MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS MAJOR: INDUSTRIAL MANAGEMENT OPTIMAIZE THE OPERATION ACTIVITIES IN MEASUREMENT SYSTEM ANALYSIS AT BOSCH VIETNAM CO., LTD INSTRUCTOR: NGUYEN THI ANH VAN STUDENT: TRAN THI TU QUYEN Ho Chi Minh city, July 2024 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF ECONOMICS 🙠🙟🕮🙝🙢 GRADUATION THESIS OPTIMIZE THE OPERATION ACTIVITIES IN MEASUREMENT SYSTEM ANALYSIS AT BOSCH VIETNAM CO., LTD Student: Tran Thi Tu Quyen Student ID: 20124084 Major: Industrial Management Advisor: PhD. Nguyen Thị Anh Van HO CHI MINH CITY, JULY 2024 COMMENTS OF ADVISOR. Ho Chi Minh City, 11/August/2024 Advisor PhD. Nguyen Thị Anh Van i ACKNOWLEDGEMENTS The author is honored to be one of the students of the Faculty of Economics - Ho Chi Minh City University of Technology and Education.
During the period studying at school, the author learned a lot of useful knowledge from specialized knowledge to other soft skills. To reach the end of the journey today, the author would like to sincerely thank the school administration and the teachers of the Faculty of Economics for creating conditions and teaching the author during the past time. Besides, the author would like to send his deepest thanks to PhD. Nguyen Thi Anh Van - instructor of the author's graduation internship.
Thank you for always closely following and providing dedicated guidance to the author during the past time. The knowledge she conveys is extremely valuable lessons that help the author perfect the topic as well as draw personal experiences to apply in work and life in the future. On the company's side, the author would like to thank the board of directors of Bosch company for creating conditions for the Author to have an internship opportunity at the company. The author would also like to thank the direct managers Ms.
Nguyen Thi Giang and Ms. Ho Thi Hao of QMM6 department for their guidance and help to the author a lot during the internship and implementation of this topic. With limited time and knowledge, this essay cannot avoid shortcomings. The author would like to receive valuable comments from teachers to improve the topic and serve as a tool for future practical work.
Once again, the author would like to sincerely thank and wish all teachers good health, happiness and success in their careers. Ho Chi Minh City, 11/August/2024 Student name Tran Thi Tu Quyen ii LIST OF ABBREVIATION ABBREVIATION EXPLANATION AIAG Automotive Industry Action Group BPS Bosch Powertrain Solutions BQMS Belt Quality Monitoring System Co. Ltd Limited company CTG Controlling CVT Continuously Variable Transmission EAS Engineer Acceptance Standard ETC Engineering Technology Center FCM Facility Management FTE Full Time Equivalent HC Headcount HcP Ho Chi Minh City Plant HRL Human Resources HSE Health Safety Environment IATF International Automotive Task Force ICO Information Coordination & Organization iii LOG Logistics MFG Manufacturing MSA Measurement System Analysis PAS Production Acceptance Standard PC Commercial Plant Management PT Technical Plant Management QMM Quality Management and Method QMS Quality Management System TEF Technical Function TGA Technical Industrial Apprenticeship iv LIST OF TABLES Table 1. 1: DMAIC method in thesis.
1: DMAIC in thesis. 2: Classify and reaction plan results. 3: Inspector results in 2021. 4: Inspector results in 2022.
5: Form of Internal service quality survey to find out the reason for not detecting failure modes on operators’ tests. 2:Detailed implementation plan. 4: RASIC Matrix’s project. 5: Pareto chart data.
6: Detailed plan BQMS Digital Library. 7: Before and after consuming time and FTE. 91 v LIST OF FIGURES Figure 1. 1: Robert Bosch (1861-1942) - the first founder of the group.
2 : Bosch at a glance. 3: Bosch’s business sectors. 4: Bosch organization chart in Vietnam. 5: Some brands of Bosch.
