Detection

Q R Q
QRQC
C
Verification
r a i
MEETIN

in
G
n gCommunication

T
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 2
 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 3
 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 4
 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 5
  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 6
  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 7
  Understand QRQC

Auto Quality
Matrix
Weekly
Report
Red Box FTA
Control
5 Whys
Red Project
Report Management
PDCA
ISHIKAW
A
5 Whys

INDICATOR
S
QRQC
VALEO 5000
VALEO 1000

San Gen Shugi

5 axes
GROUND
Modified 12 March 03 8
  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 9
  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 10
 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 11
  Understand QRQC

u r y, P ro j e cts,
y s te m : it is o a r e a: I n dustr
i s n o t a tool/s i ed in e very
QRQC w i ll b e ap p l
ct iv it y that , etc
lt ur e / A o g is t i cs
Cu F in a n ce , L
s, HR ,
Supplier

Modified 12 March 03 12
 QRQC
 How to do QRQC?
CORRECTIVE EDUCATE…
ACTION EDUCATE…
IMPLEMENTATIO
N 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
QRQC COACH USING
SHANGENSHUGI!
ASSIGNMENT
SHEET

Modified 12 March 03 13
 QRQC Deployment status

20 minutes for Division Manager:

 Introduction on Division QRQC deployment

progress

 Show deployment and efficiency program

 Discussion

Modified 12 March 03 14
 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 15
  How to do QRQC in Line ?

Detection
Red Box
Control
Communication
Verification LINE AQM
Confirmation QRQC Quick Response
For action Action Plan board
Analysis
QUICK RESPONSE ACTION PLAN

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 16
  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 17
  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 18
  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 19
  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 ? : (30’ )
i me!
- Using presentation boards with following information :
e c kt
Ch
- 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 20
  How to do QRQC in APU : Example
Rules that explain the APU 1
organization of APU Problem
PPM Data A
QRQC and Division
Director's Message Pbm 1 Pbm 2 Pbm 3
PPM Data B AS SIGN MENT NU MBER:__ __ __ ___ __ __ __ _
C R IT IC ITY
LE VEL DAT E
P R EP AR ED:
D M Y MAX DATE
FOR
ANSW ER :
D M Y
A SS IGNM ENT FORM
C LASSIF YIN G P B PER LEVEL OF C RITICIT Y
A DEF EC T S R E LATE D T O SAF ET Y OR G OVE RNM ENT R EGULATION
B DEF EC T S R E LATE D T O C UST OMER ISSUES
ASSIGN MEN T N UMBER:__ _ ___ __ __ ___ __ _

A CTION PLAN AP PRO VED: M GR

(FOR A & B C RITIC ITY)
P LANT PLANT QA
M GR
C R ITIC ITY
LE VEL DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:
M Y
A SSI GNMEN T FORM
CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y
A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICI TY)
P LANT
MGR
PLANT QA
M GR

A SSIGNMEN T FO RM ASSIGN MENT IS SU ED TO C DEF EC T S R E SULT ING IN LOS S OF C OM ME R C IAL VALUE . ASSIGNMEN T IS SUED TO C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE C TS D OTHER DE FE CT S
P LANT P LANT QA * IF THE DE FE C T IS IN AP U MGR QUALITY * IF THE DE FECT IS IN APU MGR QUALI TY
C R IT ICIT Y
D M Y M AX DAT E D M Y CLASSIFYING P B PER LEVEL OF CR ITICITY Via: Via:
LE VEL DAT E A CTION PLAN AP PRO VED: MGR MGR C AT. A OR B , GE T C AT. A OR B , GET
FOR RE SULT OF CO N FIRMA TION VER SUS THE A NSWER AP U MGR S UPE RV . QUALITY TECH MGR RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
P R EP ARE D: A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION APP R OVAL FR OM T OP APP R OVAL FR OM TOP
ANS WE R : (FO R A & B C RITICITY)
B DEF ECTS R E LAT ED T O C USTO MER ISS UES MANAGER M ANAGER
A SSIGN MENT ISSUED TO C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE . - C ONF IR M IM MEDIAT ELY AFTER IMP LEM E NT ATION OF THE C OR REC TIVE ACTION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
D OTHER DEF E CT S
NO LATE R THAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
APU M GR QU ALI TY
SU BJ EC T: - APU QUALITY MUS T PR E-C HEC K A LL POINTS
SUB J EC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
Via : *IF THE DEF E CT IS IN
C AT. A OR B , GET D M Y AP PR OX. HR SHIFT LIN E AP T - APU MGR MUST PE R FOM ALL CHE CKS IN CAS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AND HR OF DATE AN D HR OF
APP R OVALF R OM TOP RESULT OF CO NFIR MA TIO N VER SUS THE AN SWER AP U M GR S UP ER V . QU ALI TY T EC H M GR - IF C AT. " C", AP U M G R MIGHT C ONFI RM ONLY 6 -15. - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
DE F EC T DE FE C T
M ANAGER A B C A B C
- CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, CU STO ME R C HEC KB Y QUALIT Y PER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
NO LATE R T HAN ONE W EE K AFTER . PAR T NUMB E R CO NF IR MATION DATE PAR T NUM B E R CONF IR MATION DATE
SUB JEC T: CONFIR MAT IO N C HEC KS CONFIR MAT IO N C HEC KS
- AP U QUALITY MUST PR E -C HEC K ALL P OINTS VE HIC LE VEHIC LE
D M Y AP PR OX. HR SH IFT LIN E APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" SUP PLIE R A B C SUPP LIER A B C
DA TE AN D HR OF
DE FE C T - IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. 1.- ¿ HA VE PARAM ETERS B EEN COR RECTED IN SAF./ OPE R. IN TR UCTIONS? 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?

Line 1: OK
A B C DE TECTE D AT P ROC ESS ST EP OP E RA TOR NAME DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME

M AD E AT P R OC ES S S TEP TEA M LE ADER NAME 2.- ¿ DO OP ERATIN G IN STRUC TIO NS M ATCH WITH Q UALIT Y CON TRO L PLAN? MADE AT P R OCES S STEP TEAM LEADER NAME 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?

Line 2 : OK
C US TOME R C HE C K B Y QUALITY P ER S HIF T /
P AR T NUM B E R
CONFIR MATIO N C HEC KS C ONFIR MATION DATE NU MBE R OF DE FE CT S NUM BE R OF DE FE CT S
3.- ¿ IS ALL DOCUM ENTATION COH EREN T? 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
VE HIC LE AC TION ON DEF EC TI VE PAR T S ACT ION ON DEFEC TIVE PAR TS
S UPP LIER A B C
4.- ¿ AR E THE INSTR UCTIO NS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.-¿ HA VE PAR AM ETERS B EEN CORR ECTED IN SAF./O PER . INTR UCTIONS? 1.- W HY DET EC T ED? DR AWING : 1.- W HY DETE C TE D? DR AW ING :
DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME
5.- ¿ AR E CR ITI CAL PO INTS C LEAR LY D ESCRIBED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?
2 .- ¿ DO OPER ATING INS TR UCTIO NS M ATCH WIT H Q UA LITY C ON TROL PLAN ?
M ADE AT P R OC ESS ST EP T EAM LEADER NAME
6.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH TH E OPER ATING INSTR UCTIO NS? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?
NUM BE R OF DE FECT S 3 .- ¿ IS ALL DO CUM ENTAT IO N C OH ERENT?
AC T ION ON DEF EC TIVE PAR T S
7.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH EXPEC TED CO R RECTIVE A CTION ? 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
4 .- ¿ ARE T HE INSTR UCTION S CLEAR ? 2.- DE FE C T DES C R IPT ION 2.- DE FE C T DESC R IPT ION
1.- WHY DETE C TE D? DR AWING:
8.- ¿ AR E OP ERATO RS AWARE OF THE DEF EC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?
5 .- ¿ ARE C RITIC AL PO IN TS CLEAR LY DE SC RIB ED?
9.- ¿ AR E OP ERATO RS AWARE OF THE EXP EC TED C OR RECT IV E ACTIO N? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?
6 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H THE O PER ATING INSTR UCTIONS?
10.- AR E THE N EW POI NTS CH ECKED? WITH GOOD METH OD AN D TOOLS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
7 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H EXPEC TED CO RR ECTIVE AC TION ? 3.- S UGGEST ION OF 3.- S UGGEST ION OF
2 .- DEF E CT DES C R IPT ION CO RR E C TIVE A CT ION C OR R E C TIVE A CT ION
11.- ¿IS THERE A VIS UA L A ID? 1.- ¿IS THER E A VIS UA L A ID?
8 .- ¿ ARE OPER ATO RS AWA RE O F THE DEFEC T?
12.- ¿IS IT P OSTED O N A V IS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?
9 .- ¿ ARE OPER ATO RS AWA RE O F THE EXPEC TED C OR RECTIVE A CTION?
"AN SWE R QU ICKL Y!" 13.- ¿IS TH E CONTENT CLEA R? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?
10.- AR E THE NEW P OIN TS CHEC KED? WITH GOOD METHO D AND TOOLS? A NSWER A NSWER

PPM Data A PPM Data A

3 .- S UG GE ST ION OF
C ORR E C TIVE AC T ION 1.-C AUSE: D RAWIN G: 14.- ¿IS IT C OHER ENT WITH THE CO NTENT OF THE C OR REC TIVE A CTIO N? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?
11.- ¿IS TH ER E A VISUA L AID?
15.- ¿H AS IT B EEN MODIFIED? 15.- ¿H AS IT BEEN MODIFIED?
12.- ¿IS IT POSTED O N A VISIB LE SP OT?
C OMM ENTS: COMM ENTS :
"A NS WE R QUI CKLY!" 13.- ¿IS THE C ONTENT CLEAR ? D ECISIO N OK OK OK DECISION OK OK OK
AN SWER
NG NG NG NG NG NG
1.-C AUSE: DR AWING: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO RR ECTIVE A CTION ?

