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  • Case Study QCC Quality Containment Centre Major UK Automotive OEM

  • 5. Quality Confirmation Centre Concept

  • 5. Quality Confirmation Centre

  • 5. Quality Containment Model - 10 Steps

    1. Issue Identified => 2. Go Look See => 3. Determine Liabilities & Containment Actions => 4. Raise formal rejection and PRR with Supplier (bill payer) & inform

    OEM originator => 5. Create WES (work element sheet) & Risk Assessment => 6. Obtain WES approval – signature from Supplier & OEM => 7. Train and Verify skilled inspector => 8. WES & process Audit incl. poke-yoke gauge & fixtures where

    applicable 9. Report Data to Supplier & OEM simultaneously => 10. Customer satisfaction Survey / Lessons Learnt =>

  • 5. Quality System Standardised in QCC

    - Audit QCC Operation independently

    to identify the gaps

    - Action plan to close the gaps

    where applicable

    - BRIDGE Certification Audit

    - Monitor

    Elements of Quality System Foundation & Certification – Bridge Group

    1.  Fast Response 2.  Control of Non-Conforming Product 3.  Verification Station + Error Proofing

    Verification 4.  Standardised Work

    5.  Standardised Training 6.  Layered Process Audits

    7.  Risk Reduction 8.  Contamination Control

    9.  Supply Chain Management 10.  Managing Change

    11.  Maintenance 12.  Manufacturing & Material Flow

    Management 13.  External Logistics

    14.  Strategy and Project Management 15.  Part and Process Control 

  • Standard 6 panel I-Chart with presentation graphs

    5. Services Approach Concept – Web Portal Based Data Management

    6 PANEL I-CHART Start Date: 9/8/15 Chart Mng: Michael Rivera Champion: Michael Rivera Updated: 16/04/2016

    IP DASH X260 Firewall 2

    Step 19c

    282 277

    256

    194

    135 133

    112 99

    91 80 79 74

    67 53 51 46 42

    28 26 19

    0

    50

    100

    150

    200

    250

    300

    S t e

    p 1

    c

    S t e

    p 1

    5 b

    S t e p

    6 b

    S t e

    p 2

    2 c

    S t e

    p 6

    a

    S t e

    p 9

    b

    S t e

    p 1

    2

    S t e

    p 7

    S t e

    p 1

    6 a

    S t e

    p 1

    7

    S t e

    p 1

    8 a

    S t e

    p 5

    9

    S t e

    p 1

    8 b

    S t e

    p 2

    6 b

    S t e

    p 2

    2 e

    S t e

    p 2

    1 b

    S t e

    p 8

    S t e

    p 3

    1

    S t e

    p 2

    S t e

    p 2

    8 a

    Pareto of Defects from Mon 11th April 2016 (Week 15)

    Fault Number (see table on the right for description)

    1 1

    9 8

    1 9

    3 7

    1 4

    9 2

    1 2

    4 51 4

    3 2

    1 7

    6 7

    1 6

    2 4

    6 9

    27 8

    5

    3 7

    3

    7 9

    2

    3 5

    8

    0

    500

    1000

    1500

    2000

    2500

    W e e

    k 4

    8

    W e

    e k 4

    9

    W e

    e k 5

    0

    W e

    e k 5

    1

    Weekly Defects found per shift

    M orn in g Afterno on N ig h ts

    4 .3

    4 .2

    4 .6

    3 .8

    3 .5

    4 .2

    4 .0

    2 .3

    4 .3

    3 .2

    3 .6

    3 .1

    0.0

    0.5

    1.0

    1.5

    2.0

    2.5

    3.0

    3.5

    4.0

    4.5

    5.0

    W e

    e k 4

    8

    W e

    e k 4

    9

    W e

    e k 5

    0

    W e

    e k 5

    1

    Weekly defects found per IP

    Morning Afternoon Nights

    Week 44 Week 45 Week 46 Week 47 Week 48 Week 49 Week 50 Week 51 Step 1c 0.582 0.529 0.650 0.666 0.458 0.377 0.374 0.375 Step 6b 0.398 0.391 0.572 0.433 0.416 0.459 0.449 0.340 Step 15b 0.356 0.303 0.330 0.367 0.301 0.225 0.282 0.368 Step 17 0.541 0.464 0.467 0.209 0.171 0.219 0.133 0.106 Step 22c 0.376 0.421 0.511 0.422 0.385 0.445 0.445 0.258

    0.000

    0.100

    0.200

    0.300

    0.400

    0.500

    0.600

    0.700

    D e fe

    c ts

    p

    e r U

    n it

    ( D

    P U

    )