6: Some customers of Bosch. 7: Bosch Powertrain Solutions Plant. 8: Bosch Vietnam’s logo. 9: Slogan “We LEAD Bosch”.
10: Continuously Variable Transmission pushbelt (CVT pushbelt). 11: Organizational chart of HcP. 12: Organizational chart of Quality Department. 13: Organizational chart of QMM6.
1: The composition of Push Belt. 2: Total operators’ qualification both BQMS and MSA. 3: Sources of data collection. 4: Inspection process at BQMS.
5: Overview of MSA processes at Bosch. 6:Overview testing results in 2021. 7: Overview testing results in 2022. 8:Overview Internal Quality survey results in 2021 and 2022.
9: Overview Ability to work at BQMS. 1: Overview Quality awareness room. 2:Overview Q-methods sharing. 3: Overview Quality skills competition.
4: Product quality inspection skills competition questions. 5: Before and after result of Quality Mindset enhancement survey. 6: Detailed timeline for phase 1. 7: Detailed timeline for phase 2,3.
8: Sample storage cabinet. 9: Source of reference document and Measurement report. 10: Flowchart new associates. 11: Flowchart current associates.
12: Flowchart current associates. 16: Before and After Operators' MSA test and Result in May Q2. 17: Monitor employee status in BQMS system. 18: Measurement System Analysis Master List.
19: Missed defect rate in Loopset at lines in 2022. 20: Missed defect rate in Loopset at BQMS in 2022. 21: The main causes of slip through in Loopset. 22: Cause and effect of visual inspection skill operator in Loopset.
23: Cause and effect of training for operators in Loopset. 24: Compare results between 2022 and 2023. 25: Main screen of the BQMS Management System. 26: Items in the BQMS Management System.
28: Web forms screen. 29: Acceptance standards screen. 30: BQMS test results screen. 31: BQMS report screen.
32: Items in the BQMS Management System. 33: Add new failure picture screen. 90 viii TABLE OF CONTENTS COMMENTS OF ADVISOR.ii LIST OF ABBREVIATION. iii LIST OF TABLES.
v LIST OF FIGURES. vi TABLE OF CONTENTS. Scope and object. Structure of thesis.
4 CHAPTER 1: INTRODUCTION ABOUT BOSCH VIETNAM CO.1 Introduction about Bosch Vietnam Co.1 Bosch Global Group .3 Bosch Powertrain Solutions Plant in Dong Nai .2 Introduction about the Quality Department .1 Overview of the QMM6 .2 Overview of BQMS. 17 CHAPTER 2: LITERATURE REVIEW.1 Resource monitoring and measurement .2 Measurement System Analysis (MSA) .3 Quality Management System (QMS) .6 Production Acceptance Standard (PAS) .7 Engineer Acceptance Standard (EAS) .8 Some other concepts of study .1 Internal service quality survey form. 31 CHAPTER 3: ANALYSIS OF THE OPERATION ACTIVITY STATUS IN MEASUREMENT SYSTEM ANALYSIS OF BQMS AT QUALITY MANAGEMENT AND METHOD DEPARTMENT .1 Overview the status .2 Automotive Industry Transformation .3 Importance of Push Belt in CVT .4 BQMS Role in Quality Assurance. 33 Define and Measure .7 Current status of BQMS .1 Visual inspection activities for operators .2 How to assess MSA of BQMS .3 The current status of operators’ missed failure mode .4 Capacity working at BQMS .8 Assess the current status of BQMS activities .1 Strength of current BQMS .2 Limitations of current BQMS.
