7-Series Project: The Root Cause Of BMW Quality Issues

BMW The 7-Series Project (A)

AGENDA

1) Abstract/Executive Summary

2) Problem Statement

3) Case Analysis

4) Alternative Solutions

5) Recommendations

6) Limitations

7) Appendix

Abstract/Executive Summary

• To explore the BMW decision about how to manufacture the Prototype vehicles.

• Previously, BMW prototypes were handcrafted at the company by skilled artists.

• There is a proposal to change the process and make prototypes inorder to better understand the issues that may arise during final production phase.

• There is a thought at company that new approach shall help the production of New Models and increase the product Quality.

• But they also have a alternative thought that it may be difficult to change the Designs during Development Cycle.

• There is issue over the Cockpit Design.

• How to tackle the different ways to improve the Flexibility / Quality etc.

Case Analysis

• What is the Root Cause of BMW Quality issues?

• What is the consequence of these issue on the New BMW products ?

• What Improvement measures to be taken ?

• Due to use of various Tools etc in Prototyping Vs Production Model has lead to Non-Conformity with the desired results at Production Model.

• Using Clay Model & Used part Designer Drawing, as compared to Pre-Production Tools in Prototyping Stage has lead to Quality Issues. It has lead to masking several mfg. issues. It requires more skilled labor, cost & time.

• The Mixed Model Ramp-Up Strategy, Produces New Series on same Production Line as Old Model.

• Workers spend more time on Bigger issues and less time spent on Minor issues.

• More Customer Complaints.

• More Confusion among workers, leading to Logistics issues.

• All issues are not Fixed at Pilot Phase.

• Involvement of Suppliers in Final Engg. Drawing & Commercial Production Process.

• In case Suppliers come across issues during Commercial Production then it takes time to adjust the

• Gain maximum understanding from tools & prototypes etc.

• Make frequent Prototypes & reduce the time taken for development Process.

• Early involvement of the suppliers at design process.

Strategic Recommendations

• Company can use the Benchmarking Technique.

• Company can work on to decrease the Lead time at Development Process.

• Company can use the Lean Process/Six Sigma.

• Company can work on to increase the communication, interaction b/w the different suppliers & departments etc.

• By working on the above points and implementing them BMW shall have lesser issues with respect to the new prototypes.

• It shall help to maintain consistency at quality & lesser customer complaints.

• It shall help the company to capture more market share.

Limitations

• It is always difficult to implement Changes.

• If Lean / Six Sigma is not successful then there could be loss.

• The investment on New Process & Procedures may be Costly.

• The application of Innovative ways depends on company’s approach towards Creativity.

• Applying new changes may Delay the Time to market of the product.

Appendix

• BMW The 7-Series Project (A),