15.- ¿HA S IT BEEN MODIFIED?

R E S ULT OF FOL LOW - UP AP U MGR S UPE RV . QUALITY TECH MGR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
CO MM ENTS: OK OK OK 2.- C OR RECT IVE A CTIO N 2.-C OR RECTIVE A CTIO N
D ECISION - P ERF ORM CHE CK1 M O N TH AF TER TH EC OR RECT IVE AC TION IMP LE MEN TATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
- IN CAS E O FC AT. "A ", MAK EFOR MAL REP OR T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
NG NG NG - IN CAS E OF CA T. " B" ,IF RES UL TO FFO L LOW6UP ISO K, SEN D AN O FF ICIAL CLO SU RE T O - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
CUS TOME R C US TOMER

RE SU LT OF F OL LOW - UP Y M D A CTION IF NG (NOT GO O D) Y M D A CTION IF NG (N OT GO O D)

AP U M GR S UP ER V . QU ALI TY T EC H M GR
2 .- CO R RECTIVE A CTION
- P ERF ORM CHEC K 1 MO N T H AFTER T HE C ORR ECTIVE AC TIO N IMPLEME N TATIO N. YE AR AND DATE OF YE AR AND DAT E OF
APU MGR S UPE R V. QUALITY TE C H MGR APU M GR S UPE R V. QUALITY TE CH M GR
- IN C AS E O FC AT. "A ", MA KE FOR MAL RE PO R T C ONF IR MATION C ONF IR MAT ION
- IN C AS E OF CAT. "B" , IF RE SU LTO F FO LLOW6UP IS O K, SEN D AN OFFIC IAL CLO SU RE TO COM MITM ENT DATE FOR D M Y COM MITM ENT D ATE FOR D M Y

Answer with
C US TOME R IM PLEMEN TED IM PLEMEN TED
COR R EC TIVE AC TION GEN ER AL DECIS ION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG
Y M D A CTIO N IF N G (NO T G O O D )
APU MGR SUPE R V . QUALITY TEC H MGR YE AR A ND D AT E OF
C ONF IR M AT ION
C OM MITM ENT DATE FOR D M Y
IM PLEMEN TE D
C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG

assignement
PPM Data B PPM Data B ASSIGN MEN T IS SUED TO
C R ITIC ITY
LE VEL DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:
M Y
A SS IGNMEN T FORM
CLASSIFYIN G P B PER LEVEL OF CR IT ICITY
A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE CT S
ASS IGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

ACTION PLAN AP PRO VED:

(FOR A & B C RITICITY)
P LANT
MGR
PLANT QA
M GR

ASSIGN MENT ISSUED TO

C R IT ICIT Y
LE VEL DAT E
P R EP ARE D:
D M Y M AX DAT E D
FOR
ANS WE R :
M Y
ASS IGN MENT FO RM
CLASSIFYIN G P B PER LEVEL OF CR IT ICITY
A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION
B DEF ECTS R E LAT ED T O C USTO MER ISS UES
C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE .
D OTHER DEF E CT S
ASS IGN MENT NU MBE R:__ __ __ ___ __ __ __ _

A CTION PLAN AP PROVED:

(FO R A & B C RIT ICITY)
P LANT
MGR
P LANT QA
MGR

ASSIGNMEN T IS SUED TO
C R ITIC ITY
LE VEL DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:
M Y
A SSI GNMEN T FORM
CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y
sheet
A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE CT S
ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICI TY)
P LANT
MGR
PLANT QA
M GR

Consolidated data
* IF THE DE FECT IS IN APU MGR QUALI TY *IF THE DEF E CT IS IN APU M GR QU ALI TY * IF THE DE FECT IS IN APU MGR QUALI TY
Vi a: Via : Via:
C AT. A OR B , GET C AT. A OR B , GET C AT. A OR B , GET
APP R OVAL FR OM TOP
RESULT OF CONFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
APP R OVALF R OM TOP
RESULT OF CO NFIR MATIO N VER SUS TH E ANSWER AP U M GR S UP ER V . QU ALI TY T EC H M GR
APP R OVAL FR OM TOP
RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
M ANAGER M ANAGER M ANAGER
- CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION, - CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
NO LATER THAN O NE WEEK AF TE R . NO LATE R T HAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
SUB JEC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
SUB JEC T: - AP U QUALITY MUST PR E -C HEC K ALL P OINTS
SUB J EC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
D M Y AP PR OX. HR SHIF T LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B " D M Y AP PR OX. HR SH IF T LINE APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AN D HR OF DA TE AN D HR OF DATE AN D HR OF
- IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5. - IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
DE FE C T DE FE C T DE FE C T
A B C A B C A B C

CUS TOM E R C HEC K B Y QUALITY PER S HIFT / C US TOME R C HE C K B Y QUALITY P ER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
PAR T NUM B E R CONF IR MATION DATE P AR T NUM B E R C ONFIR MATION DATE PAR T NUM B E R CONF IR MATION DATE
CO NFIR MAT IO N C HEC KS CO NFIR MATION C HEC KS CONFIR MAT IO N C HEC KS
VEHIC LE VE HIC LE VEHIC LE
SUPP LIER A B C S UPP LIER A B C SUPP LIER A B C
1.- ¿ HAVE PA RAM ETERS B EEN CO RR ECTED IN SAF./OPE R. INTR UCTIO NS? 1.-¿ HA VE PAR AM ETERS B EEN CO RR ECTED IN SAF./OPER . INTR UCTION S? 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?
DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME

MADE AT P R OCES S STEP TEAM LEADER NAME 2.- ¿ DO OPE RATIN G IN STRUCTIONS M ATCH WITH QUALIT YC ONTRO L PLAN ? M ADE AT P R OC ESS ST EP T EAM LEADER NAME 2 .- ¿ DO OPER ATIN G INS TR UCTIONS M ATCH WITH QUALIT Y C ONTRO L PLAN ? MADE AT P R OCES S STEP TEAM LEADER NAME 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?

of APU by shift
NUM BE R OF DE FE CT S 3.- ¿ IS ALL D OCUM ENTA TIO N C OHEREN T? NUM BE R OF DE FECT S 3 .- ¿ IS A LL DO CUM ENTAT IO N C OHEREN T? NUM BE R OF DE FE CT S 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
ACT ION ON DEFEC TIVE PAR TS AC T ION ON DEF EC TIVE PAR T S ACT ION ON DEFEC TIVE PAR TS
4.- ¿ AR E THE INSTR UCTIONS CLEAR ? 4 .- ¿ ARE T HE INSTR UCTIONS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.- W HY DETE C TE D? DR AW ING : 1.- WHY DETE C TE D? DR AWING: 1.- W HY DETE C TE D? DR AW ING :
5.- ¿ AR E CR IT IC AL POINTS CLEAR LY D ESCRIB ED? 5 .- ¿ ARE C RITIC AL POIN TS CLEAR LY DE SC RIB ED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?

6.- ¿ DOES ACTUA L P RO CESS MA TCH WITH THE O PER ATING INSTR UCTIO NS? 6 .- ¿ DOE S ACTUA L PR O CESS MA TCH WIT H THE O PER ATING INSTR UCTION S? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?

Line 3 : OK Line 4 : NOK

7.- ¿ DOES ACTUA L P RO CESS MA TCH WITH EXPEC TED CORR ECTIVE A CTION? 7 .- ¿ DOE S ACTUA L PR O CESS MA TCH WIT H EXPEC TED CORR ECTIVE AC TION? 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
2.- DE FE C T DESC R IPT ION 2 .- DEF E CT DES C R IPT ION 2.- DE FE C T DESC R IPT ION

8.- ¿ AR E OP ER ATORS A WARE O F THE D EFEC T? 8 .- ¿ ARE O PER ATORS AWARE O F THE DEFEC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?

9.- ¿ AR E OP ER ATORS A WARE O F THE EXPEC TED C OR RECTIVE A CTIO N? 9 .- ¿ ARE O PER ATORS AWARE O F THE EXPEC TED C OR RECTIVE A CTION ? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?

