內(nèi)容六西格瑪exhibit q updated vrt form4single point lesson

1、Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QFAP02-053 VRT Form 4 Single Point LessonExhibit Q3/30/12 Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QBSAQ Customer Pareto The BSAQ Customer Pareto Chart Sets The Rank Priority For Common Cause Issues Shown In The Pareto

2、Detail Sort Of The Form 4. It Is Available By Total Vehicle And Core Engineering Function / VFG.Both LTIS & HTIS Supporting Customer Indicators. Each of the seven (7) indicators are weighted equally at 14.3%. Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QForm 4 - Overall Structure Fo

3、rm 4 Is A Layered Report That Links Issues From ECB / Pareto With Actions In BSAQ.LayerDescription1) RankThe rank is the first layer of a Form 4 report. It is shaded tan and sets the priority of the issue. The rank row contains general information for the issue, paynter data from ECB and overall iss

4、ue status. Each rank can have multiple BSAQ concerns linked.2) ConcernThe concern layer contains all the concerns that have been linked to the issues (repair diagnosis) associated with the rank. The concern row contains: leader, SAQ number, ICA/PCA actions, ICA/PCA dates and concern status. A concer

5、n can have multiple linked repair diagnosis from ECB. If no concerns are linked from ECB, the system will provide a purple ”No Data” row.3) LinkThe link layer contains information associated with the link between ECB and BSAQ including: 7 position repair diagnosis, VRT, CCC, vehicle lines, plants, a

6、nd paynter data. At the Plant Level a unique link is created for differences in positions A, B, or Source Data (e.g. Warranty, GQRS). In the above example, two links are created, one for GQRS Data and one for Warranty Data. Each link can have multiple Critical Xs.4) Critical XThe Critical X layer co

7、ntains information for containment mapping, process validation, verification and critical X status. The same Critical X can be associated with more than one link. In the above example, the same Critical X is used for both the warranty and GQRS links.12341234Rank RowConcern RowCritical X LayerLink -

8、Repair Diagnosis to the Concern and paynter data (GQRS & Warranty)33CONCERN GENERAL INFORMATIONCONTAINMENT / MAPPINGPROCESS VERIFICATIONVALIDATIONCONCERN STATUS VALIDATION / CONFIRMATIONRANK STATUSPhase 1Phase 2Phase 3RankPart (Item)Concern / Concern TypePosition A, B, C, DFunctionCCC - Cust. Concer

9、n CodeSrc = Origin. Source, CountPVL = Paynter Vehicle LinesLPT = Linked PlantCritical XPre-DeliveryA = AuditD = Date/TextDeptI = Insp/CPD = Date/TextCapabilityWorkstation AnalysisTraining/VersatilityAcceptance CriteriaReaction PlansReplication/ContainmentProcess ImprovementError ProofingReplicated

10、Internal IndicatorCritical X StatusTitleTL = Team LeaderSAQ NumberPDS = Process /Supply/DesignRS = Resolution Scheme(C) Containment Production (P) Permanent Corrective ActionDateA-Actual P-PlannedContainment StatusPermanent Corrective StatusSource20110320110420110520110620110720110820110920111020111

11、12011122012012012022/12/20122/19/20122/26/20123/4/2012Last 4 WKSLast 4 MOPSMYTDContainment StatusPermanent Corrective StatusPart(Item)ConcernTypePOS. APOS. BPOS. CPOS. DCp/CpKBeforeAfterIssue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit Q General Information Describing The Overall Issues F

12、or Both The Rank And BSAQ Concern Layers.Top Concern Containment Validation Mapping Concern General Information Layer Found InTitleDescriptionRank Row OnlyRankThe ”Tan Row” is the priority of issue based on filters selected, such as Region, Plant, Vehicle Line, Function, or VFG. Items assigned durin

13、g the Binning Process (Utilizing the QLS Dictionary):Both Rank & ConcernPart (Item)Examples: Door, Hood, Seat, Mirror, Engine, Transmission etcBoth Rank & ConcernConcernExamples: Defective, Loose, Missing, Damaged, Inoperable, Out of Spec, Out of Balance Leaking, Noisy etcBoth Rank & ConcernConcern

14、TypeFurther definition of QLS Concern, examples: Creaking, Squeaking, Clunking, Leaks, Runs Rough, Wont Shift etcNot a default settingPosition ANot part of default standard setting for Rank, examples: Left / Right / Both Not a default settingPosition BNot part of default standard setting for Rank, e

