Application of project quality

management to increase the successful

rate of car project: a case study in China

Group Presentation by 

Asmat Ullah
Hussam Zain
Naila Shahid
Raheel Malik
Saba Saif
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MS Project Management Project Quality Management

 Content
 Abstract
 Introduction
 Project Quality Aspects
 Case Study Analysis
 Results and Conclusion

MS Project Management Project Quality Management

 Abstract
 The case of Beijing Mercedes Benz C-Class car project in view of
implementation of following Quality Management (QM) processes was studied:
i. Quality Planning
ii. Quality Assurance
iii. Quality Control
 Results showed that introducing project QM processes in the car project results
in:
i. Improved Product Quality
ii. Enhance Customer Satisfaction

MS Project Management Project Quality Management

 INTRODUCTION
Challenges faced by Large Scale Automobile Industry and wayforward:
Challenges:
 Poor design and development ability of product.
 Management of manufacturing processes and systems and on schedule delivery of
new car model.
Deficiency:
 Project QM principle of Project Management (PM).
 Lack of advanced project management technology and integrate limited resources.
If deficiency is removed, what can be the outcomes?
 Rapid translation of customer requirements into product with high quality and low
cost.
 Improved Competitive Ability of the company.
 Development of new car model; adaptable to the quality, cost, and time requirements
of domestic and foreign markets. 4

MS Project Management Project Quality Management

 INTRODUCTION
Beijing Mercedes Benz C-Class Car Project:
Quality Planning Phase:
I. Importance of project organization structure on the quality management was
studied; Advanced Product Quality Planning (APQP)
II. To identify customer requirements and the quality characteristic demand of
customer; Quality Function Deployment (QFD) Technique
III. To ensure the maximum recognition of potential defects and take preventive
measures before product forming; Failure Mode And Effects Analysis
(FMEA)
Quality Assurance Phase:
 To attain continuous improvement during implementation process and
guaranteeing the whole process of quality of the project; Plan-Do-Check-Action
(PDCA) by using gate audit method (defines the state of each stage)
Quality Control Phase:
 To monitor products quality effectively and take improvement measure; Statistical
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Process Control (SPC) Method.Project Quality Management
MS Project Management
 Purpose of the Study
 To give some reference for the QM of new car
development project that would help domestic
automobile enterprises to have high success rate
and improved competitive advantage.

MS Project Management Project Quality Management

 Theory of PQM
 PQM refers to command, coordination, control and other activities of project
quality.
 Its basic aim is to ensure that the project is successfully implemented in
accordance with requirements.
 Three main aspects of project quality management are:

Assurance

PMP

Planning Control

MS Project Management Project Quality Management

 PROJECT QUALITY PLANNING
Identify which quality standards are suitable for the project, and determine how to
meet those standards; bringing the quality in the planning and designing.
 Use of QFD tool to carry out project functional requirements analysis and then use of
FMEA for product and process planning, could timely discover hidden problems in
advance
QFD – Quality Function Deployment:
The process starts from customer demand and is composed of four phases; product
planning, parts design, process design and production control.
FMEA- Failure Mode And Effects Analysis:
FEMA is to improve design through detailed analysis of potential failure mode and
effect degree of product design and development process, to prevent the occurrence
of failure and improve the success rate of projects.
Tthe FMEA team calculates risk priority number (RPN) according to the severity,
occurrence, and detection of failure mode. If the RPN value is high, means high
risk, measures must be taken to reduce the RPN value.
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MS Project Management Project Quality Management

 PROJECT QUALITY Assurance
A systematic way of creating an environment to ensure that the project being
developed meets the quality requirements.

Plan-Do-Check-Action (PDCA)-Gate Audit Technology:

 A kind of project quality assurance management tool, used to audit whether a
series of steps have been performed and what are the implementation results.
 It is a corresponding gate examination at every milestone of project to confirm
whether the project could be smoothly carried out to the next stage.

The purpose of gate audit is to ensure that all activities of the project are in line
with the early planning requirements, to ensure that the project quality meet the
quality planning scheduled and is under control.