10.- AR E THE NEW P OIN TS CHE CKED? WIT H G OOD METHOD A ND TOO LS? 10.- AR E THE NEW P OINTS CHEC KED? WITH GO OD METHO D A ND TOO LS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
3.- S UGGEST ION OF 3 .- S UG GE ST ION OF 3.- S UGGEST ION OF
C OR R E C TIVE A CT ION C ORR E C TIVE AC T ION C OR R E C TIVE A CT ION
11.- ¿IS TH ER E A VISUAL A ID? 11.- ¿IS TH ER E A VISUAL AI D? 1.- ¿IS THER E A VIS UA L A ID?

Data A: data per month

12.- ¿IS IT PO STED O N A V IS IB LE SP OT? 12.- ¿IS IT PO STED ON A VIS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?

" AN S WE R Q U IC KLY!" 13.- ¿IS THE C ON TENT CLEAR ? "AN S WE R Q UIC KLY!" 13.- ¿IS THE C ON TENT CLEAR ? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?
ANSWER AN SWER A NSWER
1.- C AUSE: DR A WIN G: 14.- ¿IS IT CO HER ENT WIT H TH E CO NTEN T OF THE COR RECTIVE A CTION? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT CO HER ENT WITH TH E CONTENT O F THE CO RR ECTIVE ACTION ? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?

15.- ¿H AS IT BEEN MO DIF IED? 15.- ¿HAS IT BEEN MOD IFIE D? 15.- ¿H AS IT BEEN MODIFIED?
CO MM ENTS: CO MM ENTS: COMM ENTS :
D ECIS IO N OK OK OK D ECIS ION OK OK OK DECISION OK OK OK

NG NG NG NG NG NG NG NG NG

PPM Data A PPM Data A

RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR RE SU LT OF F OL LOW - UP AP U M GR S UP ER V . QU ALI TY T EC H M GR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
2.-C OR RECTIVE A CTION 2 .- CO R RECTIVE ACTION 2.-C OR RECTIVE A CTIO N
- P ERFO RM CH E CK 1 MO NT H AFTE R TH EC ORRE CTIVE AC T ION IMPLE MEN TAT IO N. - P ERFO RM CHEC K 1 MO NT H AF TER THE C ORR ECTIVE AC TIO N IMP LEMEN T ATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
- IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T - IN C AS E OF C AT. "A ",MA KE F OR MAL REP O R T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
- IN C AS E OF CA T." B" , IF RE S ULTO F FO LLOW6U PI S O K, SE N D AN OFFI CIAL CLO S URE TO - IN C AS E OF CAT. " B" ,IFR E SU LTO FF O LLOW6UP IS O K, SEN DA N OF FIC IAL CLO SU RE TO - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
C US TOME R C US TOME R C US TOMER

Data B: Data per day

Y M D A CTI ON IF NG (N OT G O OD) Y M D A CTIO N IF N G (NO T G O O D ) Y M D A CTION IF NG (N OT GO O D)
YE AR AND DAT E OF YE AR A ND D AT E OF YE AR AND DAT E OF
APU M GR S UPE R V. QUALITY TE CH M GR APU MGR SUPE R V . QUALITY TEC H MGR APU M GR S UPE R V. QUALITY TE CH M GR
C ONF IR MAT ION C ONF IR M AT ION C ONF IR MAT ION
COM MIT M ENT D ATE FOR D M Y C OM MIT M ENT DA TE FOR D M Y COM MITM ENT D ATE FOR D M Y
IM PLEMENTED IM PLEMENTE D IM PLEMEN TED
COR REC TIVE AC TIO N GENE RAL DEC ISI ON OK NG C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG

of month
PPM Data B PPM Data B A SSIGN MENT ISSUED TO

Via :
C R IT ICIT Y
LE VEL

*IF THE DEF E CT IS IN

DAT E
P R EP ARE D:
D M Y M AX DAT E D
FOR
ANS WE R :

APU M GR
M

QU ALI TY
Y
A SSIGNMEN T FO RM
CLASSIFYING P B PER LEVEL OF CR ITICITY
A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION
B DEF ECTS R E LAT ED T O C USTO MER ISS UES
C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE .
D OTHER DEF E CT S
AS SIGN MENT NU MBER:__ __ __ ___ __ __ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICITY)
P LANT
MGR
P LANT QA
MGR

ASSIGN MENT IS SU ED TO

Via:
C R IT IC ITY
LE VEL

* IF THE DE FE C T IS IN
C AT. A OR B , GE T
DAT E
P R EP AR ED:
D M Y MAX DATE
FOR
ANSW ER :

AP U MGR
D M

QUALITY
Y
A SS IGNM ENT FORM

C LASSIF YIN G P B PER LEVEL OF C RITICIT Y

A DEF EC T S R E LATE D T O SAF ET Y OR G OVE RNM ENT R EGULATION
B DEF EC T S R E LATE D T O C UST OMER ISSUES
C DEF EC T S R E SULT ING IN LOS S OF C OM ME R C IAL VALUE .
D OTHER DE FE C TS
ASSIGN MEN T N UMBER:__ _ ___ __ __ ___ __ _

A CTION PLAN AP PRO VED: M GR

(FOR A & B C RITIC ITY)
P LANT PLANT QA
M GR

ASSIGNMEN T IS SUED TO

Via:
C R ITIC ITY
LE VEL

* IF THE DE FECT IS IN
C AT. A OR B , GET
DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:

APU MGR
M Y

QUALI TY
A SSI GNMEN T FORM

CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y

A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE CT S
ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICI TY)
P LANT
MGR
PLANT QA
M GR

C AT. A OR B , GET APP R OVAL FR OM T OP RE SULT OF CO N FIRMA TION VER SUS THE A NSWER AP U MGR S UPE RV . QUALITY TECH MGR APP R OVAL FR OM TOP RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
APP R OVALF R OM TOP RESULT OF CO NFIR MA TIO N VER SUS THE AN SWER AP U M GR S UP ER V . QU ALI TY T EC H M GR MANAGER M ANAGER
M ANAGER - C ONF IR M IM MEDIAT ELY AFTER IMP LEM E NT ATION OF THE C OR REC TIVE ACTION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
- CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, NO LATE R THAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
SU BJ EC T: SUB J EC T:
NO LATE R T HAN ONE W EE K AFTER . - APU QUALITY MUS T PR E-C HEC K A LL POINTS - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
SUB JEC T: - AP U QUALITY MUST PR E -C HEC K ALL P OINTS D M Y AP PR OX. HR SHIFT LIN E AP T - APU MGR MUST PE R FOM ALL CHE CKS IN CAS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AND HR OF DATE AN D HR OF
DA TE AN D HR OF
D M Y AP PR OX. HR SH IFT LIN E APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" DE F EC T - IF C AT. " C", AP U M G R MIGHT C ONFI RM ONLY 6 -15. DE FE C T - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
- IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. A B C A B C
DE FE C T
A B C
CU STO ME R C HEC KB Y QUALIT Y PER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
PAR T NUMB E R PAR T NUM B E R
C US TOME R C HE C K B Y QUALITY P ER S HIF T / CONFIR MAT IO N C HEC KS CO NF IR MATION DATE CONFIR MAT IO N C HEC KS CONF IR MATION DATE
P AR T NUM B E R
CONFIR MATIO N C HEC KS C ONFIR MATION DATE VE HIC LE SUP PLIE R A B C VEHIC LE SUPP LIER A B C
VE HIC LE S UPP LIER A B C
DE TECTE D AT P ROC ESS ST EP OP E RA TOR NAME 1.- ¿ HA VE PARAM ETERS B EEN COR RECTED IN SAF./ OPE R. IN TR UCTIONS? DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?
DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME
1.-¿ HA VE PAR AM ETERS B EEN CORR ECTED IN SAF./O PER . INTR UCTIONS?
2.- ¿ DO OP ERATIN G IN STRUC TIO NS M ATCH WITH Q UALIT Y CON TRO L PLAN? 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?
M AD E AT P R OC ES S S TEP TEA M LE ADER NAME MADE AT P R OCES S STEP TEAM LEADER NAME
2 .- ¿ DO OPER ATING INS TR UCTIO NS M ATCH WIT H Q UA LITY C ON TROL PLAN ?
M ADE AT P R OC ESS ST EP T EAM LEADER NAME NU MBE R OF DE FE CT S 3.- ¿ IS ALL DOCUM ENTATION COH EREN T? NUM BE R OF DE FE CT S 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
AC TION ON DEF EC TI VE PAR T S ACT ION ON DEFEC TIVE PAR TS
NUM BE R OF DE FECT S 3 .- ¿ IS ALL DO CUM ENTAT IO N C OH ERENT?
AC T ION ON DEF EC TIVE PAR T S 4.- ¿ AR E THE INSTR UCTIO NS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.- W HY DET EC T ED? DR AWING : 1.- W HY DETE C TE D? DR AW ING :
4 .- ¿ ARE T HE INSTR UCTION S CLEAR ?
1.- WHY DETE C TE D? DR AWING: 5.- ¿ AR E CR ITI CAL PO INTS C LEAR LY D ESCRIBED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?
5 .- ¿ ARE C RITIC AL PO IN TS CLEAR LY DE SC RIB ED?

