605

A

Abstraction, 151Active root cause verification, 361Activity network, 586Advanced product quality planning

(APQP), 7, 8, 18, 32, 257258characteristics, and relationship

with production part approval process, 911

control plans, 263fundamental elements of, 260262initiatives, 258259reporting, 259260reviews, 207risk assessment, 262263Schaefflers characterization, 264274supplement K worksheet, 263, 275

Affinity diagram, 586AIAG, see Automotive Industry Action

Group (AIAG)All around symbol, 308All around this side of parting line, 308Amateur errors, 203American Society of Mechanical

Engineers (ASME), 305, 306, 308, 316, 320, 324326, 328

Analogy, 151Anderson-Darling statistic, 394Andon, 100Angularity, 308ANOVA, 244, 252, 445Applied problem solving (APS),

152,200APQP, see Advanced product quality

planning (APQP)APS, see Applied problem solving (APS)APW, see Average production weekly

(APW)Arc length, 308Area sensors, 461ASME, see American Society of

Mechanical Engineers (ASME)AS 9100, 13, 15, 51

Auditchecklists and, 195196definition, 179performing, 182183

error-proofing audit, 193layered process auditing (LPA),

188193process audit, 184188product audit, 183184

preparation, 463503successful, 55types, 180182

Auditing, definition of, 179Automotive Industry Action Group

(AIAG), 397, 441CQI-8, 188

Autonomation, 92, 104Average production weekly (APW), 285,

291, 300

B

Balanced scorecard, 69, 71Bar chart, 84, 248, 251, 586587Beam sensors, 461Benchmarking, 5, 85, 117, 414Bilateral tolerance, 316Birdbeak, 326Black belts, 401Brainstorming, 121, 152, 222223, 587Breakthrough, 158Business costs, 224BX life, 395396

C

Capacity analysis, 289capacity analysis report (CAR), 291293capacity information maintenance,

301302goal, 289291overall equipment effectiveness

(OEE), 293294for availability, 296

Index

606 Index

demonstrated, 296297demonstrated OEE

improvement,295enablers to improve demonstrated

OEE, 298evaluation, 294295for performance efficiency, 296for quality rate, 296required, 298299

reaction and plan expectations, 300301

shared loading analysis and, 299300thought starters for supplier capacity

volume improvement and, 302303

total allocation, 300Capacity analysis report (CAR), 291293CAR, see Capacity analysis report (CAR)Cause and effect, 122, 587CEO, see Chief executive officer (CEO)Champion, 340, 353, 364, 370371

Six Sigma, 401402Changeover time, 561562Chargebacks, 392Checklists, 183, 195196, 449452, 533Check sheet, 119, 587588Chief executive officer (CEO), 109Chief process officer (CPO), 109Chronic problem, 158Circular runout, 330CMM, see Coordinate measuring

machine (CMM)Coaxial controls overview, 330Color marking sensors, 461Column chart, 579Complete data, 394Comprehension model, 152153Concentricity, 308Conical taper, 308Contact method, 200Continual improvement, 6971, 108, 112,

130, 414; see also Kaizenboard, 382383control strategies, 101items of concern in

one-piece flow, 7477process flow diagram, 7785value stream map, 8692

objective of, 116

process, 116117process teams, 7174tools used, 586599visual factory (6s), 92101visual management and

relationships, 101Continuous feature symbol, 308Continuous flow, 566567Contour plot, 396Control chart, 122, 139, 144, 217, 444,588Controlled radius, 308309Control method, 220, 444Control plan, 19, 3132, 263, 278, 450, 523

gauge, 527and operator instructions, 33, 443444requirements, 14simplified, 524

Control points evaluation, 80Coordinate measuring machine (CMM),

241, 322, 325Counterbore/spotface, 309Countersink, 309CPO, see Chief process officer (CPO)Critical items, for customers, 411412Critical success factors, 52CtM (3D CAD data file), 313Cultural costs, 224Customer cross-functional teams, 6, 7,

