Value Stream Q-Basics in the supply chain

Value Stream Q-Basics

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 Value Stream Q-Basics in the supply chain

We want
our customers
to be happy!

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

We are looking for basic in Quality standards

A standard is the best method to carry out an activity which is defined clearly,
described in simple language & visualized

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 Value Stream Q-Basics in the supply chain
Principle 1

Customer complaints are communicated within the production site and

displayed at the station in question.
Using problem-solving techniques, they are processed in a fast and systematic
manner. IPN production sites are promptly informed.

How is the awareness of customer complaints? Horizontal deployment of actions ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 1

A STOP sign process with all of the 8D elements is

displayed on the shop floor. A standard review process
involving the production management and quality
management takes place. The decision to end the STOP
sign process is taken by production management after a
review of the measures’ effectiveness.
It is necessary to ensure that customer complaints are
communicated quickly within all IPN value streams.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

8.5.2
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.3.1, 6.5.3, 7.4

Q-Basics Value Stream

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Value Stream Q-Basics in the supply chain

6
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 Value Stream Q-Basics in the supply chain
Principle 2

In the event of deviations in quality or if control limits are exceeded

in the value stream (source, make, deliver), the employee needs
to stop the process and escalate.

Empowerment of operators ? Is there a system to communicate on-time ?

How strong is the incoming inspn. at suppl. ? Is there short control loops ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 2

There is a system (e.g. Andon cord) in place that

allows the operator, if he notices deviations, to
choose to stop the process and notify his supervisor
immediately. Deviations can occur if control limits are
exceeded, and also based on subjective observations
(for example, the power screwdriver is not running
smoothly, material has been funneled into the
incorrect chute, or the associate is not working to the
standards set). After stopping the system there needs
to be a well-defined process governing the restarting
of the system. The process then has to be released
by the shop floor management.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

8.3
Process audit: Mapping to VDA 6.3 (2010)
6.3.1, 6.2.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

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 Value Stream Q-Basics in the supply chain
Principle 3

Security, health, production, and inspection instructions are complied with.

5S standards are put in place and observed.

Is the work instructions comprehensive in nature ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 3

The production and inspection instructions are clearly

visible at every station. A consistent set of symbols is
available, the right/left hand movement becomes
evident from the instruction. The error modes from the
FMEA and special characteristics from the control plan
are taken into account. Detailed photos support the
process. There is a feedback loop in place that
ensures the consistency of the control plan, FMEA,
and directions. Health and safety instructions are
carried out according to the plan. Participation is
compulsory and will be documented. All deviations
shall be resolved using the 8D method.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

For HSE and 5S: 6.4, 6.4.1, 6.4.2
For production and inspection instructions: 7.5.1, 7.5.1.2
Process audit: Mapping to VDA 6.3 (2010)
6.4.3, 7.4

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

Input

Input

Input
Input

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 Value Stream Q-Basics in the supply chain
Principle 4

The target values/tolerances for all stated process parameters are observed.

Is there monitoring of process parameters? Is the process parameters adjusted

by authorized persons ? Access protected ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 4

All process parameters that affect product quality are

clearly defined and systematically checked on basis of
the control plan. All required inspection criteria are
implemented according to specification. Process
validations are performed to determine whether target
values/tolerances of the defined parameters have been
observed. Deviations are systematically recorded and
eliminated.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.5.1, 7.5.1.1, 7.5.1.3, 8.1, 8.2.4
Process audit: Mapping to VDA 6.3 (2010)
6.2.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

• Risk if the process parameters are not maintained to be

Mitigated through FMEA
• Limits for all critical parameters to be identified in
control plan & to be visualized on the instrument .

•This makes it easy for the operator/supervisor to check &

escalate at the appropriate moment.

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 Value Stream Q-Basics in the supply chain
Principle 5

Measuring and test equipment is defined, and monitoring intervals are

observed.

Is the Inspection frequency followed as per control plan ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 5

The type of measuring and test equipment and its

uses is defined for all processes in the control
plans.
All measuring and test equipment is calibrated and
only utilized with valid inspection certificate sticker.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.6, 7.5.1.1
Process audit: Mapping to VDA 6.3 (2010)
6.4.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

Input from CDQ1001 & 1002 Instructions for

Input from Norm N51…. checking Master

Gauges Instruments Masters

Validation sheet
for Master

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 Value Stream Q-Basics in the supply chain
Principle 6

The “check the checker” principle is applied, and the “checker’s” suitability is
ensured.

Can the checker identify deviations or failures in the process ?