Generalization
6.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH TH E OPER ATING INSTR UCTIO NS? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?
6 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H THE O PER ATING INSTR UCTIONS?
2.- DE FE C T DES C R IPT ION 7.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH EXPEC TED CO R RECTIVE A CTION ? 2.- DE FE C T DESC R IPT ION 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
2 .- DEF E CT DES C R IPT ION
7 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H EXPEC TED CO RR ECTIVE AC TION ?
8.- ¿ AR E OP ERATO RS AWARE OF THE DEF EC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?
8 .- ¿ ARE OPER ATO RS AWA RE O F THE DEFEC T?
9.- ¿ AR E OP ERATO RS AWARE OF THE EXP EC TED C OR RECT IV E ACTIO N? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?
9 .- ¿ ARE OPER ATO RS AWA RE O F THE EXPEC TED C OR RECTIVE A CTION?
10.- AR E THE N EW POI NTS CH ECKED? WITH GOOD METH OD AN D TOOLS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
3.- S UGGEST ION OF 3.- S UGGEST ION OF
10.- AR E THE NEW P OIN TS CHEC KED? WITH GOOD METHO D AND TOOLS? CO RR E C TIVE A CT ION C OR R E C TIVE A CT ION
3 .- S UG GE ST ION OF 11.- ¿IS THERE A VIS UA L A ID? 1.- ¿IS THER E A VIS UA L A ID?
C ORR E C TIVE AC T ION 11.- ¿IS TH ER E A VISUA L AID?
12.- ¿IS IT P OSTED O N A V IS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?
12.- ¿IS IT POSTED O N A VISIB LE SP OT?
"AN SWE R QU ICKL Y!" 13.- ¿IS TH E CONTENT CLEA R? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?

Consolidated data
"A NS WE R QUI CKLY!" 13.- ¿IS THE C ONTENT CLEAR ? A NSWER A NSWER
AN SWER 14.- ¿IS IT C OHER ENT WITH THE CO NTENT OF THE C OR REC TIVE A CTIO N? 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?
1.-C AUSE: D RAWIN G: 1.- C AUSE: DR AWIN G:
1.-C AUSE: DR AWING: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO RR ECTIVE A CTION ?
15.- ¿H AS IT B EEN MODIFIED? 15.- ¿H AS IT BEEN MODIFIED?

Capitalization
15.- ¿HA S IT BEEN MODIFIED? C OMM ENTS: COMM ENTS :
CO MM ENTS: D ECISIO N OK OK OK DECISION OK OK OK
D ECISION OK OK OK
NG NG NG NG NG NG
NG NG NG

R E S ULT OF FOL LOW - UP AP U MGR S UPE RV . QUALITY TECH MGR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
RE SU LT OF F OL LOW - UP 2.- C OR RECT IVE A CTIO N 2.-C OR RECTIVE A CTIO N
AP U M GR S UP ER V . QU ALI TY T EC H M GR - P ERF ORM CHE CK1 M O N TH AF TER TH EC OR RECT IVE AC TION IMP LE MEN TATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
2 .- CO R RECTIVE A CTION - IN CAS E O FC AT. "A ", MAK EFOR MAL REP OR T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
- P ERF ORM CHEC K 1 MO N T H AFTER T HE C ORR ECTIVE AC TIO N IMPLEME N TATIO N.
- IN C AS E O FC AT. "A ", MA KE FOR MAL RE PO R T - IN CAS E OF CA T. " B" ,IF RES UL TO FFO L LOW6UP ISO K, SEN D AN O FF ICIAL CLO SU RE T O - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
- IN C AS E OF CAT. "B" , IF RE SU LTO F FO LLOW6UP IS O K, SEN D AN OFFIC IAL CLO SU RE TO CUS TOME R C US TOMER
C US TOME R
Y M D A CTION IF NG (NOT GO O D) Y M D A CTION IF NG (N OT GO O D)
Y M D A CTIO N IF N G (NO T G O O D )

of line by shift
APU MGR S UPE R V. QUALITY TE C H MGR YE AR AND DATE OF APU M GR S UPE R V. QUALITY TE CH M GR YE AR AND DAT E OF
YE AR A ND D AT E OF C ONF IR MATION C ONF IR MAT ION
APU MGR SUPE R V . QUALITY TEC H MGR
C ONF IR M AT ION COM MITM ENT DATE FOR D M Y COM MITM ENT D ATE FOR D M Y
C OM MITM ENT DATE FOR D M Y I PLEMEN TED
M I PLEMEN TED
M
IM PLEMEN TE D COR R EC TIVE AC TION GEN ER AL DECIS ION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG
C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG

Data A: data per month

Data B: Data per day
of month
Have defective
parts available

Modified 12 March 03 21
  How to use Assignment sheet ?
FILL-IN B. CUSTOMER ISSUES =
ASSIGNMENT NUMBER:________________
CRITICITY ACTUAL OR RISK OF:
LEVEL C R ITIC ITY M AX DATE
ASSIGNMENT FORM
1 OFFICIAL CUSTOMER
C LAS S IF YING P B P E R LEVEL OF C R ITIC ITY PLANT PLANT QA
DATE
D M Y D M Y AC TION P LAN AP P R OVED: M GR
LEVEL M GR
FOR

COMPLAINT OR RESIDENT
PR EP ARED: A DEFEC TS R ELATED TO SAFETY OR GOVER NM ENT R EGULATION
ANSWER : (F OR A & B C R ITIC ITY)
B DEFEC TS R ELATED TO CUSTOM ER ISS UES
C DEFEC TS R ESULTING IN LOSS OF C OM M ER C IAL VALUE .
AS S IGNM ENT IS S UED TO

ALERT
D OTHER DEFEC TS

* IF THE DEFEC T IS IN APU M GR QUALITY

Via :
C AT. A OR B , GET

2 LINE RETURN
APP R OVAL FR OM TOP
R ES ULT OF C ONF IR M ATION VER S US THE ANS WER APU M GR S UPER V. QUALITY TEC H M GR

A. SAFETY ISSUES =
M ANAGER
- C ONFIR M IM M EDIATELY AFTER IM P LEM ENTATION OF THE C OR R EC TIVE AC TION,

S UB J EC T:

ACTUAL OR RISK OF: 3 WARRANTY RETURN

NO LATER THAN ONE WEEK AFTER .
- APU QUALITY M US T PR E-C HEC K ALL POINTS

DATE AND HR OF
DEFEC T
D M Y AP P R OX. HR S HIF T LINE AP T
APU QUALITY APU QUALITY
- APU M GR M UST P ER FOM ALL C HEC KS IN C ASE OF C AT. " A" OR " B "
- IF C AT. " C " , APU M GR M IGHT C ONFIR M ONLY 6 -15.
A B C

1 HUMAN DAMAGE
C USTOM ER
SELECTS ISSUES AND REGISTER C HEC K B Y QUALITY P ER SHIFT /
P AR T NUM BER
THEM PRIOR TO QRQC: C ONF IR M ATION C HEC KS C ONFIR M ATION DATE

2 VEHICULE DAMAGE
VEHIC LE

DETECTED AT PR OC ESS STEP

S UP PLIER

OPER ATOR NAM E

1.- ¿ HAVE P AR AM ETER S B EEN C OR R EC TE D IN S AF ./OP ER . INTR UC TIONS ?
A B C

A SAFETY ISSUES
2.- ¿ DO OP ER ATING INS TR UC TIONS M AT C H WITH QUALITY C ONT R OL P LAN?
M ADE AT PR OC ESS S TEP TEAM LEADER NAM E
NUM B ER OF DEFEC TS 3.- ¿ IS ALL DOC UM E NTATION C OHER ENT?

B CUSTOMER COMPLAINTS
AC TION ON DEFECTIVE PAR TS
4.- ¿ AR E THE INS TR UC TIONS C LEAR ?
1.- WHY DETEC TED? DR AW ING:

C LOSS OF COMMERCIAL VALUE 5.- ¿ AR E C R ITIC AL P OINTS C LEAR LY DES C R IB ED?

D OTHER 6.- ¿ DOES AC TUAL P R OC ES S M ATC H WITH THE OP ER ATING INS TR UC TIONS ?

7.- ¿ DOES AC TUAL P R OC ES S M ATC H WITH EXP E C TED C OR R E C TIVE AC TION?

2 .- DEFEC T DESC R IPTION
8.- ¿ AR E OP ER ATOR S AWAR E OF THE DEF EC T?

9.- ¿ AR E OP ER ATOR S AWAR E OF THE EXP EC TE D C OR R EC TIVE AC TION?

10.- AR E THE NEW P OINT S C HEC KE D? WITH GOOD M ETHOD AND TOOLS ?
3 .- SUGGES TION OF
COR R EC TIVE AC TION
11.- ¿ IS T HER E A VIS UAL AID?

12.- ¿ IS IT P OS TED ON A VIS IB LE S P OT?

"A N S WE R Q UIC KLY !" 13.- ¿ IS T HE C ONTENT C LEAR ?

ANS WER
1.- C AUS E: DR AWING: 14.- ¿ IS IT C OHER ENT WITH THE C ONTENT OF THE C OR R EC TIVE AC TION?

15.- ¿ HAS IT B EEN M ODIF IED?