27, 3637Customer satisfaction, 46, 116, 130, 386,

532, 550Cycle time, 82, 105, 574, 576Cylindricity, 309

D

Datum, 324327, 331332feature, 309and target datum symbols, 323targets, 309, 325326

Datum reference frame (DRF), 323Datum translation symbol, 312DCOV, see Define, characterize, optimize,

and verify (DCOV) modelDCP, see Design control plan (DCP)Decision tree, 588Defect, 202, 335, 398, 455

comparison with error, 205206, 455456

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

607Index

comparison with mistake, 199, 200, 218, 456

definition, 565relationship with Sigma, 399zero, 116, 208, 210212, 216, 382

Define, characterize, optimize, and verify (DCOV) model, 401

and statistical process control (SPC),149

Define, measure, analyze, design, and verify (DMADV), 400401

Define, measure, analyze, improve, and control (DMAIC), 399400

and statistical process control (SPC),149

Demand-based flow manufacturing, see Lean manufacturing

Department improvement teams (DITs), 175

Deployment flowchart, 581Depth/deep, 309Descriptive geometry, 305Design control plan (DCP), 440, 441Design failure mode and effect analysis

(DFMEA), 37, 207, 278, 313Design of experiments (DOE), 145, 589Destructive testing, 248DFMEA, see Design failure mode and

effect analysis (DFMEA)Diameter, 309Dimension origin, 309Displacement sensors, 461Disposition, 2324

approvalachieved, 25denied, 24revoked, 25

nonmanufacturing site, 26required, 24tier 2, 25waived, 2526working toward quality system, 24

DITs, see Department improvement teams (DITs)

DMADV, see Define, measure, analyze, design, and verify (DMADV)

DMAIC, see Define, measure, analyze, improve, and control (DMAIC)

Dock to dock (DTD), 558559

DOE, see Design of experiments (DOE)Double feed sensors, 461DRF, see Datum reference frame (DRF)DTD, see Dock to dock (DTD)DtM (2D drawing), 313DtMC (2D drawing and 3D CAD data

file), 3138D model, 156, 208, 335336

application criteria, 336337interim containment action (ICA),

352353evaluating questions, 354355process guidelines, 353354

PCAs choosing and verification for root cause and escape point, 362

evaluating questions, 363364process guidelines, 362363

PCAs implementation and validation, 364365

evaluating questions, 366367ICA removal, 365process guidelines, 365366

problem description, 344346development process, 348351evaluating questions, 351352process guidelines, 346348

problem recurrence prevention, 367369

evaluating questions, 371372process guidelines, 369371

problem-solving process preparation, 337339

process flow and team establishment, 339340

membership, 343344process guidelines, 342343team composition, 340342warming up, 343

root cause and escape point definition and verification, 355356

evaluating questions, 357358generic simple root-cause

analysis, 358guidelines, 356357root cause determination, 358361root cause verification, 361supplemental tools, 361

success factors, 378379summary evaluation, 375378

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

608 Index

team and individual contributions recognition, 372373

evaluating questions, 374375process guidelines, 373374

E

Employee balance chart, 575576Employee readiness and training

review, 32Enterprise alignment and continuous

process improvement, 93Error and defect, comparison

between,206Error-proofing; see also Poka-yoke

approaches, 565audit, 193

partial form of, 194benefits, 566defect definition, 565error definition, 565method, 565566sides, 564teams, 565

Evaluation model, 153Execution and communication

model,153Executive management, 116, 401, 402

F

Facilitator, 341342Failure mode and effect analysis

(FMEA), 3132, 145, 207, 397, 440, 589

reviews, 208Failure rate vs. time plot, 396Fake flow, 92Fast response board (FRB), 6970, 72Fault tree analysis, 589590FCF, see Feature control frame (FCF)FDJ, see Final data judgement (FDJ)Feature control frame (FCF), 309,

