Feedback loop for manufacturing corrections

[Kukailimoku]

Does anyone know how Ram manufacturing inputs "Lessons Learned" from the field back into the production processes?

Conventional wisdom holds that a whole model-year's worth of manufacturing takes place without fixing any bugs mid-stream, and year number two incorporates all the fixes for the bugs discovered in year-one. Conventional wisdom furthermore holds that this improvement/correction style only takes place for a couple/three years then fixes are abandoned at some point either because all the bugs are already fixed (optimistic worldview) or because design team and R&D monies are being put toward the next gen effort (cynical worldview).

But does it really happen this way? Is there another methodology for spiraling improvements into the production stream? Can anyone speak toward this with some legit veracity (and not just made-up suppositions)?

For example, hypothetically, might there be 90-day "cycles" or "lots" of production, say, wherein they bundle fixes derived from analyzing amassed warranty work To-Date and cram the fixes for those issues into the production line for the following "lot" of units? (That was just an arbitrary number but you get my drift.)

What is the "real" spiral time for FCA to ID a problem, develop a solution/design changes, re-tool/re-jig/re-train workers/re-program robots/change purchase requirements for upstream suppliers, and get those fixes into the next "batch" of vehicles produced?

Is it possible the circle takes place multiple times within one model/calendar year? Or does old layperson conventional wisdom that fixes only happen "next year" turn out to be more correct?

 

[JB1]

Good question

 

[MADDOG]

I would imagine there are several avenues for that feedback to FCA.

One would be dealer warranty claim processing. Those repairs must be approved by FCA before a dealer goes forward with any repair. Tracking and analyzing the warranty claim data provides some input on repeated failures experienced with vehicle systems.

Another method is customer focus groups. I've participated in several associated with the LX platform (Charger, 300, Magnum) and we were advised that input from those groups is used in several ways. Categories such as future design, desired options, interior enhancements, exterior colors, etc... are all noted during those discussions. And information on what's not working well, repairs performed or current issues are also tabulated and provided to the warranty and design groups at FCA as further data to analyze and track.

Lastly, groups such as ours here at RamForum provide information when generating threads and posts on issues we are experiencing. This site, plus others, have registered members who work for the manufacturers and those posts and threads provide another information pipeline to FCA,

Now, as to what the parameters are that initiate an engineering effort or change in design, well, someone will have to ask FCA about that. Obviously, safety issues they self report require a recall be issued within a very short period of time per NHTSA regulations. The timeline for engineering, testing, parts production and rollout vary.

 

[n-humble]

You asked for no speculation, but here is my educated guess as an IT professional...

Fiat Chrysler is committed to ISO 9000 standards. As such, they must follow those International guidelines for manufacturing and software development. A lot of systems in automobiles these days are software driven. As such, there must be change management in place to control the modification, testing, and rollout of fixes/patches of software that has already been released. I have no idea what FCA's software release/patch cycle is, but I would assume they would integrate critical bug fixes and modification in the manufacturing line as soon as they are feasible, and issue Technical Service Bulletins to dealerships for the same.

 

[Fitz-0518]

It is, a great question. The factual answer will only be known when FCA decides there is a beneficial reason for making their operating policy and decision making process public. Employee's who are engaged in the internal process may share their experience. The rest of us can only suspect what the answer may be. I do believe it is factual to say, safety issues drive the companies focus and corrective action.
As a customer who is waiting for an exact replacement of their factory defect truck to be built. My expectation is, the replacement truck will not have the same issue. The recalls to date will be handled before delivery. If FCA uses a lessons learned process to determine cause and effect assembly issues, then my expectations will be met. Will see

 

[SilverBullet85]

Does anyone know how Ram manufacturing inputs "Lessons Learned" from the field back into the production processes?


For example, hypothetically, might there be 90-day "cycles" or "lots" of production, say, wherein they bundle fixes derived from analyzing amassed warranty work To-Date and cram the fixes for those issues into the production line for the following "lot" of units? (That was just an arbitrary number but you get my drift.)


Is it possible the circle takes place multiple times within one model/calendar year? Or does old layperson conventional wisdom that fixes only happen "next year" turn out to be more correct?

If I can find the post I'll link it here and who knows if the 'guy' knows what he's talking about but...in another thread someone mentioned that they have for example a 90 day run...make minor adjustments to production if needed etc...and go another 90 days. I believe his response was to someone worried about buying a first year redesign. His logic was that really only the first production batch is 'green' but steadily improves/updates for each production quarter. Seems to make sense in my head...much cheaper to offer a recall on a small batch then when something gets away for 8 model years and you recall millions of vehicles.

 

[Kukailimoku]

If I can find the post I'll link it here and who knows if the 'guy' knows what he's talking about but...in another thread someone mentioned that they have for example a 90 day run...make minor adjustments to production if needed etc...and go another 90 days. I believe his response was to someone worried about buying a first year redesign. His logic was that really only the first production batch is 'green' but steadily improves/updates for each production quarter. Seems to make sense in my head...much cheaper to offer a recall on a small batch then when something gets away for 8 model years and you recall millions of vehicles.

Makes sense.