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QRQC
Verification MEETIN Communication
G
Analysis
Agenda of the day
Introduction (Greeting)
Presentation of today's objective by KK.
Presentation of QRQC once again by Branch Quality Director
20 minutes by Division Manager of this site
1. Introduction on Division QRQC deployment progress
2. Show deployment and efficiency program
Observation of QRQC 1st example 50 min. on shop-floor (Line Level or APU
Level QRQC)
Coffee Break
Explanation of how to do Line QRQC
1. How to select the Problem
2. How to Assign
3. How to Analyze
4. How to Confirm
Lunch time with supervisor and APU managers
Observation and suggestion in same time for QRQC 2nd example 60 min.
(Plant Level QRQC)
Explanation of how to do QRQC at APU and Plant Level
Coffee Break
Conclusion of how to do Division Director's OJT (On Job Training)
Wrap-up meeting to decide Division Manager's Management Task
Modified 12 March 03 1
Output expected
Modified 12 March 03 2
Output expected
Modified 12 March 03 3
Output expected
Keywords :
• Applauding people,
• Getting better Relationships,
• Learn from Gemba
Customer's
No No Logic
Voice Slow
Responsibility to Improve
Analysis
(System)
Post Mortem
Analysis
Modified 12 March 03 6
Understand QRQC
Auto Quality
Matrix
Weekly Red Box
Report
FTA
Control
5 Whys
Red Project
Report Management
PDCA
ISHIKAW
A
5 Whys
INDICATOR
S
QRQC
VALEO 1000
5 axes
Modified 12 March 03 9
SAN GEN SHUGI
Modified 12 March 03 11
How to do QRQC?
QRQC EDUCATE…
CORRECTIVE
ACTION
EDUCATE…
IMPLEMENTATION EDUCATE…
CHECK THIS IS DAILY
ON JOB
Detection TRAINING!
(OJT)
QRQC
Verification MEETIN Communication
G
APPLAUDE
OR Analysis
REQUEST MORE LISTEN AND
DATA UNDERSTAND
Modified 12 March 03 12
QRQC Deployment status
Discussion
Modified 12 March 03 13
Example on Shop floor
Modified 12 March 03 14
How to do QRQC in Line ?
Detection
Red Box
Control
Communication
Verification LINE AQM
Confirmation QRQC Quick Response
For action Action Plan board
QUICK RESPONSE ACTION PLAN
Analysis What happened ? What is root cause ? What are C/M ? What are expectations Resp When
Who attends ? :
- Operators with Supervisor and Team Leader
What ? :
- Treat line problems
When ? :
- Each time a problem happens on the line, after stopping the line
- In the 5" meeting every operator would be convinced what they shall do
today
How ? :
- Using a simple paper board near the line (Quick Response Action Plan
board) :
What is the problem ? What is the root cause ? What is C/M? What is Expectation? Responsible? Date ?
Modified 12 March 03 16
How to do QRQC in Line?
QUICK RESPONSE ACTION PLAN
What happened ? What is root cause ? What are C/M ? What are expectations Resp When
Use a simple
paper board,near the line.
It is filled in by hand by
team leader or supervisor,
with operators
Modified 12 March 03 17
How to do QRQC in APU ?
Detection
Select 3 main
concerns from
QRAP
Communication
Verification APU Assignment
QRQC sheet
Analysis
PDCA
FTA
QRQC APU ASSIGNS actions for main problems
that are not solved at line level
Modified 12 March 03 18
How to do QRQC in APU?
Who attends ? :
- APU Manager and APU Quality
- Plant Manager & Quality Manager
- Supervisors
- Method, Maintenance
- Others as required : SQA, Project, Logistics…
Contents :
- Review impact of yesterday’s actions
- Review 3 most important problems of the APU (Choice done by APU Manager,
Importance is based on criticity, complexity, recurrence and quantity of parts)
When ? :
- Every day
How ? :
- Using presentation boards with following information :
- Action rules
- Quality consolidated results of APU
- Results split by APU’s : for each APU, have every day result of the month, and monthly results
- Assignment sheets for 3 main concerns
- Answers to 3 concerns
- Confirmation system and knowledge sharing
Modified 12 March 03 19
How to do QRQC in APU : Example
Line 1: OK Line 2 : OK
PPM Data A PPM Data A
Answer with
assignement
PPM Data B PPM Data B sheet
Consolidated data
of APU by shift Line 3 : OK Line 4 : NOK
Data A: data per month
PPM Data A PPM Data A
Data B: Data per day
of month
PPM Data B PPM Data B
Generalization
Consolidated data Capitalization
of line by shift
Data A: data per month
Data B: Data per day
of month
Have defective
parts available
Modified 12 March 03 20
How to use Assignment sheet ?
FILL-IN B. CUSTOMER ISSUES =
CRITICITY ACTUAL OR RISK OF:
LEVEL 1 OFFICIAL CUSTOMER
COMPLAINT OR RESIDENT
ALERT
2 LINE RETURN
A. SAFETY ISSUES =
ACTUAL OR RISK OF: 3 WARRANTY RETURN
APU QUALITY
1 HUMAN DAMAGE SELECTS ISSUES AND REGISTER
THEM PRIOR TO QRQC:
2 VEHICULE DAMAGE
A SAFETY ISSUES
B CUSTOMER COMPLAINTS
C LOSS OF COMMERCIAL VALUE
D OTHER
Standard I Difference
Modified 12 March 03 22
How to use FTA (Factors Tree Analysis) ?
