Documente Academic
Documente Profesional
Documente Cultură
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2000 2001 2002 2003 2004
Year
Predict
Check/Act Plan
Planning process-
informational content
in FMEAs and CPs
Protect Prevent
Quality process- Manufacturing process -
containment
detection & & standardized work and
responsiveness error proofing
Do
Issues
not predict the defect?
P1
Why? P2
Why? P3
Why? P4
Other Products
Why did the manufacturing Predict
process not prevent the Why? Pn Corrective Action
defect? M1
Predict Root Cause
Why? M2
Why? M3
Why? M4
Prevent
Why did the quality process
not protect GM from the Why? Mn Corrective Action
Q1
defect?
Prevent Root Cause
Why? Q2
Why? Q3
Why? Q4
Protect
Why? Qn Corrective Action
Wide
Implementation
(Read Across)
Emerging Emerging
Prevention Launch Issues Current Issues
should
start here
Functional Build
Issues Plant Issues
Spills
Spills / MD
Repeat EIs
Chronic Suppliers
Functional Build
Issues Plant Issues
All Suppliers
Supplier Process Issues
Drill Deep & Wide Workshop Training 5.0 Revision 5.0
03/08/04
Drill Deep Training
Date: 02/24/04
GM Form 1927-84
Issue title: Product XYZ Fuel Tank Rollover Valve Assembly
Customer concern: Loose parts found in Product XYZ fuel tanks. PRR# 30011223-989898.
Defect on part: End cap not fully seated into window on valve.
P3
Predict P4
Planning process -
inf orm at ional cont ent P5
in FM EAs and CPs
FMEA training plan to be developed
Inadequate knowledge of FMEA
P-RC and monthly FMEA layered audit J. Smith 03/15/04
methodology.
review to be implemented.
Q3
Prot ect Q4
Qualit y process -
det ect ion & Q5
responsiveness
False sense of security in error Re-evaluate prevention error-proofing
Q-RC proofing prevention of positive stops process and implement detection J. Smith 03/15/04
in tooling. error-proofing process.
Engineering change management Develop regular change control
What are the key findings based on K1 J. Smith 03/31/04
execution. meetings with entire team.
this quality issue and the above 5
Why analysis? Develop Supplier Change Request
K2 PPAP / PTR execution. J. Smith 03/31/04
audit process.
Re-evaluate prevention error-proofing
Insufficient error-proofing
K3 process and implement detection J. Smith 03/31/04
incorporated into valve assembly.
error-proofing process.
FMEA training plan to be developed
Inadequate knowledge of FMEA
K4 and monthly FMEA layered audit J. Smith 03/15/04
methodology.
review to be implemented.
K5
many Whys as Control Plan was not updated to The last "why" is the underlying
Prevent M3 indicate recalibration for new family
insert. Root Cause. Please add a
necessary.
M anuf act uring process - Manufacturing was not aware of a
st andardized w ork and M4
new family insert. corrective action, owner, and
error proof ing
Poor communication between date to the right.
M5 Product Development &
Manufacturing on design change.
Why?
No detection error-proofing for "end
Q1
Why did the quality process not cap fully seated". Therefore. .
protect GM from the defect?Why?Q2
.
Q3
Prot ect Q4
Qualit y process -
det ect ion & Q5
responsiveness
False sense of security in error Re-evaluate prevention error-proofing
Q-RC proofing prevention of positive stops process and implement detection J. Smith 03/15/04
in tooling. error-proofing process.
K5
Date: 02/24/04
Customer concern: Loose parts found in Product XYZ fuel tanks. PRR# 30011223-989898.
Defect on part: End cap not fully seated into window on valve.
P3
Predict P4
Planning process -
inf orm at ional cont ent P5
in FM EAs and CPs
FMEA training plan to be developed
Inadequate knowledge of FMEA
P-RC and monthly FMEA layered audit J. Smith 03/15/04
methodology.
review to be implemented.
Q3
Prot ect Q4
Qualit y process -
det ect ion & Q5
responsiveness
False sense of security in error Re-evaluate prevention error-proofing
Q-RC proofing prevention of positive stops process and implement detection J. Smith 03/15/04
in tooling. error-proofing process.
Engineering change management Develop regular change control
What are the key findings based on K1 J. Smith 03/31/04
execution. meetings with entire team.
this quality issue and the above 5
Why analysis? Develop Supplier Change Request
K2 PPAP / PTR execution. J. Smith 03/31/04
audit process.
Re-evaluate prevention error-proofing
Insufficient error-proofing
K3 process and implement detection J. Smith 03/31/04
incorporated into valve assembly.
error-proofing process.
FMEA training plan to be developed
Inadequate knowledge of FMEA
K4 and monthly FMEA layered audit J. Smith 03/15/04
methodology.
review to be implemented.
K5
SUPPLIER: PQE/SQE:
Name: XYZ Corporation Name: Jane Quality
Location: Springfield Phone: 321-555-1212
Duns: 12345789 GM location / Provider
Contact Name: John Doe Contact Phone:
Contact Phone: 123-555-1212 E-mail: jquality@gm.com
E-mail: john.doe@xyzcorp.com
Mark with an O for the Originating location Mark with an X all locations where the defect may occur
O Original Location
X Another Location which contains the same process
R Repeat Issues Mark with an R if the problem was repeated at another location
N/A Not Applicable
Completed & 3rd Party/GM verified
Completed & Supplier verified only
Not Completed
Color code each box that has a letter in it according to this scheme
Widget
Module Florida Knob shy Knob not secure 1/3/2004
22609999
RC 3 7 RC 1 6
RC 5 5 RC 5 4
RC 4 4 RC 2 2
RC 2 2 RC 3 1
RC 1 1 RC 4 1
0 1 2 3 4 5 6 7 8 0 2 4 6 8
RC 3
RC 1
RC 5 RC 5
RC 4 RC 2
RC 1 RC 4
RC 5 3 RC 1 4
RC 1 2 RC 3 2
RC 2 1 RC 2 1
RC 3 1
RC 4 1
0 1 2 3 4 0 1 2 3 4 5
RC 5 RC 1
RC 1 RC 3
RC 2 RC 2
RC 3
RC 4
0 5 10 15 20 25 0 5 10 15
Work
FMEA - not included Instruction
not follow ed
Protect
Packaging
Key
Quality System Key Findings
0 2 4 6 8
0 5 10 15 20 25
Measurement/CP
Visual
inspection
No detection -
occurs after
pack
Plant 1
Plant 2
Plant 3
Plant 4
Plant 5
Issue Corrective Actions Champion Due Date
Predict
Prevent
Protect
Key Findings
Protect
Packaging
Key
Quality System Key Findings
0 2 4 6 8
0 5 10 15 20 25
Measurement/CP
Visual
inspection
No detection -
occurs after
pack
Plant 1
Plant 2
Plant 5
Issue Corrective Actions Champion Due Date
The highest
Departmental frequency root cause
Review,
Predict Failure Mode Not Included Doe 2/30/04 O x x
from each
On-line Pareto chart is transferred here.
workshop
Prevent Work Instructions not Followed Cross training matrix Doe 2/30/04 O x x
Workshop:
Go through the presentation material
Work one Drill Deep in detail and review two Drill Deep with team
Review the read across for all three PRRs
Group the root causes for all PRRs
Complete the 4 root cause pareto charts (predict, prevent, protect & key
findings)
Start the systemic issues read these across
Confirm the workshop deliverables were met and review follow-up items
Group & Pareto Group & Pareto Group & Pareto Group & Pareto
All Root Causes All Root Causes All Root Causes All Root Causes