55 CHAPTER 4: PROPOSED SOLUTIONS OPTIMIZING THE OPERATION ACTIVITIES IN MEASUREMENT SYSTEM ANALYSIS OF BELT QUALITY MANAGEMENT SYSTEM. 57 Improve and Control.1 Enhancement project "Quality Mindset enhancement" - Quality Talk at HcP .2 Project "Annual improvement of BQMS":.3 Solution to minimize missed errors on the Loopset process: .4 Project "BQMS Digital Library":. Introduction In recent years, manufacturers have faced increasing economic uncertainty forcing many businesses to shift their focus to maximizing efficiency and productivity across their entire operations. As a result, business leaders are increasingly investing their resources in initiatives that promote manufacturing excellence (Patrick Lemay, 2023) Beyond investing in the most advanced machinery or technology, quality management is a comprehensive strategy that covers every aspect of a company's operations from process optimization and waste reduction to empowerment and safety for the workforce.
According to Salvatore Castro (2020), monitoring and analyzing measurement systems is considered one of five important quality management tools widely used in assessing, ensuring and predicting the level of quality. Stability of employees, equipment, and plant operations. To minimize costs and quality risks for both the company and customers. Recognizing the importance of the QMS department of the Quality department at Bosch Vietnam, it plays a key role in controlling, evaluating and managing products.
However, there are still difficulties and inconveniences in the implementation process. such as how to use documents, database collection tools as well as optimize time for employee evaluation. Therefore, the author chose the topic: "Optimize the operation activities in the measurement system analysis at Bosch Vietnam Co. Objectives Analyze quality assurance monitoring activities in the measurement analysis system at the BQMS department of the method and quality management department at Bosch Vietnam Co.
1 Analyze and evaluate the capacity of operating staff (process 7 in the measurement analysis system) at Bosch Vietnam Co. Analyze the main errors that operators missed failure mode, thereby providing solutions to optimize the operation of process 7 in the measurement analysis system at Bosch Vietnam Co. Evaluate the effectiveness of the implementation process to optimize monitoring activities to ensure quality and achieved results 3. Scope and object Research object: capacity of operating staff at Bosch Vietnam Co., Ltd Research scope: - Space scope: Bosch Long Thanh Factory - Bosch Vietnam Co., Ltd - Time range: from January 2020 to January 2023 4.
Research methodology - Apply the mixed method research including both qualitative and quantitative method. It allows author to collect secondary data as well as primary one more easily. For example, through using qualitative method author can have some communication with operators and interview expertises of all fields and functions to catch up specific problems in manufacturing. Besides, taking advantage of quantitative method like 5 Whys, Pareto Chart and quality tools helps author tackle issues and root causes more quickly.
2 Define Available data study Project chapter Project scope Voice of customer DMAIC flow chart Measure Measurement system study Pareto chart Quality tools Analyze Search for root causes using cause and effect studies Validation of cause and effect relationship Process flow chart Survey form Improve 5 whys Timeline RASIC matrix Fishbone PDCA cycle Control MSA Master List ( Control Plan) Standard operating procedures Digital numerical control The meeting for final Table 1. 1: DMAIC method in thesis Source: Author 3 Source: Author 5. Structure of thesis Utilize the secondary data and documents through reports from the quality department from 2020 to 2023 in order to discover the quality management problems the company encountered in the past. Thanks to the use of secondary documents, the author is able to collect information more easily; available documents are stored in the quality department's document folder.
Data updated and recorded in the last 3 years will reflect the actual state of awareness of operators' quality thinking and their ability to detect defective products. Simultaneously, utilize quality control tools like Pareto charts, fishbone diagrams, and MSA to collect and analyze data to find out the root cause and then come up with solutions to improve skills as well as detect errors at the factory. Moreover, the author combined with quality experts through interviews and conversations about the current state of operation activities in measurement system analysis at the factory. Thereby, enhance the evaluation activities of the BQMS department of the Methodology and Quality Management department.
The report is divided into four chapters, in particular: Chapter 1: Introduce Bosch Vietnam Co. This first chapter of the report presents an overview of the company, history of foundation and growth, business sectors, company products, and organizational structure of departments, in particular the BQMS department. Hence, provide readers with an overview of the company. Chapter 2: Literature review The chapter presents some concepts and theoretical foundations of the topic, such as the theory of MSA, the PDCA cycle, and other concepts.