C OM M E NT S : OK OK OK
DEC IS ION
NG NG NG

C. LOSS OF COMMERCIAL VALUE

2.- C OR R EC TIVE AC TION
R E S U LT O F F O LLO W - U P
- P ERFOR M C HECK 1 M ON TH AFTER THE CORRECTIVE ACTION IMP LEMENTATION .
- IN CAS E OF CAT. "A", MAKE FOR MAL REP ORT
APU M GR S UPER V. QUALITY TEC H M GR

•PARETO OF INTERNAL - IN CAS E OF CAT. "B", IF RES ULT OF FOLLOW6 UP IS OK, S END AN OFFICIAL CLOS URE TO
CUS TOMER

PROBLEMS, RANKED BY COST

Y M D A CTIO N IF NG ( NO T G O O D)
YEAR AND DATE OF
APU M GR SUPER V. QUALITY TEC H M GR
C ONF IR M ATION

•ADD ONLY IF LESS THAN 3 OPEN

C OM M ITM ENT DATE F OR
IM P LEM ENTED
C OR R EC TIVE AC TION
D M Y

GENER AL DEC ISION OK NG

ASSIGNMENTS
Modified 12 March 03 22
  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 23
  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 24
  How to use FTA (Factors Tree Analysis) ?
Judgement / Observation
Standard : Is it the right standard?
Is it clear ?
Quality : Is there any difference
Standard I Difference
or deviation ?
Judgement can be :
O : No difference
These are all the
X : Difference vs standard
Different conclusions
: Doubt (there is no difference,
that may come out
but 1 specific peak)
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 25
  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 26
  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 27
  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

! (30’)
t i me
h e ck
C

Modified 12 March 03 28
  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 AS SIGN MENT NU MBER:__ __ __ ___ __ __ __ _
C R IT IC ITY
LE VEL DAT E
P R EP AR ED:
D M Y MAX DATE
FOR
ANSW ER :
D M Y
A SS IGNM ENT FORM
C LASSIF YIN G P B PER LEVEL OF C RITICIT Y
A DEF EC T S R E LATE D T O SAF ET Y OR G OVE RNM ENT R EGULATION
B DEF EC T S R E LATE D T O C UST OMER ISSUES
ASSIGN MEN T N UMBER:__ _ ___ __ __ ___ __ _

A CTION PLAN AP PRO VED: M GR

(FOR A & B C RITIC ITY)
P LANT PLANT QA
M GR
C R ITIC ITY
LE VEL DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:
M Y
A SSI GNMEN T FORM
CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y
A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICI TY)
P LANT
MGR
PLANT QA
M GR

A SSIGNMEN T FO RM ASSIGN MENT IS SU ED TO C DEF EC T S R E SULT ING IN LOS S OF C OM ME R C IAL VALUE . ASSIGNMEN T IS SUED TO C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE C TS D OTHER DE FE CT S
P LANT P LANT QA * IF THE DE FE C T IS IN AP U MGR QUALITY * IF THE DE FECT IS IN APU MGR QUALI TY
C R IT ICIT Y
D M Y M AX DAT E D M Y CLASSIFYING P B PER LEVEL OF CR ITICITY Via: Via:
LE VEL DAT E A CTION PLAN AP PRO VED: MGR MGR C AT. A OR B , GE T C AT. A OR B , GET
FOR RE SULT OF CO N FIRMA TION VER SUS THE A NSWER AP U MGR S UPE RV . QUALITY TECH MGR RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
P R EP ARE D: A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION APP R OVAL FR OM T OP APP R OVAL FR OM TOP
ANS WE R : (FO R A & B C RITICITY)
B DEF ECTS R E LAT ED T O C USTO MER ISS UES MANAGER M ANAGER
A SSIGN MENT ISSUED TO C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE . - C ONF IR M IM MEDIAT ELY AFTER IMP LEM E NT ATION OF THE C OR REC TIVE ACTION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
D OTHER DEF E CT S
NO LATE R THAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
APU M GR QU ALI TY
SU BJ EC T: - APU QUALITY MUS T PR E-C HEC K A LL POINTS
SUB J EC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
Via : *IF THE DEF E CT IS IN
C AT. A OR B , GET D M Y AP PR OX. HR SHIFT LIN E AP T - APU MGR MUST PE R FOM ALL CHE CKS IN CAS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AND HR OF DATE AN D HR OF
APP R OVALF R OM TOP RESULT OF CO NFIR MA TIO N VER SUS THE AN SWER AP U M GR S UP ER V . QU ALI TY T EC H M GR - IF C AT. " C", AP U M G R MIGHT C ONFI RM ONLY 6 -15. - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
DE F EC T DE FE C T
M ANAGER A B C A B C
- CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, CU STO ME R C HEC KB Y QUALIT Y PER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
NO LATE R T HAN ONE W EE K AFTER . PAR T NUMB E R CO NF IR MATION DATE PAR T NUM B E R CONF IR MATION DATE
SUB JEC T: CONFIR MAT IO N C HEC KS CONFIR MAT IO N C HEC KS
- AP U QUALITY MUST PR E -C HEC K ALL P OINTS VE HIC LE VEHIC LE
D M Y AP PR OX. HR SH IFT LIN E APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" SUP PLIE R A B C SUPP LIER A B C
DA TE AN D HR OF
DE FE C T - IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. 1.- ¿ HA VE PARAM ETERS B EEN COR RECTED IN SAF./ OPE R. IN TR UCTIONS? 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?

APU 1: OK
A B C DE TECTE D AT P ROC ESS ST EP OP E RA TOR NAME DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME

M AD E AT P R OC ES S S TEP TEA M LE ADER NAME 2.- ¿ DO OP ERATIN G IN STRUC TIO NS M ATCH WITH Q UALIT Y CON TRO L PLAN? MADE AT P R OCES S STEP TEAM LEADER NAME 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?

APU 2 : OK
C US TOME R C HE C K B Y QUALITY P ER S HIF T /
P AR T NUM B E R
CONFIR MATIO N C HEC KS C ONFIR MATION DATE NU MBE R OF DE FE CT S NUM BE R OF DE FE CT S
3.- ¿ IS ALL DOCUM ENTATION COH EREN T? 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
VE HIC LE AC TION ON DEF EC TI VE PAR T S ACT ION ON DEFEC TIVE PAR TS
S UPP LIER A B C
4.- ¿ AR E THE INSTR UCTIO NS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.-¿ HA VE PAR AM ETERS B EEN CORR ECTED IN SAF./O PER . INTR UCTIONS? 1.- W HY DET EC T ED? DR AWING : 1.- W HY DETE C TE D? DR AW ING :
DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME
5.- ¿ AR E CR ITI CAL PO INTS C LEAR LY D ESCRIBED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?
2 .- ¿ DO OPER ATING INS TR UCTIO NS M ATCH WIT H Q UA LITY C ON TROL PLAN ?
M ADE AT P R OC ESS ST EP T EAM LEADER NAME
6.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH TH E OPER ATING INSTR UCTIO NS? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?
NUM BE R OF DE FECT S 3 .- ¿ IS ALL DO CUM ENTAT IO N C OH ERENT?
AC T ION ON DEF EC TIVE PAR T S
7.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH EXPEC TED CO R RECTIVE A CTION ? 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
4 .- ¿ ARE T HE INSTR UCTION S CLEAR ? 2.- DE FE C T DES C R IPT ION 2.- DE FE C T DESC R IPT ION
1.- WHY DETE C TE D? DR AWING:
8.- ¿ AR E OP ERATO RS AWARE OF THE DEF EC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?
5 .- ¿ ARE C RITIC AL PO IN TS CLEAR LY DE SC RIB ED?
9.- ¿ AR E OP ERATO RS AWARE OF THE EXP EC TED C OR RECT IV E ACTIO N? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?
6 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H THE O PER ATING INSTR UCTIONS?
10.- AR E THE N EW POI NTS CH ECKED? WITH GOOD METH OD AN D TOOLS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
7 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H EXPEC TED CO RR ECTIVE AC TION ? 3.- S UGGEST ION OF 3.- S UGGEST ION OF
2 .- DEF E CT DES C R IPT ION CO RR E C TIVE A CT ION C OR R E C TIVE A CT ION
11.- ¿IS THERE A VIS UA L A ID? 1.- ¿IS THER E A VIS UA L A ID?
8 .- ¿ ARE OPER ATO RS AWA RE O F THE DEFEC T?
12.- ¿IS IT P OSTED O N A V IS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?
9 .- ¿ ARE OPER ATO RS AWA RE O F THE EXPEC TED C OR RECTIVE A CTION?
"AN SWE R QU ICKL Y!" 13.- ¿IS TH E CONTENT CLEA R? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?
10.- AR E THE NEW P OIN TS CHEC KED? WITH GOOD METHO D AND TOOLS? A NSWER A NSWER

PPM Data A PPM Data A

3 .- S UG GE ST ION OF
C ORR E C TIVE AC T ION 1.-C AUSE: D RAWIN G: 14.- ¿IS IT C OHER ENT WITH THE CO NTENT OF THE C OR REC TIVE A CTIO N? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?
11.- ¿IS TH ER E A VISUA L AID?
15.- ¿H AS IT B EEN MODIFIED? 15.- ¿H AS IT BEEN MODIFIED?
12.- ¿IS IT POSTED O N A VISIB LE SP OT?
C OMM ENTS: COMM ENTS :
"A NS WE R QUI CKLY!" 13.- ¿IS THE C ONTENT CLEAR ? D ECISIO N OK OK OK DECISION OK OK OK
AN SWER
NG NG NG NG NG NG
1.-C AUSE: DR AWING: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO RR ECTIVE A CTION ?