323324Feature of size (FoS), 319322, 325,

328329Fiber sensors, 461FIFO, see First-in first-out (FIFO)

Final data judgement (FDJ), 36First-in first-out (FIFO), 466, 472, 478,

493, 572First-party audit, 180First time quality (FTQ), 70, 471First time through (FTT), 5565585-step model, 160

correction verification, 164problem correction, 163164problem recurrence prevention,

164165problem root cause finding, 163problem selection, 163recycle, 165

5 Whys model, 156, 2125X number of places, 310Fixed-value method, 200Flatness, 306, 309Flow chart, 119, 590; see also Process flow

diagrambasic (macro level), 580581deployment, 581opportunity, 581process, 77, 87, 268, 542, 590, 582

FMEA, see Failure mode and effect analysis (FMEA)

Focal objects method, 152Force field analysis, 122, 590Ford production system (FPS), 382384Forgetfulness, 202203FoS, see Feature of size (FoS)FPS, see Ford production system (FPS)FRB, see Fast response board (FRB)Free state variations, 309FTQ, see First time quality (FTQ)FTT, see First time through (FTT)Function analysis, 405

G

Gant chart, 591Gauge repeatability and reproducibility

(GR&R), 33, 230234, 278, 445, 474, 519520

in Minitab, 238240nested, 250selection process for crossed, 244

GD&T, see Geometric dimensioning and tolerancing (GD&T)

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

609Index

Geometric dimensioning and tolerancing (GD&T), 305306

coaxial controls overview, 330datum, 324327

targets, 325326datum and target datum

symbols,323diamond P and D requirements,

315316drawing types, 313feature control frames (FCF),

323324feature of size (FoS), 319321independency, 323key elements to review, 330332

MMC and LMC, 332regardless of feature size (RFS),

332334language, 306312least material condition (LMC), 322maximum material condition

(MMC), 321orientation, 327

projected tolerance zone, 328329

rules applied and things to remember, 327

profile controls, 329330circle U modifier, 329

title blocks and notes, 314315tolerance modifying symbols, 323tolerance types, 316317

basic dimensions, 317319line conventions on production

drawings, 319virtual condition, 322

Geometric tolerance, 316Good parts produced (GPP), 297GPP, see Good parts produced (GPP)GR&R, see Gauge repeatability and

reproducibility (GR&R)Green belts, 401Green rating, for items, 96, 259GROW model, 153154Growth, in quality perception, 411

H

Histogram, 84, 122, 591

How to solve it model, 154Hypothesis testing, 152

I

IATF, see International Automotive Task Force (IATF)

ICA, see Interim containment action (ICA)IDEFO (ICOM definition), 591592Identification mistakes, 203Inadvertent mistakes, 203204Incoming quality control, 33Independency symbol, 310Information inspection, 216In-process supermarket, 567568Intentional mistakes, 204Interim containment action (ICA),

352353development, 376evaluating questions, 354355process guidelines, 353354removal, 365

International Automotive Task Force (IATF), 14, 280

International Standard Organization (ISO), 127129; see also individual entries

individual certifiable clauses, 131analysis, measurement, and

improvement requirements, 134135

management requirements, 132133management system general

requirements, 131132resource requirements, 133services and products

requirements, 133134key elements, 129131pending changes for 2015 revision,

135136Interval/left censored data, 394ISO, see International Standard

Organization (ISO)ISO 9001, 1314, 31, 51, 127, 131, 179ISO 13485, 51ISO 14000, 52ISO 14001, 14, 15, 23, 49, 439ISO/TS 16949, 1516, 23, 49, 51, 182,

439440

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

610 Index

J

Jidoka principle, 92, 104, 385JIT, see Just-in-time (JIT)Judgment inspection, 216217Just-in-time (JIT), 385, 387, 388, 566