15、xamples: Front / Rear / BothBoth Rank & ConcernPosition CWhich / Where, examples: Upper / Lower / Top / Bottom - C/UT 1.4 PFI (Engine Code)Both Rank & ConcernPosition DFurther definition, examples: Connector Number / Part Grid Location / Pin NumberBoth Rank & ConcernVRTVRT code associated with CCC s

16、elected durning binningBoth Rank & ConcernCustomer Concern Code (CCC)The Dealer Service Write-up Manager listens to the customer then selects the most appropriate code from a list to put on the claim. Will contain all applicable CCCs. Plant Binners read the Warranty Claim and confirm or “Re-Bin” the

17、 CCCRank Row OnlyOrigination Source (Src)Automatically records the source of the concern information (Warranty GQRS, QLS, or Other) and the count.Both Rank & ConcernPaynter Vehicle Lines (PVL)Automatically populates the Vehilce that contribute to the Paynter Data Vehicle LinesConcern Row OnlyLinked

18、Plant (LPT)The Plant(s) that are linked for the specific Concern.Rank RowConcern RowIssue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTitleDescriptionCritical XCritical Xs are the key controllable and measurable characteristics or inputs of a product or process whose performance standard

19、s, or specification limits, must be met in order to satisfy the customer regardless of binning (Process, Design, Supplier Process or Suppler Design).Top Concern Containment Validation Mapping Containment / Mapping SectionContainment Mapping Detail:Critical X:Concerns typically will have at least one

20、 Critical X and may have several others.In order to contain a Critical X you must be able to replicate the customers concern, detect it and distinguish between Good and Bad.Primary Critical Xs are those items that can be controlled within the Manufacturing Plant.Suppler Process or Supplier Design Is

21、sues may have one or more Critical Xs and can be added to show what has been identified and implemented at the Supplier to map and contain the concern. Each Critical X is shown on a seperate row. Critical Xs Are Key Controllable & Measureable Characteristics.1Issue Date: 20110701 Revised Date: 20120

22、330FAP02-053 Exhibit QTitleDescriptionPre-Delivery Audits:Date / TextIdentify inspection stations, and Finished Product Audits. Examples Assy GFCPA, Surveillance Audits and CAL inspection, CBT, S&R, PT Dyno Test / Drive, Final Quality Audit , Dock Audit. As well as date check intitiated and any addi

23、tional information.Dept:Date / TextIdentify the different inspection stations, control points and audits. Examples Assy - Base Department EOL and Base Department Control Points, PT 100% Final/Cold Test, In-Process Testing additional added inspection items or locations. If a NEW inspection is added b

24、e sure to add it to the Quality Confirmation Maps per procedure VOPQUG-273 or PTP07-273 with the date it was added.Capability Cp/CpKIf critical X is related to a machine, provide the capability. It is important to understand the tooling process capability for identifying interim and permanent correc

25、tive actions. This may include Pp/Ppk.Top Concern Containment Validation Mapping Containment / Mapping Section (Continued)Containment Mapping Detail (continued):Pre-Delivery Audits: When Mapping a Critical X where in the Assy Process GFCPA, Surveillance Audits and CAL or in the PT Process Dyno Test,

26、 FQA or Dock Audits could we have found the customer concern. If there is an inspection for it, why did we not see it. What do we need to change in the inspection to better replicate the Customer Concern? Dept. Audits: This is also done for any additional inspection in the base dept. If we are not l

27、ooking for it, “where can we look for it”, and then ensure we add it to the Quality Confirmation Maps per VOPQUG-273 or PTP07-273.Capability: If a process can be measured for capability (Cp/Cpk or Pp/Ppk) it should also be recorded in this section of the Form 4.General:The Mfg VRT/PRT Co-Lead is res

28、ponsible to ensure the plant is performing all audits and related processes correctly. They also must ensure that they are documented and checked correctly in the Containment Mapping section of the Form 4.The team is tasked with making every effort to replicate, detect and contain the customer conce

29、rn in the Manufacturing Plant.Even if the customer concern issue is latent, plant must do its due diligence to ensure if it occurs within the plants audit processes it will be found & contained.Concerns that can be detected at the Suppliers operation should also be documented as to where and how the