15.- ¿HA S IT BEEN MODIFIED?

R E S ULT OF FOL LOW - UP AP U MGR S UPE RV . QUALITY TECH MGR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
CO MM ENTS: OK OK OK 2.- C OR RECT IVE A CTIO N 2.-C OR RECTIVE A CTIO N
D ECISION - P ERF ORM CHE CK1 M O N TH AF TER TH EC OR RECT IVE AC TION IMP LE MEN TATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
- IN CAS E O FC AT. "A ", MAK EFOR MAL REP OR T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
NG NG NG - IN CAS E OF CA T. " B" ,IF RES UL TO FFO L LOW6UP ISO K, SEN D AN O FF ICIAL CLO SU RE T O - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
CUS TOME R C US TOMER

RE SU LT OF F OL LOW - UP Y M D A CTION IF NG (NOT GO O D) Y M D A CTION IF NG (N OT GO O D)

AP U M GR S UP ER V . QU ALI TY T EC H M GR
2 .- CO R RECTIVE A CTION
- P ERF ORM CHEC K 1 MO N T H AFTER T HE C ORR ECTIVE AC TIO N IMPLEME N TATIO N. YE AR AND DATE OF YE AR AND DAT E OF
APU MGR S UPE R V. QUALITY TE C H MGR APU M GR S UPE R V. QUALITY TE CH M GR
- IN C AS E O FC AT. "A ", MA KE FOR MAL RE PO R T C ONF IR MATION C ONF IR MAT ION
- IN C AS E OF CAT. "B" , IF RE SU LTO F FO LLOW6UP IS O K, SEN D AN OFFIC IAL CLO SU RE TO COM MITM ENT DATE FOR D M Y COM MITM ENT D ATE FOR D M Y
C US TOME R IM PLEMEN TED IM PLEMEN TED
COR R EC TIVE AC TION GEN ER AL DECIS ION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG
Y M D A CTIO N IF N G (NO T G O O D )
APU MGR SUPE R V . QUALITY TEC H MGR YE AR A ND D AT E OF
C ONF IR M AT ION
C OM MITM ENT DATE FOR D M Y
IM PLEMEN TE D
C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG

Answer with
PPM Data B PPM Data B A SS IGNMEN T FORM
ASS IGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

ASS IGN MENT FO RM

ASS IGN MENT NU MBE R:__ __ __ ___ __ __ __ _

A SSI GNMEN T FORM

PDCA formats ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

C R ITIC ITY CLASSIFYIN G P B PER LEVEL OF CR IT ICITY P LANT PLANT QA C R IT ICIT Y CLASSIFYIN G P B PER LEVEL OF CR IT ICITY P LANT P LANT QA C R ITIC ITY CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y P LANT PLANT QA
DAT E D M Y M AX DATE D M Y ACTION PLAN AP PRO VED: MGR DAT E D M Y M AX DAT E D M Y A CTION PLAN AP PROVED: MGR DAT E D M Y M AX DATE D M Y A CTION PLAN AP PRO VED: MGR
LE VEL FOR M GR LE VEL FOR MGR LE VEL FOR M GR
P R EP AR ED: A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION P R EP ARE D: A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION P R EP AR ED: A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
ANS WE R: (FOR A & B C RITICITY) ANS WE R : (FO R A & B C RIT ICITY) ANS WE R: (FO R A & B C RITICI TY)
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES B DEF ECTS R E LAT ED T O C USTO MER ISS UES B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
ASSIGN MEN T IS SUED TO C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE . ASSIGN MENT ISSUED TO C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE . ASSIGNMEN T IS SUED TO C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE CT S D OTHER DEF E CT S D OTHER DE FE CT S

Consolidated data
* IF THE DE FECT IS IN APU MGR QUALI TY *IF THE DEF E CT IS IN APU M GR QU ALI TY * IF THE DE FECT IS IN APU MGR QUALI TY
Vi a: Via : Via:
C AT. A OR B , GET C AT. A OR B , GET C AT. A OR B , GET
APP R OVAL FR OM TOP
RESULT OF CONFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
APP R OVALF R OM TOP
RESULT OF CO NFIR MATIO N VER SUS TH E ANSWER AP U M GR S UP ER V . QU ALI TY T EC H M GR
APP R OVAL FR OM TOP
RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
M ANAGER M ANAGER M ANAGER
- CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION, - CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
NO LATER THAN O NE WEEK AF TE R . NO LATE R T HAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
SUB JEC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
SUB JEC T: - AP U QUALITY MUST PR E -C HEC K ALL P OINTS
SUB J EC T: - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
D M Y AP PR OX. HR SHIF T LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B " D M Y AP PR OX. HR SH IF T LINE APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AN D HR OF DA TE AN D HR OF DATE AN D HR OF
- IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5. - IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
DE FE C T DE FE C T DE FE C T
A B C A B C A B C

CUS TOM E R C HEC K B Y QUALITY PER S HIFT / C US TOME R C HE C K B Y QUALITY P ER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
PAR T NUM B E R CONF IR MATION DATE P AR T NUM B E R C ONFIR MATION DATE PAR T NUM B E R CONF IR MATION DATE
CO NFIR MAT IO N C HEC KS CO NFIR MATION C HEC KS CONFIR MAT IO N C HEC KS
VEHIC LE VE HIC LE VEHIC LE
SUPP LIER A B C S UPP LIER A B C SUPP LIER A B C
1.- ¿ HAVE PA RAM ETERS B EEN CO RR ECTED IN SAF./OPE R. INTR UCTIO NS? 1.-¿ HA VE PAR AM ETERS B EEN CO RR ECTED IN SAF./OPER . INTR UCTION S? 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?
DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME

MADE AT P R OCES S STEP TEAM LEADER NAME 2.- ¿ DO OPE RATIN G IN STRUCTIONS M ATCH WITH QUALIT YC ONTRO L PLAN ? M ADE AT P R OC ESS ST EP T EAM LEADER NAME 2 .- ¿ DO OPER ATIN G INS TR UCTIONS M ATCH WITH QUALIT Y C ONTRO L PLAN ? MADE AT P R OCES S STEP TEAM LEADER NAME 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?

of plant by shift
NUM BE R OF DE FE CT S 3.- ¿ IS ALL D OCUM ENTA TIO N C OHEREN T? NUM BE R OF DE FECT S 3 .- ¿ IS A LL DO CUM ENTAT IO N C OHEREN T? NUM BE R OF DE FE CT S 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
ACT ION ON DEFEC TIVE PAR TS AC T ION ON DEF EC TIVE PAR T S ACT ION ON DEFEC TIVE PAR TS
4.- ¿ AR E THE INSTR UCTIONS CLEAR ? 4 .- ¿ ARE T HE INSTR UCTIONS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.- W HY DETE C TE D? DR AW ING : 1.- WHY DETE C TE D? DR AWING: 1.- W HY DETE C TE D? DR AW ING :
5.- ¿ AR E CR IT IC AL POINTS CLEAR LY D ESCRIB ED? 5 .- ¿ ARE C RITIC AL POIN TS CLEAR LY DE SC RIB ED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?

6.- ¿ DOES ACTUA L P RO CESS MA TCH WITH THE O PER ATING INSTR UCTIO NS? 6 .- ¿ DOE S ACTUA L PR O CESS MA TCH WIT H THE O PER ATING INSTR UCTION S? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?

APU 3 : OK APU 4 : NOK

7.- ¿ DOES ACTUA L P RO CESS MA TCH WITH EXPEC TED CORR ECTIVE A CTION? 7 .- ¿ DOE S ACTUA L PR O CESS MA TCH WIT H EXPEC TED CORR ECTIVE AC TION? 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
2.- DE FE C T DESC R IPT ION 2 .- DEF E CT DES C R IPT ION 2.- DE FE C T DESC R IPT ION

8.- ¿ AR E OP ER ATORS A WARE O F THE D EFEC T? 8 .- ¿ ARE O PER ATORS AWARE O F THE DEFEC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?

9.- ¿ AR E OP ER ATORS A WARE O F THE EXPEC TED C OR RECTIVE A CTIO N? 9 .- ¿ ARE O PER ATORS AWARE O F THE EXPEC TED C OR RECTIVE A CTION ? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?

