Built In Quality

• Built In Quality Assessment

• Area Manager

  Select Sam Dekok Annette Richards Lenny Coloca

  • Sam Dekok
  • Annette Richards
  • Lenny Coloca

• Focus Area

  Select Preweigh Mixing Plate Stamping Plate Preperation IAG Moulding Troika Moulding Line 1 Line 2 Stores & RM Store Warehouse pick & pack

  • Preweigh Mixing
  • Plate Stamping
  • Plate Preperation
  • IAG Moulding
  • Troika Moulding
  • Line 1
  • Line 2
  • Stores & RM Store
  • Warehouse pick & pack

• Document No.

• Conducted on

  Date

Standardised Work

Standard Operation Sheets (SOS) Production + HSE

• Have SOS sheets been implemented for all equipment and processes?

  Yes

  No

  N/A

• Is a program in place to monitor level of creation and implementation of existing SOS?

  Yes

  No

  N/A

• Is there a process to review, improve and periodical change SOS based on findings (planned and respected)?

  Yes

  No

  N/A

• Is SOS strictly followed by operators?

  Yes

  No

  N/A

• Is Standard Work for leaders in place and followed?

  Yes

  No

  N/A

Training, Skill and Cell Certification

• Is a flexibility (multiple-skill) matrix in place and implemented including target?

  Yes

  No

  N/A

• Is training scheduled an schedule plan is respected?

  Yes

  No

  N/A

• Is there training for new operators outside the production line eg dexterity school?

  Yes

  No

  N/A

• Are operators individual skills certified?

  Yes

  No

  N/A

• Is there team recognition of good performance and results?

  Yes

  No

  N/A

Standard Combination Sheet

• Is a process in place to periodically review or improve Standard Combination Sheets based on findings?

  Yes

  No

  N/A

Process Change Log (6M Changes)

Planned Change

• Does NPI planning, information flow down to operators?

  Yes

  No

  N/A

• Is info of planned change communicated on 6M board?

  Yes

  No

  N/A

• Is a tracking system in place for changes?

  Yes

  No

  N/A

Unplanned Change

• Is information of unplanned change communicated on the 6M board?

  Yes

  No

  N/A

• Are unplanned changes included in escalation process?

  Yes

  No

  N/A

• Is there an internal 8D/RCA system in place and functional?

  Yes

  No

  N/A

• Is there a tracking system in place for changes and reaction?

  Yes

  No

  N/A

Visual Management

Data Driven Process Control.

• Is capability data collection in place and SPC used for critical characteristics?

  Yes

  No

  N/A

• Is a plan in place to perform regular analysis of control chart, Cpk etc?

  Yes

  No

  N/A

• Is a system in place to perform continuous improvement for process capabilities?

  Yes

  No

  N/A

• Is RTY/FPY yield data collection in place for critical processes?

  Yes

  No

  N/A

• Is a system in place to hourly track rework or rejected parts?

  Yes

  No

  N/A

• Is system in place to identify and separate the scrap and rework part flow?

  Yes

  No

  N/A

• Are visual systems in place, installed on the lines?

  Yes

  No

  N/A

• Are layered audits in place and execution plan is respected?

  Yes

  No

  N/A

5S

• Is 5S system in place and effective, with clear standard quality points?

  Yes

  No

  N/A

Jidoka-Autonomation

Escalation Process, Andon To Stop And Fix The Problem

• Is quality performance visualised on performance boards (eg customer PPM, internal PPM, cost of scrap, quality pyramid)?

  Yes

  No

  N/A

• Do operators have possibility and authority to stop the line?

  Yes

  No

  N/A

• Are clear responsibilities assigned with defined triggers (eg #scrap/rework, SPC, PY) to start escalation)?

  Yes

  No

  N/A

• Is system in place and functional for visual tracking of issues?

  Yes

  No

  N/A

• Is system in place for improvement at all levels?

  Yes

  No

  N/A

Elimination cause of defects

Rapid Problem Solving

• Are trigger points for Root Cause Analysis defined?

  Yes

  No

  N/A

• Is there a system visual system in place to understand the actual status of Root Cause Analysis / 8D?

  Yes

  No

  N/A

• Are six sigma tools utilised (DMAIC)?

  Yes

  No

  N/A

• Are customer response times for 8D, information on time?

  Yes

  No

  N/A

Kaizen

• Are kaizen's generated and kaizen events planed to resolve quality issues ie error proofing?

  Yes

  No

  N/A

Prevention cause of quality escapes

Quality Assurance MatrixIs

• Is there a defined model for QAM (manual activities)?

  Yes

  No

  N/A

• Are clear responsibility assigned for QAM (who implements, who follows)?

  Yes

  No

  N/A

• Is QAM clearly linked to Standard Operation Sheets (refer quality points)?

  Yes

  No

  N/A

Protect The Customer

• Is there a PFMEA RPN score reduction program in place?

  Yes

  No

  N/A

• Are control plans and Standard Operation Sheets updated and linked to PFMEA?

  Yes

  No

  N/A

• Are CARE / Quality gates linked with Andon system and rapid Problem Solving?

  Yes

  No

  N/A

• Is early production containment linked with Andon and rapid problem solving?

  Yes

  No

  N/A

Error Proofing

• Is there a list of error proofing, classification and owner established?

  Yes

  No

  N/A

• Is there a reaction plan in case of malfunction (through escalation process)?

  Yes

  No

  N/A

• Is effectiveness of error proofing checked?

  Yes

  No

  N/A