K

Kaizen, 112, 158, 383, 385, 580, 582; see also Continual improvement

Kanban, 385, 568572Kano model, 130, 592Kappa statistic, 592

calculation, 235236Cohen, 235Fleiss, 235

Kendalls coefficient of concordance, 235, 236

Kepner-Tregoe model, 154

L

Lack of standards mistakes, 204Lateral thinking, 152Launch overlay, 48Layered process auditing (LPA),

188193, 195benefits of, 192business impact of, 192193elements of, 188indicating documentation and

progress, 191typical format of, 189typical form of management, 190typical form to track

nonconformances in, 196Leadership, significance of, 130Lead time, 86, 8889, 228Lean manufacturing, 103104, 577; see

also individual entrieseasier application for, 108112goals and strategy, 105106lean deployment guideline sheet,

554556lean functions, for lean enterprise, 554model, 156, 158steps to achieve systems of, 106108warning for, 112113

Lean sensei, 104Least material condition, 306, 309, 322,

332, 333Liability costs, 224Life data analysis, 394395Limited involvement overlay, 4849Line graph, 84, 592593Long-term corrective action, 221LPA, see Layered process auditing (LPA)LRT P, 394

M

Manufacturing capabilitydemonstration, 442447planning, 31, 439442

Manufacturing site assessment (MSA), 2225, 27

typical form, 2934Maslows theory of needs, 505, 512516Master black belts, 401Material delivery date (MDD), 261Matrix data analysis chart (MDAC), 593Matrix diagram, 593Maximum material condition, 310, 320,

321, 332, 333Maximum production weekly (MPW),

285, 291, 300MDAC, see Matrix data analysis chart

(MDAC)MDD, see Material delivery date (MDD)Mean life, 395Means-ends analysis, 152Measurement system analysis,

227229,278data types, 229230Minitab, 230

attribute, 235241gauge repeatability and

reproducibility (GR&R), 230234key to success, 253254percentage numbers explanation,

248, 252253possible bias causes, 254possible linearity issues, 254repeatability and reproducibility

issues, 253variable, 241248, 249252

Metal passage detectors, 461

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

611Index

Minitab, 394; see also under Measurement system analysis

Mistake proofing, see Poka-yokeMisunderstanding mistakes, 203Morphological analysis, 152Motion-step method, 200Movable datum targets, 310MPW, see Maximum production weekly

(MPW)MSA, see Manufacturing site assessment

(MSA)Muda (non-value-adding work), 103Mura (unevenness), 104Muri (overburden), 103

N

NAT, see Net available time (NAT)Net available time (NAT), 297Net ideal cycle time (NICT), 297New-tooled end-item (NTEI), 28NICT, see Net ideal cycle time (NICT)Nominal group technique, 121, 593594Non-value-added activity, 88, 209, 215NTEI, see New-tooled end-item (NTEI)

O

Observe, orient, decide, and act (OODA) loop, 154155

OEE, see Overall equipment effectiveness (OEE)

One-piece flow, 7477On-site evaluation, 3740OODA, see Observe, orient, decide, and

act (OODA) loopOpportunity flowchart, 581Original wastes, 105106Overall equipment effectiveness (OEE),

34, 70, 9192, 293294, 559561for availability, 296demonstrated, 296297

enablers to improve, 298demonstrated OEE improvement, 295evaluation, 294295for performance efficiency, 296for quality rate, 296required, 298299

improving, 299

Overlays, 48launch overlay, 48limited involvement overlay, 4849quality overlay, 48

P

PACT principle, 512Painter chart, 85Parallelism, 310Pareto chart, 70, 8485, 121, 594Pareto principle, 119Parting lines, 310Part submission warrant (PSW), 7, 35,

40, 42, 388, 452Passive root cause verification, 361Paynter chart, 122PCAs, see Permanent corrective actions

