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Detection

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

 Understand what is QRQC


 Why QRQC has been required for Valeo ?
• Key word : “What have you improved yesterday ?”

• Concept : QRQC has been put in place to counter


our main weaknesses
It should be always done, based on San Gen Shugi

Modified 12 March 03 2
Output expected

 How to do QRQC in Line,


APU and Plant ?
 Red Box, QCDM, Auto Quality Matrix are needed as
tools
• Key words :
Who should be the teachers to establish our own
culture?
• Concept :
Daily action and training = On Job training

Modified 12 March 03 3
Output expected

 Do On Job Training “OJT”


Why do you need to do “OJT” ?

Keywords :
• Applauding people,
• Getting better Relationships,
• Learn from Gemba

Concept : Build your strong team


• Getting motivation
• Making fair promotion
Modified 12 March 03 4
 Understand QRQC

Before talking QRQC :

Let’s be aware of our situation and weaknesses

Let’s change our thinking way

THIS IS HOW WE CAN SUCCEED!


Modified 12 March 03 5
 Understand QRQC

Customer's
No No Logic
Voice Slow
Responsibility to Improve
Analysis

(Strategy) Weekly Management


Management Skill Report
(Structure)
Quality Control
and System
QRQC FTA

(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 San Gen Shugi7


GROUND
 Understand QRQC

Thierry Morin commented :

On 01/02 : “Quality is one of the biggest


weaknesses of our Company”

On 07/02 : “We will change our Culture,


based on San Gen Shugi”

On 10/02 : “Every site needs to apply QRQC and


San Gen Shugi”

WE NEED TO USE QRQC !


Modified 12 March 03 8
 Understand QRQC

What are the methodologies to be able to do Real QRQC?

I have only two methodologies: my eyes and my legs.


These are all I need to see, to judge, to consider, to decide.

This is the basis of “SanGenShugi”. . .


(Kazuo Kawashima, Valeo Group Quality Director
Valeo Info, June, 2002)

Modified 12 March 03 9
SAN GEN SHUGI

San means "3" - Gen means "real" or "actual" -


Shugi means "ideology"

San Gen Shugi


Understand what is behind
1. Real Place (Gen-ba) on shop floor

2. Real Parts (Gen-butsu) with real bad parts

3. Reality (Gen-jitsu) with data


Modified 12 March 03 10
 Understand QRQC

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

APPROVE COACH USING


QRQC
SHANGENSHUGI!
ASSIGNMENT
SHEET

Modified 12 March 03 12
QRQC Deployment status

20 minutes for Division Manager:

 Introduction on Division QRQC deployment


progress

 Show deployment and efficiency program

 Discussion

Modified 12 March 03 13
Example on Shop floor

Let ’s go to the Genba ! :


Line QRQC / APU QRQC

Observation of QRQC 1st example


50 min on shop-floor
Feedback

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

Stop the line


To analyze

QRQC Line makes ACTIONS to solve problems


immediately
Modified 12 March 03 15
 How to do QRQC in Line ?

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

Rules that explain the APU 1


organization of APU PPM Data A
Problem
QRQC and Division
Director's Message Pbm 1 Pbm 2 Pbm 3
PPM Data B

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

C. LOSS OF COMMERCIAL VALUE


•PARETO OF INTERNAL
PROBLEMS, RANKED BY COST
•ADD ONLY IF LESS THAN 3 OPEN
ASSIGNMENTS
Modified 12 March 03 21
 How to use FTA (Factors Tree Analysis) ?

1. We first used FTA to understand “Why the problem happened?”

Standard I Difference

Why the 4. Compare the real


problem data and measurement
versus the standard.
happened ?
If there is a difference between the real
data and the standard, we must consider this as
a POTENTIAL cause which will be 3. Verify the
analyzed by using the 5 Whys standard (technical
specifications, data
1. Define with tolerances, etc.)
Factors based 2. Define
on 4M’s control points

Modified 12 March 03 22
 How to use FTA (Factors Tree Analysis) ?

2. We used a second FTA to understand “Why the problem was not


detected?”

Standard I Difference

Why the If there is a difference between the real


problem was
data and standard, we must consider this as
not detected?a POTENTIAL cause which will be
analyzed by using the 5 Whys

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) ?

At this point, we determine


Why the problem
occurred.

For each item on the Factor Tree


Analysis that received an “X”,
Ask 5 times Why and verify
Each action until you have found
the root cause - make sure you
verify with DATA!

Modified 12 March 03 25
 How to do QRQC in Plant ?

Detection
ALL Customer
claims

Verification PLAN Communication


by Plant Mgr's T Assignment
San Gen Shugi Action QRQC sheet

Analysis
PDCA
FTA

QRQC Plant checks and approves PDCA’s for ALL


customers claims in presence of Management
Modified 12 March 03 26
 How to do QRQC in Plant ?

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

Rules that explain the Plant


Customer
organization of APU PPM Data A Claims
QRQC and Division
Director's Message Pbm 1 Pbm 2 Pbm 3
PPM Data B

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 :

Promote QRQC by Division Director

Doing OJT

And then you'll applaud and recognize efforts


made

Finally you can learn from Gemba

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 ?

Capitalization is done through :

A of PDCA : through real One Problem to find out common


weakness

Link with R&D activity : Quick Response Projects Control

FMEA should be improved by PDCA analysis


(“Yoko Ten”, Toyota terminology)

Plant QRQC (for transversal activities)

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.

Step 1 objectives are:


> to involve management daily in the problem solving process
> to increase our detection, information, analysis and verification abilities
> to establish QR(Project)C
> to establish QR(Safety)C
> to establish QRSQC to manage issues with suppliers
… simultaneously

The objectives of next steps will be:


> Make Quality Assurance (QA) matrix to validate the percentage of efficiency
of action plan

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

Detection -Do we have red boxes and segregation areas?


-Do we have AQM or other means when AQM is not applicable?
-Do we have in each product lines daily updated defects tracking
charts with objectives and history?
-Is defective part properly identified to make the defect location
obvious ?

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

Verification -Is implementation checklist systematically used and verified on


GEMBA?
-Is a chart used to track the evolution of the defects followed in QRQC
meeting?

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?

Total number of Y answers /20

Modified 12 March 03 34
 Your homework : 1 page,
within 2 weeks

Your understanding of objective 1

Your understanding of objective 2


Your understanding of objective 3

Your Program for OJT

Next step comments

Modified 12 March 03 35
Conclusion

San Gen Shugi

Weekly Reporting

Factor Tree Analysis

Will you do it?


Modified 12 March 03 36