10.- AR E THE NEW P OIN TS CHE CKED? WIT H G OOD METHOD A ND TOO LS? 10.- AR E THE NEW P OINTS CHEC KED? WITH GO OD METHO D A ND TOO LS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
3.- S UGGEST ION OF 3 .- S UG GE ST ION OF 3.- S UGGEST ION OF
C OR R E C TIVE A CT ION C ORR E C TIVE AC T ION C OR R E C TIVE A CT ION
11.- ¿IS TH ER E A VISUAL A ID? 11.- ¿IS TH ER E A VISUAL AI D? 1.- ¿IS THER E A VIS UA L A ID?

Data A: data per month

12.- ¿IS IT PO STED O N A V IS IB LE SP OT? 12.- ¿IS IT PO STED ON A VIS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?

" AN S WE R Q U IC KLY!" 13.- ¿IS THE C ON TENT CLEAR ? "AN S WE R Q UIC KLY!" 13.- ¿IS THE C ON TENT CLEAR ? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?
ANSWER AN SWER A NSWER
1.- C AUSE: DR A WIN G: 14.- ¿IS IT CO HER ENT WIT H TH E CO NTEN T OF THE COR RECTIVE A CTION? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT CO HER ENT WITH TH E CONTENT O F THE CO RR ECTIVE ACTION ? 1.- C AUSE: DR AWIN G: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?

15.- ¿H AS IT BEEN MO DIF IED? 15.- ¿HAS IT BEEN MOD IFIE D? 15.- ¿H AS IT BEEN MODIFIED?
CO MM ENTS: CO MM ENTS: COMM ENTS :
D ECIS IO N OK OK OK D ECIS ION OK OK OK DECISION OK OK OK

NG NG NG NG NG NG NG NG NG

PPM Data A PPM Data A

RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR RE SU LT OF F OL LOW - UP AP U M GR S UP ER V . QU ALI TY T EC H M GR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
2.-C OR RECTIVE A CTION 2 .- CO R RECTIVE ACTION 2.-C OR RECTIVE A CTIO N
- P ERFO RM CH E CK 1 MO NT H AFTE R TH EC ORRE CTIVE AC T ION IMPLE MEN TAT IO N. - P ERFO RM CHEC K 1 MO NT H AF TER THE C ORR ECTIVE AC TIO N IMP LEMEN T ATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
- IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T - IN C AS E OF C AT. "A ",MA KE F OR MAL REP O R T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
- IN C AS E OF CA T." B" , IF RE S ULTO F FO LLOW6U PI S O K, SE N D AN OFFI CIAL CLO S URE TO - IN C AS E OF CAT. " B" ,IFR E SU LTO FF O LLOW6UP IS O K, SEN DA N OF FIC IAL CLO SU RE TO - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
C US TOME R C US TOME R C US TOMER

Data B: Data per day

Y M D A CTI ON IF NG (N OT G O OD) Y M D A CTIO N IF N G (NO T G O O D ) Y M D A CTION IF NG (N OT GO O D)
YE AR AND DAT E OF YE AR A ND D AT E OF YE AR AND DAT E OF
APU M GR S UPE R V. QUALITY TE CH M GR APU MGR SUPE R V . QUALITY TEC H MGR APU M GR S UPE R V. QUALITY TE CH M GR
C ONF IR MAT ION C ONF IR M AT ION C ONF IR MAT ION
COM MIT M ENT D ATE FOR D M Y C OM MIT M ENT DA TE FOR D M Y COM MITM ENT D ATE FOR D M Y
IM PLEMENTED IM PLEMENTE D IM PLEMEN TED
COR REC TIVE AC TIO N GENE RAL DEC ISI ON OK NG C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG

of month
PPM Data B PPM Data B A SSIGN MENT ISSUED TO

Via :
C R IT ICIT Y
LE VEL

*IF THE DEF E CT IS IN

DAT E
P R EP ARE D:
D M Y M AX DAT E D
FOR
ANS WE R :

APU M GR
M

QU ALI TY
Y
A SSIGNMEN T FO RM
CLASSIFYING P B PER LEVEL OF CR ITICITY
A DEF ECTS R E LAT ED T O SAF ETY O R GOVE RNME NT R EGULATION
B DEF ECTS R E LAT ED T O C USTO MER ISS UES
C DEF ECTS R E SULTING IN LOS S OF COM ME R C IA L V ALUE .
D OTHER DEF E CT S
AS SIGN MENT NU MBER:__ __ __ ___ __ __ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICITY)
P LANT
MGR
P LANT QA
MGR

ASSIGN MENT IS SU ED TO

Via:
C R IT IC ITY
LE VEL

* IF THE DE FE C T IS IN
C AT. A OR B , GE T
DAT E
P R EP AR ED:
D M Y MAX DATE
FOR
ANSW ER :

AP U MGR
D M

QUALITY
Y
A SS IGNM ENT FORM

C LASSIF YIN G P B PER LEVEL OF C RITICIT Y

A DEF EC T S R E LATE D T O SAF ET Y OR G OVE RNM ENT R EGULATION
B DEF EC T S R E LATE D T O C UST OMER ISSUES
C DEF EC T S R E SULT ING IN LOS S OF C OM ME R C IAL VALUE .
D OTHER DE FE C TS
ASSIGN MEN T N UMBER:__ _ ___ __ __ ___ __ _

A CTION PLAN AP PRO VED: M GR

(FOR A & B C RITIC ITY)
P LANT PLANT QA
M GR

ASSIGNMEN T IS SUED TO

Via:
C R ITIC ITY
LE VEL

* IF THE DE FECT IS IN
C AT. A OR B , GET
DAT E
P R EP AR ED:
D M Y M AX DATE D
FOR
ANS WE R:

APU MGR
M Y

QUALI TY
A SSI GNMEN T FORM

CLASSIF YIN G P B PER LEVEL OF CR ITICIT Y

A DEF EC T S RE LAT ED T O SAFET Y OR GOVE R NMENT R E GULATION
B DEF EC T S RE LAT ED T O CUST OM ER ISS UES
C DEF EC T S RE SULTIN G IN LOS S OF COMM E R CIAL VALUE .
D OTHER DE FE CT S
ASSIGN MEN T NU MBER:__ __ __ ___ _ ___ __ _

A CTION PLAN AP PRO VED:

(FO R A & B C RITICI TY)
P LANT
MGR
PLANT QA
M GR

C AT. A OR B , GET APP R OVAL FR OM T OP RE SULT OF CO N FIRMA TION VER SUS THE A NSWER AP U MGR S UPE RV . QUALITY TECH MGR APP R OVAL FR OM TOP RESULT OF CO NFIR MA TIO N V ER SUS THE A NSWER AP U MGR S UP ERV. QUALI TY T EC H MGR
APP R OVALF R OM TOP RESULT OF CO NFIR MA TIO N VER SUS THE AN SWER AP U M GR S UP ER V . QU ALI TY T EC H M GR MANAGER M ANAGER
M ANAGER - C ONF IR M IM MEDIAT ELY AFTER IMP LEM E NT ATION OF THE C OR REC TIVE ACTION, - CO NF IR M IMM EDIATE LY AFT ER IM PLE ME NTATION OF T HE COR R EC T IVE AC TION,
- CONF IRM IM MEDIATE LY AFT ER IMPLEM ENT ATION OF T HE C OR RE CTI VE AC TION, NO LATE R THAN ONE W EE K AFTER . NO LATER THAN O NE WEEK AF TE R .
SU BJ EC T: SUB J EC T:
NO LATE R T HAN ONE W EE K AFTER . - APU QUALITY MUS T PR E-C HEC K A LL POINTS - AP U QUALITY M UST PR E-CHEC K ALL P OINTS
SUB JEC T: - AP U QUALITY MUST PR E -C HEC K ALL P OINTS D M Y AP PR OX. HR SHIFT LIN E AP T - APU MGR MUST PE R FOM ALL CHE CKS IN CAS E OF C AT . " A" OR "B" D M Y AP PR OX. HR SHIFT LIN E AP T - AP U M GR M UST PE RF OM ALL C HEC KS IN C AS E OF C AT . " A" OR "B "
DATE AND HR OF DATE AN D HR OF
DA TE AN D HR OF
D M Y AP PR OX. HR SH IFT LIN E APT - AP U MGR MUST P ER F OM ALL CHEC KS IN C AS E OF C AT . " A" OR "B" DE F EC T - IF C AT. " C", AP U M G R MIGHT C ONFI RM ONLY 6 -15. DE FE C T - IF C AT. " C" , AP U MGR MIGHT C ONFIR M ONLY 6 -1 5.
- IF C AT. "C ", AP U MGR M IGHT C ONFIR M ONLY 6- 15. A B C A B C
DE FE C T
A B C
CU STO ME R C HEC KB Y QUALIT Y PER S HIF T / CUS TOM E R C HEC K B Y QUALITY PER S HIFT /
PAR T NUMB E R PAR T NUM B E R
C US TOME R C HE C K B Y QUALITY P ER S HIF T / CONFIR MAT IO N C HEC KS CO NF IR MATION DATE CONFIR MAT IO N C HEC KS CONF IR MATION DATE
P AR T NUM B E R
CONFIR MATIO N C HEC KS C ONFIR MATION DATE VE HIC LE SUP PLIE R A B C VEHIC LE SUPP LIER A B C
VE HIC LE S UPP LIER A B C
DE TECTE D AT P ROC ESS ST EP OP E RA TOR NAME 1.- ¿ HA VE PARAM ETERS B EEN COR RECTED IN SAF./ OPE R. IN TR UCTIONS? DETE CTED AT PR OCE SS ST EP OP ER AT OR NAME 1.- ¿ HA VE PARAM ETERS B EEN CORR ECTED IN SAF./ OPE R. INTR UCTIONS?
DE TE C TE D AT P ROC E SS STEP OP ER AT OR NAME
1.-¿ HA VE PAR AM ETERS B EEN CORR ECTED IN SAF./O PER . INTR UCTIONS?
2.- ¿ DO OP ERATIN G IN STRUC TIO NS M ATCH WITH Q UALIT Y CON TRO L PLAN? 2.-¿ DO OPE RATIN G IN STRUCTIO NS M ATCH WITH Q UALIT YC ON TRO L PLAN?
M AD E AT P R OC ES S S TEP TEA M LE ADER NAME MADE AT P R OCES S STEP TEAM LEADER NAME
2 .- ¿ DO OPER ATING INS TR UCTIO NS M ATCH WIT H Q UA LITY C ON TROL PLAN ?
M ADE AT P R OC ESS ST EP T EAM LEADER NAME NU MBE R OF DE FE CT S 3.- ¿ IS ALL DOCUM ENTATION COH EREN T? NUM BE R OF DE FE CT S 3.-¿ IS ALL DOCUM ENTATIO N C OH EREN T?
AC TION ON DEF EC TI VE PAR T S ACT ION ON DEFEC TIVE PAR TS
NUM BE R OF DE FECT S 3 .- ¿ IS ALL DO CUM ENTAT IO N C OH ERENT?
AC T ION ON DEF EC TIVE PAR T S 4.- ¿ AR E THE INSTR UCTIO NS CLEAR ? 4.-¿ AR E THE INSTR UCTION S CLEAR ?
1.- W HY DET EC T ED? DR AWING : 1.- W HY DETE C TE D? DR AW ING :
4 .- ¿ ARE T HE INSTR UCTION S CLEAR ?
1.- WHY DETE C TE D? DR AWING: 5.- ¿ AR E CR ITI CAL PO INTS C LEAR LY D ESCRIBED? 5.-¿ AR E CR IT IC AL PO INTS CLEAR LY D ESCRIB ED?
5 .- ¿ ARE C RITIC AL PO IN TS CLEAR LY DE SC RIB ED?