(PCAs)PDCA, see Plan, Do, Check, Act (PDCA)

modelPDPC, see Process decision program

chart (PDPC)Permanent corrective actions

(PCAs),336choosing and verification for root

cause and escape point, 362,377evaluating questions, 363364process guidelines, 362363

implementation and validation, 364365, 377

evaluating questions, 366367ICA removal, 365process guidelines, 365366

Perpendicularity, 310PFMEA, see Process failure mode and

effect analysis (PFMEA)Physical layout, 583586Pitch, 573575PITs, see Process improvement teams

(PITs)Plan, Do, Check, Act (PDCA) model,

7273, 112, 127129comparison with OODA loop, 155typical form to generate and

summarize events of, 74Planning, analysis, and synthesis

model, 153Point-to-point comparison, 392

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

612 Index

Poka-yoke, 82, 199, 455common error-proofing devices and,

460461corrective action, 221223defects and errors, 455456development process, 453essentials, 204209generic worksheet and example, 454historical perspective, 199200human mistakes correction

approaches, 213220mistake alerting signals and, 460mistake types and accompanying

causes and, 456460presentation of findings, 224red flag conditions, 220221steps and application, 210213strategy, 200202systems, 202204types of, 200zero defects concept in, 210, 211, 212

Positioning sensors, 461Position tolerance, 310, 328329, 333Post-it Notes, 576PPAP, see Production part approval

process (PPAP)Precap inspection, 183Prevention and detection approaches,

comparison of, 206207Preventive maintenance and

housekeeping, 34Prioritization matrix, 594Probability of failure, 395Probability plot, 396Problem solving and corrective

actions, 34Problem-solving methodology, 151

cycle, 160165definition, 158160model types, 151158process improvement cycle and,

167176tools, 165167

Process audit, 184188benefits of, 187business impacts of, 187188circumstances to conduct, 187partial audit form, 185186steps in, 185

Process capability, 20, 31, 171, 272, 439442, 595

Process decision program chart (PDPC), 595

Process efficiency, 228Process failure mode and effect analysis

(PFMEA), 32, 207, 278Process flow diagram, 77, 278; see also

Flow chartas is phase, 77

mission statement development,79

process boundaries definition, 79process definition, 79process owner and team member

selection and identification, 78process scope selection, 79process selection for investigation

and study, 78could be phase, 85should be phase, 7985

Process improvement cycle, 167168fourteen-step process, 168173

Process improvement measurement, 83Process improvement teams (PITs), 175Process lead, 59, 65Process monitoring, 84Process specialists, 65Process submission warrant,

280282,286full, 286interim, 286287rejected, 287

Process variability monitoring and reduction, 33

Product audit, 182, 183184, 502Product development timing, 35

organizational timing principles, 68

timing example of automotive industry timing, 811

Production part approval process (PPAP), 7, 8, 32, 277281

actual requirements, 286capacity analysis, 283284capacity report, 285checklist, 449452key clarifications, 286287misconceptions about, 285286

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

613Index

relationship with advanced product quality planning (APQP), 911

submission levels and approvals, 281282

verification flow, 282283Production system implementation,

386387Production system model, based on

American engine plant, 387388

Product realization, 1820Profile control, 329330

circle U modifier, 329Profile of a line, 310Profile of a surface, 310Profile tolerance, 308, 312, 329Program engineer, 6061Program target compatibility (PTC), 36Projected tolerance zone, 310Project risks minimization, 402403PSW, see Part submission warrant (PSW)PTC, see Program target compatibility

(PTC)Pull system, 104, 386, 493, 554556, 567P-value, 394

Q

QFD, see Quality function deployment (QFD)

QMS, see Quality management system (QMS)

QOS, see Quality operating system (QOS)

Quality audits, 179Quality function deployment (QFD),

145, 170, 414Quality management system (QMS),

17, 51Quality operating system (QOS), 19, 110,

117122, 440implementation, 122, 123, 124meeting summary, 122126need for quality and discipline

issues, 115117potential measurables, 120

Quality overlay, 48Quality system, of original equipment

manufacturing (OEM), 13

customer-specific standards, 2123disposition, 2326industry standards certification n,

