How to Build-in Quality - Value Chain Competitiveness (VCC) - Version 2 February 2020

Sep 12, 2026

Upload by Maeve

Guidance for implementing Rolls-Royce Build-In Quality (BIQ) within a Value Chain Competitiveness (VCC) context. The document explains BIQ objectives and principles aimed at meeting customer requirements through Zero Defects and Right-First-Time. It contrasts prevention and detection, emphasizing error-proofing, early detection near the point of cause, and stopping defects before they occur. It details prerequisites such as PFMEA inputs and describes how to conduct PFMEA by mapping failure modes, effects, causes, and prioritizing countermeasures using risk measures like RPN.

LanguageEnglish

CategoryPresentations

FormatPDF

Pages29

Reading Time10 min

AccessFree to download

How to Build-in Quality

Value Chain Competitiveness (VCC)

Scope and Objectives & Principles

BIQ through Effective Process Control

The Essence of BIQ

The Need for BIQ

Current State Problem Solving

Opportunity and Problem Prevention Activity

Prerequisites

Conduct PFMEA

Identify Failure Modes, Effects and Causes

How to Build-in Quality Value Chain Competitiveness (VCC) Version: 2 February 2020 This information is provided by Rolls-Royce in good faith based upon the latest information available to it; no warranty or representation is given; no contractual or other binding commitment is implied. How to Build-in Quality Map Scope Objectives & Principles 4. Compile the Control Plan Prerequisites Gate Checklist Gate Checklist Gate Checklist Gate Checklist Gate Checklist End © 2020 Rolls-Royce Scope Map This ‘How To’ will enable you to: • Understand the key principles behind the ‘Build-In Quality’ (BIQ) approach • Join-up key activities to deploy a robust Quality Assurance System • Familiarise yourself with typical ‘Build-In Quality’ tools and their use • Focus on Prevention vs. Detection • Design, implement and continuously improve the ‘Built-In’ Quality Assurance System © 2020 Rolls-Royce Objective and Principles Map To ensure that process outputs meet or exceed Customer requirements • ‘Zero Defects’ • ‘Right-First-Time’ A joined-up approach where the following are known and understood: • Product or service related risk-Design Failure Mode & Effects Analysis (DFMEA) • Process related risk-Failure Mode & Effects Analysis (PFMEA) • Necessary controls for materials, equipment and process (Control Plan) • Measurement System capability • Effective instruction and deployment of the above (Work Instructions) © 2020 Rolls-Royce Objectives and Principles – BIQ through BACK effective process control Input Process variables Checking X variables Process outputs only X X Designing a process and checking its outputs will at best highlight non-conformance and possibly help us to protect our customers. © 2020 Rolls-Royce X P P Objective and Principles – the essence BACK of BIQ Designing a process, and checking the output of the product, will only permit rework and scrap. X X Process variables P Checking outputs only Designing a process that has all the controls built-in to assure quality of inputs and process variables will permit the supply of good product to the customer, right-first-time. The priority in BIQ is to prevent non-conformance by error proofing. If not practical, then by detecting the causes of nonconformance and stopping the process before a defect occurs. As a minimum, any non-conformance that may occur should be detected early and near to the point of cause. These controls must be developed at the earliest possible stage in process and product development to allow all the equipment, tooling, fixturing and measurement devices to be specified such that they contain or effect these controls. Process Map P Defined, understood and controlled input variables P Defined, understood and controlled process variables Process P Results in greater process capability and right first time © 2020 Rolls-Royce Objective and Principles-the Need for BIQ BACK Map NEXT Current State Problem Solving First In Parts Service 􀁕 Lack of a process for identifying and resolving potential and actual problems early results in the need to develop the process and hence product during full production 􀁕 Effort is expended on returning to standard, not in cost reduction or improvement Opportunity Problem Prevention Activity First In Parts Service ✓ Build in Quality identifies the need for process control before parts are made ✓ Actively seeks out potential problems using PFMEA ✓ Error-proofs the process ✓ Controls the process using measures documented in a Control Plan © 2020 Rolls-Royce Prerequisites Map Knowledge of: • Existing or proposed manufacturing process (for current / new product) • Key product features including control features specified by Design Engineering • Any available DFMEA output studies to support process risk assessment (PFMEA) • Current / other

FAQs

What is the main purpose of Build-In Quality (BIQ)?

To ensure process outputs meet or exceed customer requirements through Zero Defects and Right-First-Time. BIQ uses a joined-up approach covering product and process risks and the controls needed to manage them.

How does BIQ differ from checking outputs only?

Checking outputs only mainly highlights non-conformance and leads to rework or scrap. BIQ focuses on building controls into the process so quality is assured in inputs and process variables to deliver good product right-first-time.

What are the prerequisites to conduct BIQ and PFMEA?

The approach requires knowledge of the manufacturing process, key product features and design-specified control features, available DFMEA studies for process risk assessment, and current or historical quality performance data.

Sep 12, 2026

Upload by Maeve