30、y are being inspected.If no actions are possible input date and N/A (Not Applicable) to show that team considered all possible opportunities. Empty Boxes Give The Appearance That The Team Is Not Considering Or Actively Addressing Containment Or Possible Solutions.234Issue Date: 20110701 Revised Date

31、: 20120330FAP02-053 Exhibit QTop Concern Containment Validation Mapping Containment / Mapping Section Empty Boxes Give The Appearance That The Team Is Not Considering Or Actively Addressing Containment Or Possible Solutions.1234CONCERN GENERAL INFORMATIONCONTAINMENT / MAPPINGPROCESS VERIFICATIONVALI

32、DATIONPhase 1Phase 2Phase 3RankPart (Item)Concern / Concern TypePosition A, B, C, DFunctionCCC - Cust. Concern CodeSrc = Origin. Source, CountPVL = Paynter Vehicle LinesLPT = Linked PlantCritical XPre-DeliveryA = AuditD = Date/TextDeptI = Insp/CPD = Date/TextCapabilityWorkstation AnalysisTraining/Ve

33、rsatilityAcceptance CriteriaReaction PlansReplication/ContainmentProcess ImprovementError ProofingReplicated Internal IndicatorCritical X StatusPart(Item)ConcernTypePOS. APOS. BPOS. CPOS. DCp/CpKBeforeAfter10CUP HOLDERDISLIKE, DESIGN, , , Function: F7CCC: B80,T49,T50Src: PVL: CI-FOCUS (NA-MP)LPT: Di

34、slike Cup Holder LocationA: DNMCEN/A N/A2/3/20122/3/20122/3/20122/3/20122/3/20122/3/2012N/A0100%CUP HOLDERDISLIKE, DESIGN, , , Function: F7CCC: B80,T49,T50Src: GQR,57PVL: CI-FOCUS (NA-MP)LPT: AP-MICHIGAN PLANTIssue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTop Concern Containment Valid

35、ation Mapping Containment / Mapping SectionTitleDescriptionPre-Delivery Audits: Date / TextIf issue was originally a Meets Design Intent ”MDI” Record as Predelivery Audit with the letters “DNMCE” Does NotMeet Customers Expectation. MDI documentation should be updated to remove issues as an MDI if is

36、sues occurrence rate is less than 100%. Quality Manager / VEM is responsible to communicate to GFCPA Auditors that MDI has been removed and that the call should be made at the observed severity level.Handling Issues Formally Known As Meets Design Intent “MDI”Create a BSAQ concern with issue descript

37、ion and impactCreate a Critical X associated with an “Other” linkCritical X Description = Describe IssuePredelivery Audit = Does Not Meet Customers Expectation “DNMCE” Formally “MDI”Concern Will Be Included in Form 4 Pareto Detail Report - Critical X Status = Not RatedRecord Replicated Internal Indi

38、cator Before = 0 After = 100%TitleDescriptionWorkstation AnalysisNotify the Process Coach and/or the Team Leader that the workstation has been identified as a potential Critical X. Verify for Assy GSPAS / APT or DCP & Process Sheets for PT and QPS-OIS are all aligned. Request the Process Coach and/o

39、r Team Leader to co-conduct a Periodic Job Observation with the VRT/PRT member to verify that the operator is following the process. Verify proper tooling torque, parts and sequence are being followed. When the process is verified as being completed correctly for all shifts and operators performing

40、the process, document with the date and Rotation, Serial, or Lot number to identify the cutoff point. Training VersatilityVerify that ALL the operators that perform the Critical X operation are fully trained. Record date of check and Rotation, Serial, or Lot number to identify the cutoff point when

41、completed for all shifts.Acceptance CriteriaFor each Critical X, check robustness of Quality Acceptance Criteria (QAC) validate the acceptance criteria meets or exceeds engineering standards and are posted at the base operation(s), the inspection and containment points, repair areas (if required) an

42、d CAL or Final Inspection. Record date of check and Rotation, Serial, or Lot number to identify the cutoff point when completed for all shifts.Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit Q123Top Concern Containment Validation Mapping Process Verification Phase 1Process Verification

43、Phase 1 Detail:At the end of this phase: 1) the team should be able to answer the questions: Is there a Standard?, Is the Standard being followed, and is the Standard sufficient? and 2) Process, Design or Supplier binning should be confirmed.1. Workstation Analysis:For Critical X operations (A) Noti

