading to higher reliability and customer satisfaction. • Standardize Unit Costs: Achieve predictable and efficient production costs, fostering a level playing field for suppliers. Driving Standardization: The CQI Approach • This standardization project leverages the power of the Automotive Industry Action Group (AIAG) and its Continuous Quality Improvement (CQI) framework. The CQI approach ensures adherence to the highest industry standards, fostering a culture of continuous improvement. 7 OBJECTIVE • To develop a comprehensive wiring CQI that proactively identifies and addresses potential quality issues throughout the entire wiring system lifecycle, from design to production and beyond.
• Improve the quality and reliability of wiring systems: Reduce defects, improve performance, and increase customer satisfaction. • Reduce warranty costs and increase profitability: Identify and mitigate risks early in the process. • Enhance safety and minimize potential recalls: Ensure robust and reliable wiring systems for all vehicles. • Optimize manufacturing processes: Streamline production, improve efficiency, and reduce waste. BENEFITS A Collaborative Effort and Record-Breaking Pace • This project is a collaborative effort between leading automotive manufacturers General Motors (GM) and Stellantis. In just eight months, the project has achieved significant progress, a remarkable accomplishment considering that CQI initiatives typically take three to four years to implement. Global Reach and Implementation Timeline • The CQI framework will be translated into five languages – English, Spanish, German, French, and Chinese – to ensure global accessibility. The project is expected to officially launch in January 2025, with a dedicated implementation period for suppliers to acquire necessary tooling, gauges, and other requirements. Key Benefits: • Improved Harness Quality: Consistent and reliable harnesses, meeting the demanding requirements of the automotive industry. • Enhanced Supplier Collaboration: A standardized approach fosters stronger relationships and smoother communication between manufacturers and suppliers. • Cost-Effectiveness: Predictable production costs and reduced waste lead to greater efficiency and profitability. 9 METHODOLOGY • Phase 1: Define • Phase 2: and scope the Develop the CQI problem Framework
Performance Tracking Suppliers and stakeholders Continuous Improvement Cycle Process Improvement Initiatives Process Documentation Supplier engagement • Phase 4: • Phase 3: Continuous Implement the Monitoring and CQI Improvement OVERALL FINAL DOCUMENT • Content (Topics) 10.Assembly Requirements 1. General manufacturing requirements 11.Inspection Requirement 2. Material Handling Requirements 12.Rework & Replace Requirements 3. Terminal and connector Manufacturer 13.High Voltage Requirements Requirements 14.Coaxial Cable Requirements 4. Crimping & Cutting Requirements 15.Barcode/Label and Traceability 5. Twisting Requirements Requirements 6. Ultrasonic Welding Requirements 16.Wiring Harness Safe Launch Plan 7. Terminal Soldering Requirements 17.Hanking Requirements 8. Heat-shrink Tube Application 18.Production Support Requirements Requirements 9. Fastener Requirements EXPECTED RESULTS • Reduction in wiring-related defects (e.g., 20% decrease in defect rate within a year). • Decrease in warranty claims related to wiring issues (e.g., 15% reduction in warranty claims within 18 months). • Improved customer satisfaction ratings (e.g., 5% increase in customer satisfaction scores related to vehicle reliability). • Reduced production downtime due to wiring-related issues (e.g., 10% decrease in production downtime within a year). • Increased efficiency in wiring assembly processes (e.g., 5% reduction in assembly time per unit). NEXT STEP JANUARY 2025 • Suppliers must thoroughly review and understand the requirements before implementing any improvements. • Our representatives will conduct an initial on-site review with suppliers to begin the process of identifying and implementing improvements. • Suppliers must begin implementing improvements in their manufacturing plants.