Poka yoke validation, Visual inspector - Poison test

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 6

The suitability of processes used to prevent or detect

errors (e.g. camera-monitored processes, sensor-based
measurements, inspection processes) needs to be
checked according to a predefined standard. Possible
errors, such as loading the incorrect camera
software/testing program or improper sensor
calibration, need to be prevented by carrying out the
inspection. These inspection processes, as well as
maintenance and set-up processes, need to be
evaluated using appropriate methods (e.g. FMEA).
Generally speaking, mistake-proofing is always
preferable to error detection (e.g. Poka Yoke).

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

8.2.3.1, 8.5.3, 7.6.1
Process audit: Mapping to VDA 6.3 (2010)
6.4.2, 4.7, 6.3.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

• List of Implemented Poka Yoke ?

• Visualization of Poka Yoke station ?

Instructions for
checking Poka yoke

Validation of Poka yoke

- Checklist

Poka yoke Masters

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 Value Stream Q-Basics in the supply chain
Principle 7

A maintenance standard is installed and observed at every station.

Is there TPM implemented or Is there a strong maintenance system in place ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 7

The four-pillar TPM model, particularly the

autonomous and preventative maintenance,
is instituted at every station. This contains
both the roles and responsibilities for
production and the supporting areas.
Systematic damage and dirt built-up on
machinery and device components need to be
consistently analyzed, recognized, and
remedied.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.5.1.4
Process audit: Mapping to VDA 6.3 (2010)
6.4.1

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

1. Bottleneck Machine/’s identified

2. Hourly monitoring sheet introduced on all critical & bottleneck processes

Critical spares mgmt.

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 Value Stream Q-Basics in the supply chain
Principle 8

Each tool has a defined service life; the current status must be recognizable.
A quality evaluation must be carried out during removal or disassembly.

Is the status of tool life evident & visible at the machine ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 8

The current service lives of all tools have been

recorded. A warning system promptly displays when
tools need to be serviced or replaced. Each tool needs
to be inspected when removed or disassembled to
check for damage/ wear and tear. In case of deviations,
it is necessary to follow measures to ensure product
quality is maintained. Restart is performed according to
clearly defined rules (see Principle 9); the standard is
regularly reviewed.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.5.1.5
Process audit: Mapping to VDA 6.3 (2010)
6.4.1

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
•Tool/Fixture wear out part trials carried out to
fix the life
•Tool/Fixture Supplier recommendation
considered

Wear out parts periodical check

Auto Tool life monitoring

Manual Tool life monitoring

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 Value Stream Q-Basics in the supply chain
Principle 9

Restart after disruptions is clearly regulated for all machinery and equipment.

Is there a Re-start procedure and Is it known to shop floor personnel ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 9

Each disruption to the continuous production process (set-up,

break, shift change, maintenance, power failure, upgrade)
presents a potential risk to quality. Downtimes can alter
process parameters, workflow sequences may change, and
the consistency of material and supplies can change. A
predefined standard for post-restart is therefore necessary.
This should detail how to deal with products in the process
after a disruption. All devices have been inspected according
to a defined standard for quality risks in connection with
disruptions (for example, an unplanned disruption to the
welding process, the injection molding process stops
unexpectedly, a product remains in thermal treatment for too
long, the silicone bead is exposed to the air for too long). The
standard also includes the analysis of critical wear parts (for
example, drill bits or welding electrodes). Following longer
disruptions (e.g. station upgrade), it is necessary to newly
release the process and carry out a process audit.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.2, 7.5.1.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

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 Value Stream Q-Basics in the supply chain
Principle 10

Products and containers are labeled according to the set standard.

Is the identification standard known to all shop floor personnel ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 10

The following criteria must always be adhered to:

- No rejected parts in the green box
- No good parts in the red box
- Rejected parts in the red box
- Consistent labeling concept at the production site:
A white card with a red diagonal stripe means: Product blocked;
a green card means: Product after additional test back in
production flow and in good condition; a yellow card means:
Product for rework; a red card means: Product is scrap;
a white card means: Product in good condition.
- Filled boxes must always be labeled.
- Products are protected against environmental influences
(e.g. contamination) in line with regulations.
- Red boxes must be secured and inaccessible on the
production line (either by locking them or placing them
at the proper location at the station; hint: red boxes may be sent
unlocked from the machine to the analysis station);
storage at the analysis station or in the collective rejects
container only in locked boxes.
- Containers for rejects must be emptied in line
with standards and the parts must be analyzed.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.3
Process audit: Mapping to VDA 6.3 (2010)
6.1.4, 6.2.5

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

Examples : Identification, Arrangement, Visualization of parts

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 Value Stream Q-Basics in the supply chain
Principle 11

The handling of rejected parts and those to be reworked is clearly

regulated.