    Top issues run chart

    Number of IP's checked in Pareto Analysis 752

    Step 1c Check RIVA hoop gapping condition 282 37.5% Step 15b Check both side vents for gapping condition 277 36.8% Step 6b Inspect centre Console speaker for flush fit 256 34.0% Step 22c Check Gap between NAS finsher and Lower Wrap Finisher 194 25.8% Step 6a Inspect topper pad for visible damage/indents, wraps and bumps 135 18.0% Step 9b Check gap sight tube to topper pad 133 17.7% Step 12 Check apperance of the lower sight tube A-surface 112 14.9% Step 7 Check IP for contamination and dirt 99 13.2%

    Step 16a Check the centre vents surface for damage and scratches 91 12.1% Step 17 Check the centre vents for gapping to the surroundings parts 80 10.6% Step 18a Ensure mid finisher present, secure with gentle pull, gaps according to standard

    and Magna PCPA alignment values, no squeak 79 10.5%

    Step 59 Check Fir tree clip fitted and secure 74 9.8% Step 18b Check mid finisher for surface defects, poor trim and damage 67 8.9% Step 26b Check knee bolster for excess material and poor trim edges 53 7.0% Step 22e Check lower wrapped finisher for damage, poor trim and wrinkles on each end of

    the lower finisher 51 6.8%

    Step 21b Check ICP panel for damage or contamination 46 6.1% Step 8 Visually inspect appearance of stitch lines 42 5.6%

    Step 31 Check glovebox lid for surface defects and damage 28

    Step 2 Check for scratches, deffects or damage on the demist panel 26 3.5% Step 28a Check glovebox latches both sides 19 2.5%

    3 5

    6

    2 2

    7

    3 8

    9

    2 7

    3

    0 0 0

    1 6

    2

    2 0

    4 2 2

    8

    9 8

    0 0 0

    8 5

    1 6

    9

    1 0

    4

    0 0 0 0

    0

    50

    100

    150

    200

    250

    300

    350

    400

    450

    1 4

    D e

    c

    1 5

    D e

    c

    1 6

    D e

    c

    1 7

    D e

    c

    1 8

    D e

    c

    1 9

    D e

    c

    2 0

    D e

    c

    Daily defects found per shift

    M orn in g Afterno on Nigh ts

    3 .7 3 .8 4

    .0

    3 .5

    0 .0

    0 .0

    0 .0

    2 .2

    2 .8 2 .9

    1 .2

    0 .0

    0 .0

    0 .0

    2 .5

    3 .1

    4 .0

    0 .0

    0 .0

    0 .0

    0 .0

    0.0

    0.5

    1.0

    1.5

    2.0

    2.5

    3.0

    3.5

    4.0

    4.5

    1 4

    D e

    c

    1 5

    D e

    c

    1 6

    D e

    c

    1 7

    D e

    c

    1 8

    D e

    c

    1 9

    D e

    c

    2 0

    D e

    c

    Daily defects found per IP

    Morning Afternoon Nights

  • 5. Services Approach Concept - KPIs

    • H&S KPIs (as stated in SOR) • Zero accident and 100% adherence to near-miss reporting • Absence tracking • Job completion within budget • Number and frequency of layered audits • Problem response time • Non-conformance closure • Inspection cycle / takt time

  • Administration &

    Data Facilitator

    Site Operational Manager

    Darren Smith

    Team Leader

    Press shop

    Nightshift Supervisor

    Team Leader

    Body-in-white

    Dayshift Supervisor

    Core team of inspectors

    Regional Operations Manager

    Darren Jones

    HR Talent Acquisition

    Team Leader

    Trim and Final Team Leader

    Trim and Final

    Team Leader

    Press shop Team Leader

    Body-in-White

    Team Leader

    Trim and Final Team Leader

    Trim and Final

    Core team of inspectors

    Retrofit Facilitator

    Standby cover Standby cover Standby cover Standby coverStandby cover Standby cover

    Group HR Manager

    Sue Brind

    SQ Support Engineer

    SQ Support Engineer

  • • Quality Engineer present on each shift – WES generation, Training signoff, standards generation, Quality audits, Data Management and reporting

    • Hourly to Team Leader ratio 10:1 • 3 reserve inspectors (floaters) per shift, assigned to process auditing

    when not called upon.

    Recruitment / HR person permanently on site responsible for • Recruitment by Bridge Specialist Resourcing

    o Maintaining a pool of available resources • Retrofit activities undertaken by specially trained inspection staffs,

    managed by the dedicated retrofit facilitator / supervisor supported by BSR for specific expertise where required

    • Supervisor attendance at daily GCA

    5. Operating Concept

  • 5. Reaction times and how we deliver

  • 4. HR Elements, Safety at Work, Training

  • 4. Recruitment & Development Process

  • 4. Human Resources Elements • Bridge Specialist Re