AutoDCP Case Study
Automotive is a large Tier 1
automotive supplier whose products
include body structures and assemblies, suspension modules and systems,
Class A surfaces and modules, and lower vehicle structures.
Tower’s customers include Daimler Chrysler, Fiat, Ford,
General Motors, Honda, Isuzu, Mazda and Nissan. Tower has over 70
locations in four continents employing over 16,000 and annual revenues
of over $2.5 billion.
Al Lawson is the Quality Leader at Tower who has the responsibility for
the GMX 320 program from General Motors. This important undertaking
marked the first time Tower had been awarded the job of assembling the
front suspension module and powertrain dress module then marrying the 2
modules together for a GM vehicle. The project is of strategic
importance to Tower as an important opportunity to prove
Tower’s capabilities for this type of large modular assembly.
Al had previous experience with other PPAP software such as MPACT.
After seeing a demonstration of AutoDCP software in late 2000, Al
viewed the decision to use this software on his project as academic. Al
began using AutoDCP on the GMX 320 in December, 2000 starting with his
process flow and process fmea. In February 2001, GM imposed a deadline
on Al’s team to have the control plan for the GMX 320
completed by March 15, 2001. Al’s process at this point
included 3000 characteristics to be addressed in this control plan.
On Feb. 21, 2001 Al made a request of CDS to help him with the deadline
looming on the control plan. At Al’s request, CDS accelerated
development of the AutoDCP command language and committed to have the
enhancement ready for Al to test within 2 weeks. On Mar. 7, 2001 CDS
installed the enhanced version on Al’s machine for testing
and use. On Sat., Mar. 10, 2001 Al Lawson called CDS President Jim
Crenshaw to inform him that he had just completed his font size 6, 106
page control plan in 2.5 hours using the new AutoDCP feature.
Al has been freed to address the other challenges of the GMX 320
program without the PPAP process being an issue he has to worry about.
AutoDCP has just completely eliminated the exhaustive effort that
otherwise would have been required. At a minimum the development time
for completion of control plan documentation has been reduced by 75-80%
through the use of AutoDCP. This frees up resource time for developing
other Quality System documentation in this new facility.
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