MS Project Management Project Quality Management

 PROJECT QUALITY Control
Quality Control is a system of maintaining standards in manufactured
products by testing a sample of the output against the specification.
SPC Technology:
 It is a project product quality control tool; its purpose is to establish and
maintain product quality acceptable and stable, to ensure that products and
services meet the requirements.
 Statistical tool i.e. Control chart is used to analyze and judge that the process
is in control with state boundaries map.
 The principle of control chart is when the random variable of quality
characteristic value obey normal distribution, the probability of variable μ ±
3σ range is 0.9973. According to the principle of small probability events can
be ignored, if the variable is beyond the scope of μ ± 3σ, it could be conclude
that mutation exists in the process. It is used to determine process capability
and stability analysis and improvement.

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MS Project Management Project Quality Management

Important Concepts
• Begins with customer demands
QFD • Composed of planning, parts design, process
design, and production control of four phases
• DFMA – Design FMA and Process FMA
FMEA • FMEA calculates risk priority number according to
severity, occurrence, and detection
• QA management tool to audit whether series of
Gate Technology steps have been performed and implementation
results.
• QC tool – Control charts to analyze and
SPC understand if the product and service meet the
requirements.
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 Case Analysis
Project Background:
 Chinese automobile industry – Car models are updated quickly to adapt to
fierce competition. Rapid upgradation requires doing things right the first
time (Pilot) and quickly going into mass production.
 To avoid quality problems, Beijing Benz introduced the project
management and process audit process, to build a systematic platform in
order to ensure the product quality and process quality for new car model
development project

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MS Project Management Project Quality Management

 Case Analysis
Management Process of Beijing Benz new car model development project

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MS Project Management Project Quality Management

 Case Analysis
Project Organizational Structure:
 In past project company mainly carried out manufacturing and process
planning and digested technical standards and drawing data provided by
foreign counterpart.
 With the development of auto industry, new product development projects
gradually increased, independently design components and joint development
projects increased.
 So, Project organisational structure gradually transformed from weak matrix
for repetitive production to strong matrix in order to meet project
development.
 The project team involved project stakeholders such as R&D, quality,
purchasing, manufacturing personnel, and the necessary suppliers of
professional ability and personnel of relevant experience.
 Information sharing and feedback became quick between different
departments, which laid foundation for the process quality of products and
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product quality.
MS Project Management Project Quality Management
 Case Analysis
Key Points and Difficulty of the Project:
To ensure the quality of products under the influence following factors was
difficult for Mercedes Benz new car development project team during
implementing:
 The project started in July 2013 and project’s trial production was required to
finish before July in 2014 and mass production was required to be started i.e.
only one year of construction period.
 Difficulty in handling emergency situation.
 Communication and resource coordination issues.

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MS Project Management Project Quality Management

 Case Analysis
Quality management of the new c-class car development project:
Quality Planning Of New C-class Car Project (QFD):
 In new product development and trial production it had both commonness
and particularity.
 In order to transform customer requirements to the engineering design
quality, market competition ability and technology competition ability in
house of quality QFD was not analysed.
1. Customer Demand Induction And Product Planning: Through early
communication with clients following requirements were identified;
i. Safety of product; complying with the relevant laws, regulations,
requirements of government and automobile industry.
ii. Excellent product performance while ensure sound insulation effect.
iii. Beautiful appearance and had superb interior.
iv. After-sales quality information feedback. 16

MS Project Management Project Quality Management

 Case Analysis
Quality management of the new c-class car development project:
Quality Planning Of New C-class Car Project (QFD):
2. Product Design And Development:
Product design and development stage transformed the design requirements
into the important and measurable technology requirements that product
demanded using product design and development process matrix.
3. Process Design And Development:
Technology characteristics and parameters to ensure the realisation of
product characteristics, the process characteristics were based on product
characteristics, they were those elements must be controlled in the
manufacturing process to ensure products meet the needs.
4. Production Planning:
House of quality and the characteristic matrix graph of production planning
stage can be drawn in order to translate the output of design and
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development process into the specific production control plan.
MS Project Management Project Quality Management
 Case Analysis
Quality management of the new c-class car development project:
Quality Planning Of New C-class Car Project (QFD):
5. Product Design And Development:
 Project team set up the FMEA team.
 Team members included: design Engineer, quality engineer, technical
engineer, process engineer and manufacturing engineer.
 In vehicle structure design, the team conducted DFEMA analysis from
spraying process, performance definition, design life, body layout etc., in
which a lot of design and evaluation elements were from the graph of
QFD, house of quality played a guiding role for application of DFMEA
and PFMEA.
 After preliminary analysis, the FMEA team analysed issues of RPN,
value more than 60 to reduce risk, and formulated improvement
measures.
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MS Project Management Project Quality Management