Standard I Difference
Modified 12 March 03 23
How to use FTA (Factors Tree Analysis) ?
Judgement / Observation
Standard : Is it the right standard?
Is it clear ?
Quality : Is there any difference
or deviation ?
Standard I Difference
Judgement can be :
O : No difference
X : Difference vs standard These are all the
: Doubt (there is no difference, Different conclusions
but 1 specific peak) that may come out
from Observation and
comparaison of
Real Data vs Standard
If judgement is OK from
standard and quality points
of view, no action is needed.
If judgement is OK versus
standard but not OK versus
quality, we need to analyze
more deeply
Modified 12 March 03 24
How to use FTA (Factors Tree Analysis) ?
Modified 12 March 03 25
How to do QRQC in Plant ?
Detection
ALL Customer
claims
Analysis
PDCA
FTA
Who attends :
- Division Manager and Division Quality Manager (when present on site)
- In case of customer claim, ALL Managers must attend
What :
- Check results of plant and APU’s that have bad results
- Review of customer claims, (customer returns, warranty returns, etc)
using PDCA formats
- Sharing experience/ training between APU’s
When ? :
- Every day
How ? :
- Using presentation boards with following information :
- Action rules
- Quality consolidated Results of plant
- Results split by APU’s : for each APU, have every day result of the month, and monthly results
- Assignment sheets for 3 main Customers claims
- Answers to 3 concerns
- Confirmation system and knowledge sharing
Modified 12 March 03 27
How to do QRQC in Plant: Example
APU 1: OK APU 2 : OK
PPM Data A PPM Data A
Answer with
PPM Data B PPM Data B PDCA formats
Consolidated data
of plant by shift APU 3 : OK APU 4 : NOK
Data A: data per month
PPM Data A PPM Data A
Data B: Data per day
of month
PPM Data B PPM Data B
Generalization
Consolidated data Capitalization
by APU by shift
Data A: data per month
Data B: Data per day
of month
Have defective
parts available
Modified 12 March 03 28
On Job Training “OJT” program for
Division Director
Targets are :
Doing OJT
Modified 12 March 03 29
On Job Training “OJT” program for
Division Director
OJT program has to be organized by HR, who
Informs team leaders/ supervisors some weeks
before
Rules are :
- Programmed day
- 1 line
- 1 subject
- 1 Question : “What did you improve yesterday?”
- Use presentation method in the line
As San Gen Shugi Culture
Modified 12 March 03 30
How to capitalize from QRQC ?
Modified 12 March 03 31
Steps of QRQC
QRQC will be deployed in several steps.
We want a deployment in all sites worldwide at the same time to ensure a
consistent culture change.
When Step1 will be effectively achieved, we will define simple rules for Step 2
At the end, we will have a full roadmap.
Modified 12 March 03 32
WHERE ARE WE AT ?
Implementation as of end of 2002
Site N° APU N° Line N°
Branch
Applied Applied Applied
VT 13/19 27/33 122/174
VCC 10/10 13/25 50/126
VEC 12/17 42/50 29/148
VLS 9/16 20/31 19/217
VES 8/8 24/24 0/80
VWS 13/13 36/38 38/405
VMA 4/6 15/15 54/71
VSS 5/9 18/23 136/260
VSDS 9/9 21/25 61/199
VECS 0/20 35/41 0/243
VS 5/7 NA NA
Implementation as of 20/02/03
88% 92%
100% 65% 64%
75% 29%
50% 26%
25%
0%
Line APU Plant
Modified 12 March 03 33
Steps of QRQC : Step 1
Activities Y/N Action to improve
Information -Are complex issues broken down in smaller issues that can be treated
quickly?
-Are the 3 main issues of yesterday’s production reviewed with
management? These steps
-Are Customer line returns communicated to production site within 4
hrs of customer notification and with 5W2H & picture or drawing?
Are made for
-Are assignment sheets systematically used for assigning tasks? APU level.
-Are PDCA’s used in addition to assignment sheet for customer line
returns & complex internal issues? Similar steps
Analysis -Are APU QRQC meetings run daily GEMBA by APU manager?
will be done
-Is analysis always based on comparison: good/bad real/std for
shift1/shift2 day1/day2…? and no conclusion proposed without facts?
-Are bad/good parts always in hand? line and plant
-Have operators been involved?
-Is FTA and 5 Whys used for recurrent issues? level
Management -Are plant manager and quality manager attending APU QRQC every
day, touring all APUs at least once in a week?
-Are division manager and division quality manager lead QRQC
meetings when on site?
-Have the plant manager, the APU manager or the Supervisor done
something concrete yesterday to improve quality?
-Do management congratulate team when issue is solved?
Modified 12 March 03 34
Your homework : 1 page,
within 2 weeks
Modified 12 March 03 35
Conclusion
Weekly Reporting