Is there a re-work procedure & Is it known to shop floor personnel ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 11

As a basic rule, rework has to be avoided and is

only permissible if a respective procedure exists. If
rework is permitted the following conditions must be
met:
- an FMEA and a control plan for reassembly
and reintroduction exist,
- rework takes place on the original assembly line,
- rework is limited in time.
If the rework process is permanently required,
this must be transferred to a standard process;
approval by GB/QM.
Scrap must be disposed of in line with the standard
and unauthorized further use of these products
must be prevented (for example, by destroying
them.)

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

8.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

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 Value Stream Q-Basics in the supply chain
Principle 12

Any products that fall on the floor, into the machine or cannot be classified
must be scrapped.

Is there awareness across the organisation about how to handle

fallen parts ? (Right from sweeper to CEO)

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 12

Each individual employee must adhere to this

standard regardless of what part of the organization
he/she belongs to or his/her position within the
company.
The shop floor management must be notified. The
products must be scrapped according to procedure.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

8.3.1
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

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 Value Stream Q-Basics in the supply chain
Principle 13

Only the correct product may be provided for removal and assembly.

Is there a system which ensures right parts are available as per

production schedule ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 13

Only the correct product may be available to the

associate at the time of assembly. All other
variants or versions that are stored at the
assembly station must not be accessible to the
employee.
It is furthermore necessary to ensure, across the
entire logistics chain, that only the correct product
is retrieved or available.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.5.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

Shims of different sizes

Rollers of different size

‘O’ rings of different material Nylon washers

of different size

• Only Authorized personnel to handle parts

• Access control into production areas & Material Stores where ever possible
• Special badges designed to visualize persons who handle material
• Role based trainings for personnel who handle material logistics
• Visualization of material very transparent & clear for better identification
• Include part photos where ever possible

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 Value Stream Q-Basics in the supply chain
Principle 14

The handling of remaining items/ quantities is clearly regulated.

How are the left-over parts handled in the value stream ? How are the parts
handled during engg. changes ?

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain
Principle 14

Remaining quantities must be clearly labeled and

stored securely (using the accompanying card/on the
correct shelf). The “First In, First Out” principle must
be observed. Close attention must be paid to ensure
tidiness and cleanliness as the goods have yet to be
placed in the final packaging. Maximum storage
times must not be exceeded. The quantity of
remaining items must be taken into consideration
with regard to engineering change requests.

System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)

7.5.5.1
Process audit: Mapping to VDA 6.3 (2010)
6.1.2

Q-Basics Value Stream

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 Value Stream Q-Basics in the supply chain

• When supermarkets are planned , a procedure is made for handling parts

which are returned from immediate customer !

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 Value Stream Q-Basics in the supply chain

How to check all these at shop floor ? Assessment

Who has to check what ? By Supplier, By Bosch

What should be the frequency of checks ? Review frequency

After the check, How should the results be used ? LPC check by supplier

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 Value Stream Q-Basics in the supply chain

LPC checklist sample (Only for sustenance check)

Operator/ Shift
Process Engineer/ Month

Supervisor/ week

Manager/ Month

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 Value Stream Q-Basics in the supply chain

Customer complaints are commun- In the event of deviations in quality Security, health, production, and The target values/tolerances for all
icated within the production site and or if control limits are exceeded in the inspection instructions are complied stated process parameters are
displayed at the station in question. value stream (source, make, deliver), the with. 5S standards are put in place observed.
Using problemsolving techniques, employee needs to stop the process and and observed.
they are processed in a fast and escalate.
systematic manner. IPN production
sites are promptly informed.

Measuring and test equipment is The “check the checker” principle A maintenance standard is installed Each tool has a defined service Restart after disruptions is clearly
defined, and monitoring intervals are is applied, and the “checker’s” and observed at every station. life; the current status must be regulated for all machinery and
observed. suitability is ensured. recognizable. A quality evaluation must equipment.
be carried out during removal or
disassembly.

Products and containers are labeled The handling of rejected parts and Any products that fell on the Only the correct product may be The handling of remaining items/
according to the set standard. those to be reworked is clearly floor, into the machine or cannot provided for removal and assembly. quantities is clearly regulated.
regulated. be classified must be scrapped.

Version 1.2

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 Value Stream Q-Basics in the supply chain

Thank You

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