44、fy the Process Coach and/or Team Leader (B) Validate the QPS-OIS & QPS-WES posted at the workstation are aligned to the current Engineering process standards (GSPAS / APT / DCP / Control Plan). (C) Request the Process Coach and/or Team Leader to co-conduct a PJO to validate the operator(s) are follo

45、wing the process standard as prescribed on QPS-OIS & QPS-WES including the use of proper tooling, torque, parts and sequence (Evaluate if the QPS-OIS & QPS-WES can be followed as written?) . ( D ) Review any Single Point Lessons (SPL) or other Process information that may be posted at the workstatio

46、n, validate the information is current and relevant to the workstation (note SPL information should be contained within a QPS-WES for document control). (E) If the QPS-OIS or QPS-WES can not be followed as written request the documents get revised and the operator(s) retrained immediately. If the op

47、erator was not following the QPS-OIS or QPS-WES as described notify the Process Coach immediately and reference Phase 3 Process Improvement section A.2. Training Versatility:(A) Is there adequate cover (min 3/shift for CTQ operation). (B) This process must be verified with all operators on all shift

48、s that perform the Critical X operation. (C) Verify the dates of the Versatility records are later than the revision date on the QPS-OIS & QPS-WES. 3. Acceptance Criteria:Does the Acceptance Criteria match or exceed the customers expectations?Process VerificationMfg Co-Lead is responsible to ensure

49、Phase 1, 2 & 3 of the Process Verification gets completed.Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTop Concern Containment Validation Mapping Process Verification Phase 1 In The Example Above The Phase 1 Criteria Was Verified For The Workstation Analysis, Training / Versatility

50、And Acceptance Criteria. All Checks Were Completed On 1/5/2011 Prior To Rotation # 12345 Leaving The Workstation.123TitleDescriptionReaction PlansAt point of detection, reaction plan has been updated if necessary and is understood & followed “i.e. Place suspect material on hold (in QLS / QLSCM) noti

51、fy base operation etc. Record date of check and Rotation, Serial, or Lot number to identify the cutoff point when completed for all shifts. ”For VO Assembly QLS Tip Level Implementation verify that a QLS Tip level has been established and activated, when plants QLS system is available to do so Repli

52、cation / ContainmentVerify that the inspection process will detect the issue/ failure as experienced by our customers. Record date of check and Rotation, Serial, or Lot number to identify the cutoff point when completed for all shifts.Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTop

53、 Concern Containment Validation Mapping Process Verification Phase 212All Phases of the Process Verification section need to be completed.Process Verification Phase 2 Detail:Reaction Plans:(A) Validate the Inspector is following the reaction plan as prescribed on process documentation (QPS-OIS & QPS

54、-WES) (Evaluate if the QPS-OIS & QPS-WES can be followed as written?) . (B) Validate the Reaction Plans are documented and are understood. ( C ) Review any Single Point Lessons (SPL) or other Process information that may be posted in the inspection station, validate the information is current and re

55、levant (note SPL information should be contained within a QPS-WES for document control). (D) If the QPS-OIS or QPS-WES can not be followed as written request the documents get revised and the inspectors(s) retrained immediately. If the inspector was not following the QPS-OIS or QPS-WES as described

56、notify the Process Coach (Supervisor) immediately.This process must be performed with all Inspectors on all shifts that inspect the Critical X operation.Replication / Containment:Will current Inspection & Containment Actions meet or exceed the Customer Expectations, if not what needs to change and w

57、hen will it happen. Record date of change and Rotation, Serial, or Lot number to identify the cutoff point when completed for all shifts. Process VerificationIssue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTop Concern Containment Validation Mapping Process Verification Phase 2In The Ex

58、ample Above The Phase 2 Criteria Was Also Verified For The Reaction Plans And Replication / Containment. Checks Were Completed On 1/5/2011 Prior To Rotation # 12345 Leaving The Workstation.12Issue Date: 20110701 Revised Date: 20120330FAP02-053 Exhibit QTitleDescriptionProcess ImprovementProcess impr

59、ovements can be identified using the follow resources: (A) Operator, using the PJO-Deep Knowledge process (B) Manufacturing Workstation Readiness to validate basic standards are in place and functioning. ( C) Workstation Stability & Continuous Improvement Map that visually identifies areas for impro

60、vement based on standard metrics and evaluations. VRT/PRT must work with Process Coach/Team Leader and Engineering to identify and implement improvement actions. Record date of check and Rotation, Serial, or Lot number to identify the cutoff point when completed for all shifts. If no actions or impr