QSB Quality System Basics Q 7 tools in

QSB Quality System Basics & Q 7 tools in practice

QSB Quality System Basics & Q 7 tools in pracice Introduction QSB is a kit of tools and methods which provide a fast response in the case of claim. It also avoids our customers getting defective parts. 1. Fast reponse 2. Control of nonconforming products 3. Standardized work 4. Standard operator training 5. Risk Reduction (RPN) 6. Error proofing verification 7. Layered Audits 8. C. A. R. E 9. Lessons learned Corrective action Preventive action 2

QSB Quality System Basics & Q 7 tools in pracice Introduction 1. Fast reponse § is a system that standardizes reactions to significant internal and external quality failures, § a fast reponse meeting shall be held daily to review the significant quality concerns gathered by Quality, § is a communications meeting, meeting not a problem solving meeting. It can be a 10 - 20 minute stand up meeting held on the shop floor or in a production conference room, § is a manufacturing review meeting owned by manufacturing and supported by Quality, Engineering, Maintenance, etc… 3

QSB Quality System Basics and Q 7 tools in pracice Introduction 1. Fast reponse § At the Fast Response meeting, leadership shall § § Designate a leader (owner) for each concern/issue. Assign owner report out for next meeting § Owners shall be responsible for assuring all problem solving and exit criteria are met in a timely manner. § Owner report out shall include updates on the following: § § § § Fast Response Tracking Sheets Standardized Work Instructions Problem Solving Form(s) PFMEA Control Plan Layered Audit Workforce Notification 4

QSB Quality System Basics & Q 7 tools in pracice Introduction 1. Fast reponse § Report out to Leadership is scheduled on the Fast Response tracking form as deemed necessary. § The Fast Response Tracking form should be part of a visual management system. The format should be displayed as large as is practical in the meeting area. 5

QSB Quality System Basics & Q 7 tools in pracice Introduction 1. Fast reponse 6

QSB Quality System Basics & Q 7 tools in pracice Introduction 2. Control of nonconforming products 7

QSB Quality System Basics & Q 7 tools in pracice Introduction 3. Standardized work 8

QSB Quality System Basics & Q 7 tools in pracice Introduction 4. Standardized operator training 9

QSB Quality System Basics & Q 7 tools in pracice Introduction 5. Risk reduction (RPN) operator training 10

QSB Quality System Basics & Q 7 tools in pracice Introduction 6. Error proofing verification 11

QSB Quality System Basics & Q 7 tools in pracice Introduction 7. Layered audits 12

QSB Quality System Basics & Q 7 tools in pracice Introduction 7. Layered audits Extract from DC specific requirements for use with ISO TS 16949 QSB tool # 6 “Error proofing verification” 13

QSB Quality System Basics & Q 7 tools in pracice Introduction 7. Layered audits Extract from DC specific requirements for use with ISO TS 16949 QSB tool # 2 “Control of nonconforming products” QSB tool # 1 “Fast reponse” QSB tool # 9 “Lessons learned” 14

QSB Quality System Basics & Q 7 tools in pracice Introduction 8. C. A. R. E CUSTOMER ACCEPTANCE REVIEW & EVALUATION 15

QSB Quality System Basics & Q 7 tools in pracice Introduction 9. Lessons learned 16

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice 17

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools 18

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart 19

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart 20

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Run chart Inspection chart Pareto analysis 21

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Pareto analysis Histogram 22

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Pareto analysis Histogram Ishikawa diagram 23

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Pareto analysis Histogram Ishikawa diagram 5 why analysis 24

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Pareto analysis Histogram Ishikawa diagram 5 why analysis Action plan 25

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Pareto analysis Histogram Ishikawa diagram 5 why analysis Action plan 26

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Pareto analysis Histogram Ishikawa diagram 5 why analysis Action plan 27

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Ishikawa diagram 5 why analysis Action plan 28

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan 29

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan 30

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint 31

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint 32

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint 8 -D-Report 33

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint 8 -D-Report QSB 1 Fast response (Fast Response is the tool monitoring all other activities) 34

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report 35

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 36

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 37

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 38

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 39

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 40

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 41

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 42

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram 5 why analysis Action plan Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report PFMEA 43

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work 8 -D-Report PFMEA 44

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work 8 -D-Report PFMEA QSB 6 Error proofing Verification 45

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work 8 -D-Report PFMEA QSB 6 Error proofing Verification Controlplan 46

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training PFMEA QSB 6 Error proofing Verification Controlplan 47

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 48

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 49

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products QSB 5 Risk reduction RPN 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 50

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products QSB 5 Risk reduction RPN 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training QSB 8 C. A. R. E. QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 51

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Record failures Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products QSB 5 Risk reduction RPN 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 3 standardized work QSB 4 Standard oper. training QSB 8 C. A. R. E. QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 52

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Internal failure or customer complaint QSB 2 Contr. of NC products QSB 5 Risk reduction RPN 8 -D-Report Squeeze & picture failures Pareto analysis Histogram Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 9 Lessons learned Record failures QSB 3 standardized work QSB 4 Standard oper. training QSB 8 C. A. R. E. QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 53

QSB Quality System Basics & Q 7 tools in pracice Quality System Basics & Q 7 tools in practice The basic 7 quality tools Control chart Inspection chart Squeeze & picture failures Pareto analysis Histogram Internal failure or customer complaint QSB 2 Contr. of NC products QSB 5 Risk reduction RPN Find out root cause & solutions Ishikawa diagram Action plan 5 why analysis Action plan QSB 9 Lessons learned Record failures QSB 3 standardized work 8 -D-Report The process state of the green colored boxes is indicated here QSB 4 Standard oper. training QSB 8 C. A. R. E. QSB 7 Layered audits PFMEA QSB 6 Error proofing Verification Controlplan 54