1521ISO 14001, 15ISO 9001 certification, 1314

control plan requirements, 14Quick changeover method, 561563

R

Radius, 310Rapid problem resolution (RPR),

155156R chart, 248, 251, 252Recorder, 341Red flag conditions, 220221Red rating, for items, 9596, 259, 260Reference dimension, 310Regardless of feature size, 306, 310, 320,

332334Regardless of material boundary, 306,

320, 322Relationship diagram, 595596Reliability vs. time plot, 396Representation model, 153Resident and plant engineer, 6263Resource management, 18Resources, conscious use of, 117Responsible supplier indicators, 412414Risk priority number (RPN), 207, 397Root-cause analysis, 116, 152Root cause and escape point definition

and verification, 355356, 376377

analysis, 116, 152, 358359evaluating questions, 357358guidelines, 356357permanent corrective actions (PCAs),

362, 377evaluating questions, 363364process guidelines, 362363

root cause determination, 358361root cause verification, 361supplemental tools, 361

Roundness, 311RPN, see Risk priority number (RPN)RPR, see Rapid problem resolution

(RPR)

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

614 Index

Run chart, 110, 122, 125Runout, 311, 312, 317, 330

S

Safety and health achievement recognition program (SHARP), 382

Safety, Quality, Delivery, and Cost (SQDC) board, see Fast response board

Scatter diagram, 122, 596SCCAF, see Special Characteristics

Communication and Agreement Form (SCCAF)

Second-party audit, 180Segmentation, 45

applications, 4950definition, 4546model, 4748overlays, 48

launch overlay, 48limited involvement overlay,

4849quality overlay, 48

Self-check, 215comparison with successive

checks,217SfQ, see Sourcing for quality (SfQ)Shared loading analysis, 299300SHARP, see Safety and health

achievement recognition program (SHARP)

Short-term corrective action, 221Shut down method, 220Simplification process, 8283Simulation in lean, 596597Single minute exchange of dies (SMED),

8991Site engineer, 5960, 62, 64Six Sigma, 148149, 175, 383, 398399

forms, 505507analysis, 524control, 526definition, 512516improvement, 525526measurement, 517524miscellaneous, 526528typical, 528553

methodology, 399define, measure, analyze, design,

and verify (DMADV), 400401define, measure, analyze,

improve, and control (DMAIC), 399400

Six Sigma mastery level, 401402requirements to understand, 505,

5085126S principle, 9499, 101Slope, 311Slowness mistakes, 204SMED, see Single minute exchange of

dies (SMED)Source inspection, 215, 217Source inspection audit, 183184

benefits of, 184business impact of, 184

Sourcing for quality (SfQ), 35general procedures, 43

emergency resourcing to nonqualified facility, 44

new and initial sourcing and nonemergency resourcing, 43

sourcing to sites with waiver, 4344

supplier sourcing, 36cross-functional teams formation,

3637priority suppliers selection, 36team kickoff meetings beginning,

3742Spaghetti diagram, 582SPC, see Statistical process control (SPC)Special Characteristics Communication

and Agreement Form (SCCAF), 275

Spherical diameter, 311Spherical radius, 311Spike, 392Sporadic problem, 158Spot face, 311Square, 311SREA, see Supplier request for

engineering approval (SREA)Standardization, 27, 7677, 81, 97, 158,

583; see also International Standard Organization (ISO)

of measurable, 119

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

615Index

of operator instructions, 443of work and tasks, 111, 383, 471

Standardized work instructions (SWIs), 472473

Standard work, 577579Standard work-in process, 77Statistical process control (SPC), 33, 139,