Case - Problem and Solution (Motor
Heating)
 Problem - Sealing deformation because of motor heating
 Reason - Design of motor position because “assembly space of car body is
limited”
 Measure used - DFMEA
 RPN = 7 x 9 x 4 = 252
 Solution – Delphi Techniue
 Layer of insulation board in the motor outerwall.
 RPN = 7 x 1 x 4 = 28

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Case - Problem and Solution (Welding
Problem)
 Context – Implementation of a new world class advanced technology for
welding
 Problem – Welding process causing deformation of hardened plastic parts
 Quality Planning and PFMEA suggested to use
 Solution – SPC (frequent continuous sampling) to view real-time deviations
with 3 sigma benchmark
 Solution – Adjustments and optimization of robot welding parameters, small
air pump to provide stable pressure, regular replacement of electrode A and
B, etc.
 SPC was also used for body paint thickness, color difference, and assembly
gap)
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 Case Analysis
Quality management of the new c-class car development project:
Quality Assurance Of New C-class Car Project (Gate Audit):
 The quality assurance of Beijing Benz V205 new car model development
project was done through fate audit approach and was the “process quality
audit based on project process”.
 Examined and verified whether deliverable achievements of early stage of the
project had been completed.
 It was a necessary routine work at end of each phase of the project life cycle.
Beijing Benz formulated evaluation criterions to indicate the severity of
different problems/ The overall score of each gate should get above 80 points
can through the audit.
 The audit problems and the solutions of (or potential measures) and output
must be recorded.
 The project team tracked the problem until be solved and the problem was
closed with confirmation in the next gate audit. 21

MS Project Management Project Quality Management

 Case Analysis
Quality management of the new c-class car development project:
Quality Control And Improvement Of New C-class Car Project (SPC):
 SPC technology is widely used in project product quality control in order to ensure that;
 Whether relevant design meets the expected requirements,
 Whether related process is qualified and keeps phase stability,
 Project quality team used frequently Xbar-R process analysis control chart to analyse and judge
the quality status of product or process and following measures were adopted:
i. Adjustment and optimisation of robot welding parameter, to achieve optimal allocation of
technology and reduce shapes of parts.
ii. For each welding robot installation of small air pump to provide a stable pressure, reduce the
pressure loss caused by welding pressure, to ensure stability of technology.
iii. Regular replacement electrode A, electrode B for each welding robot, to reduce quality problems
caused by weld pool.
iv. Check vehicle bracket and replaced the damaged technology column, to ensure accurate car
body position before welding and avoid offset status.
v. Re-optimisation of welding robot profile track, to reduce dislocation problems caused by excess
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movements.
MS Project Management Project Quality Management
 Result
 Customer satisfaction
 Process quality
 Product quality
 Quality management capability

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MS Project Management Project Quality Management

 Result
 New process of Beijing Benz new C-class vehicle project was as follows:
i. By analyzing the surface requirements, designer used sketches to appear products in
the mind
ii. The designed sketches were described and literally interpreted
iii. Retouched the sketches and description to form impression drawing, the outline of
car body had been confirmed
iv. Along with determining the car appearance, the interior requirements were analysed
to map out the interior impression drawing
v. The car proposal models were made using fat lute to make sensory evaluation on the
whole
vi. After assessed the car proposal models, the decision layer would select one or
several schemes to make 1:1 clay model as finalised model
vii. After acquisition of finalised model data of three coordinate measuring, using
computer design to create 3D model, since then the development stage ended and
entered into the amount trial stage to prepare for put into production. After solved
problems in the trial production process, entered into the routine production system.
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Thus , the new car model development

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project ended
Project Quality Management
 Conclusion

 Incorporating quality into processes and products while

monitoring and improving is a fruitful technique.
 Due to “Excessive Quality Control” while ignoring
“Time Control”, the project was delayed.
 There was no better evaluation of project risks.
 Holistic and integrated approach must be adopted.

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MS Project Management Project Quality Management

 Thank You

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