Generalization
6.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH TH E OPER ATING INSTR UCTIO NS? 6.-¿ DO ES ACTUAL P RO CESS MA TCH WITH THE OPER ATING INSTR UCTIO NS?
6 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H THE O PER ATING INSTR UCTIONS?
2.- DE FE C T DES C R IPT ION 7.- ¿ DO ES AC TUAL P RO CESS MA TCH WITH EXPEC TED CO R RECTIVE A CTION ? 2.- DE FE C T DESC R IPT ION 7.-¿ DO ES ACTUAL P RO CESS MA TCH WITH EXPEC TED CO RR ECTIVE A CTION ?
2 .- DEF E CT DES C R IPT ION
7 .- ¿ DOE S ACTUA L PR OCESS MATCH WIT H EXPEC TED CO RR ECTIVE AC TION ?
8.- ¿ AR E OP ERATO RS AWARE OF THE DEF EC T? 8.-¿ AR E OP ER ATO RS AWA RE OF THE DEFEC T?
8 .- ¿ ARE OPER ATO RS AWA RE O F THE DEFEC T?
9.- ¿ AR E OP ERATO RS AWARE OF THE EXP EC TED C OR RECT IV E ACTIO N? 9.-¿ AR E OP ER ATO RS AWA RE OF THE EXPEC TED C OR RECTIVE ACTIO N?
9 .- ¿ ARE OPER ATO RS AWA RE O F THE EXPEC TED C OR RECTIVE A CTION?
10.- AR E THE N EW POI NTS CH ECKED? WITH GOOD METH OD AN D TOOLS? 10.- AR E THE N EW P OIN TS CHE CKED? WITH GOOD METH OD AN D TOOLS?
3.- S UGGEST ION OF 3.- S UGGEST ION OF
10.- AR E THE NEW P OIN TS CHEC KED? WITH GOOD METHO D AND TOOLS? CO RR E C TIVE A CT ION C OR R E C TIVE A CT ION
3 .- S UG GE ST ION OF 11.- ¿IS THERE A VIS UA L A ID? 1.- ¿IS THER E A VIS UA L A ID?
C ORR E C TIVE AC T ION 11.- ¿IS TH ER E A VISUA L AID?
12.- ¿IS IT P OSTED O N A V IS IB LE SP OT? 12.- ¿IS IT POSTED O N A V IS IB LE SP OT?
12.- ¿IS IT POSTED O N A VISIB LE SP OT?
"AN SWE R QU ICKL Y!" 13.- ¿IS TH E CONTENT CLEA R? " AN S WE R Q UIC KLY!" 13.- ¿IS THE C ONTENT CLEAR ?

Consolidated data
"A NS WE R QUI CKLY!" 13.- ¿IS THE C ONTENT CLEAR ? A NSWER A NSWER
AN SWER 14.- ¿IS IT C OHER ENT WITH THE CO NTENT OF THE C OR REC TIVE A CTIO N? 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO R RECTIVE A CTION ?
1.-C AUSE: D RAWIN G: 1.- C AUSE: DR AWIN G:
1.-C AUSE: DR AWING: 14.- ¿IS IT COHER ENT WITH THE CO NTENT O F THE CO RR ECTIVE A CTION ?
15.- ¿H AS IT B EEN MODIFIED? 15.- ¿H AS IT BEEN MODIFIED?

Capitalization
15.- ¿HA S IT BEEN MODIFIED? C OMM ENTS: COMM ENTS :
CO MM ENTS: D ECISIO N OK OK OK DECISION OK OK OK
D ECISION OK OK OK
NG NG NG NG NG NG
NG NG NG

R E S ULT OF FOL LOW - UP AP U MGR S UPE RV . QUALITY TECH MGR RE SU LT OF FOL LOW - UP AP U MGR S UP ERV. QUALI TY T EC H MGR
RE SU LT OF F OL LOW - UP 2.- C OR RECT IVE A CTIO N 2.-C OR RECTIVE A CTIO N
AP U M GR S UP ER V . QU ALI TY T EC H M GR - P ERF ORM CHE CK1 M O N TH AF TER TH EC OR RECT IVE AC TION IMP LE MEN TATIO N. - P ERF ORM CHE CK 1 MO NT H AFT ER TH EC ORR ECT IVE AC TION IMPL EMEN TATION.
2 .- CO R RECTIVE A CTION - IN CAS E O FC AT. "A ", MAK EFOR MAL REP OR T - IN C AS E O FC AT. "A ", M AKE FOR MAL REP OR T
- P ERF ORM CHEC K 1 MO N T H AFTER T HE C ORR ECTIVE AC TIO N IMPLEME N TATIO N.
- IN C AS E O FC AT. "A ", MA KE FOR MAL RE PO R T - IN CAS E OF CA T. " B" ,IF RES UL TO FFO L LOW6UP ISO K, SEN D AN O FF ICIAL CLO SU RE T O - IN C AS E OF CA T. "B" , IF R ES ULT OF FO LLOW6U PI SO K, S EN D AN OFF I CIAL CL O SU RE TO
- IN C AS E OF CAT. "B" , IF RE SU LTO F FO LLOW6UP IS O K, SEN D AN OFFIC IAL CLO SU RE TO CUS TOME R C US TOMER
C US TOME R
Y M D A CTION IF NG (NOT GO O D) Y M D A CTION IF NG (N OT GO O D)
Y M D A CTIO N IF N G (NO T G O O D )

by APU by shift
APU MGR S UPE R V. QUALITY TE C H MGR YE AR AND DATE OF APU M GR S UPE R V. QUALITY TE CH M GR YE AR AND DAT E OF
YE AR A ND D AT E OF C ONF IR MATION C ONF IR MAT ION
APU MGR SUPE R V . QUALITY TEC H MGR
C ONF IR M AT ION COM MITM ENT DATE FOR D M Y COM MITM ENT D ATE FOR D M Y
C OM MITM ENT DATE FOR D M Y I PLEMEN TED
M I PLEMEN TED
M
IM PLEMEN TE D COR R EC TIVE AC TION GEN ER AL DECIS ION OK NG COR REC TIVE AC TION GENE RAL DEC ISI ON OK NG
C OR REC TIVE ACTIO N GENE R AL DEC ISION OK NG

Data A: data per month

Data B: Data per day
of month
Have defective
parts available

Modified 12 March 03 29
  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 30
  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 31
  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 32
  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 33
 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 34
  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?
-Are PDCA’s used in addition to assignment sheet for customer line
APU level.
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
shift1/shift2 day1/day2…? and no conclusion proposed without facts?
for
-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 35
  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 36
 Conclusion

San Gen Shugi

R QC
Q
Weekly Reporting

Factor Tree Analysis

Will you do it?

Modified 12 March 03 37