171, 444model, 139141

continuous improvement of process performance, 146148

process controls definition and establishment, 144146

process identification and definition, 141

process ownership and responsibilities establishment, 141144

seven-step approach to implement, 147148

Six Sigma and, 148149Statistical tolerance, 311Straightness, 311Stratification, 122Streamlining process, 8182String diagram, 597Subsupplier quality management, 32Supplement K worksheet, 263, 275Supplier development, 5152, 188, 412

benefits, 5455fundamentals, 5254

Supplier engagement, 68, 2728, 36, 61Supplier launch success, 6Supplier request for engineering

approval (SREA), 388390service unique products, 390supplier risk for not following, 391temporary, 390391

Supplier technical engineer, 57miscellaneous functions, 64specific categories, 5964stakeholders specific responsibilities,

5859strategy and business, 6465

Surprise mistakes, 204Surrogate overall equipment

effectiveness, 294295, 297Survey, 193, 569, 597Suspended/right censored data, 394

SWIs, see Standardized work instructions (SWIs)

Symmetry, 312Synergistic approach, to problem

description, 344345System complexity, 228Systems engineering, 402404

T

Table, 597598Tact time, 75Takt time, 7576, 573, 575577Tall bar chart, 248Tangent plane, 312Tap sensors, 461Target point, 312Team and individual contributions

recognition, 372373, 378evaluating questions, 374375process guidelines, 373374

Team kickoff meetings beginning, 3742Team leader, 335, 341, 383, 480Team members, 37, 40, 71, 78, 341, 345

composition of, 222optimum selection of, 343344

Technical specialists, 6364, 65Testing and engineering specifications,

3334Third-party audit, 1803 5 Whys model, 156, 157, 212Three-Legged 5 Whys, 345346Tolerance, 244245, 252, 312, 327

modifying symbols, 323position, 310, 328329, 333profile, 308, 312, 329projected tolerance zone, 328statistical, 311types, 316317

basic dimensions, 317319line conventions on production

drawings, 319zero, 116

Tool tryout (TT), 40Total production system (TPS), 381382

Fords approach, 382384Total runout, 312Toyotas system of preventive

maintenance, 103104

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

616 Index

Toyota production system, 384385TPS, see Total production system (TPS)Trail-and-error, 152Tree diagram, 598Trend chart, 84Trimetrons, 461TRIZ model, 156TT, see Tool tryout (TT)Turnaround time, see Lead time

U

Unilateral and unequally disposed profile tolerance, 312

Unilateral tolerance, 316Unplanned downtime, 70

V

Validation, definition of, 403Value-added activity, 88, 209, 215Value-added assessment, 81Value analysis, 598Value analysis job plan, 405Value engineering, 404406Value stream map, 8692Value streams, 298299, 573Verification, definition of, 403Verification audit, 182Verification of Supplier Capability, 4042Verification of Supplier Capacity, 40, 42Verification of Supplier Failure Mode

Avoidance Strategy and Manufacturing Plan, 3738

Verification of Supplier Launch Preparation, 3839

Vibration sensors, 461Visual factory (6s), 92101, 563

levelsvisual controls, 563564visual display, 563

Visual management, 101V-model, 402403Voting, 598599

W

Walk-though process, 80Warning method, 219220Warranty, 391393Warranty time, 395Waste in process issues, 117Weibull distribution, 393397Welding position indicators, 461Willful mistakes, 203Winwin philosophy, 409, 411, 414Workload balancing, 575577Workplace organization steps, 564Worksheet

action plan, 540cost/function, 541cost index, 543data in, 237, 242function identification, 546manufacturer information

gathering, 544mistake-proofing, 454proposal selection, 538539Supplement K, 263, 275T-chart, 537triple 5-Why analysis, 534

X

Xbar chart, 248, 251

Y

Yellow rating, for items, 96, 259Yokoten, 580

Z

Zero defects, 116, 208, 216, 382flow and cycle, comparison with

improvement cycle, 211goal of, 208in mistake proofing, 210process overview, 212

Dow

nloa

ded

by [E

cole

Polyt

echn

ique d

e Mon

treal]

at 07

:14 30

Janu

ary 20

16

Index