Lessons Learnt Cards in

Incident Management System

April 2006 Property of Valeo – Duplication prohibited

1
April 2006
Lessons Learnt Cards in SRM

What is a Lesson Learnt Card (LLC)?

It is the capitalization of experience: what have we learnt from an

incident?
It is a synthesis of acquired experience classified by root cause

Why LLC?

To capitalize experience on C1, recurrent incidents, Warranty

Returns…
To help Suppliers to structure their experience

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April 2006
LLC process overview

PROCESS WITHOUT LLC

Plan Do < 5 Days Check Act < 10 Days Close

Supplier Supplier
submits submits
OK/ OK/
Analysis Analysis Close
NOK NOK
Plan Do Check Act

PROCESS WITH LLC

Plan Do < 5 Days Check Act < 10 Days Close

Supplier Supplier LLC

submits submits At “Check Act” screen, the
Analysis OK/ Analysis Supplier has to complete the OK/ Close
NOK NOK
Plan Do Check Act LLC

New data

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April 2006
When is LLC requested?

LLC requested at
“Plan Do”

LLC mandatory in case

of:
–C1 incident
–Recurrent incident
–Warranty Return

Valeo can also request a

LLC for a specific incident

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April 2006
New “Check Act” screen when LLC requested

At “Check Act”
screen, supplier
completes the LLC

1. Fill in the 5W2H in

English
2. Select main root
cause(s)
3. Enter data regarding
the main root cause

LLC must be
completed in ENGLISH
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April 2006
Selection of main root cause(s) (1/2)

By default, the “Occurrence” screen is displayed

To switch from one root cause to another, just

click on the corresponding root cause

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April 2006
Selection of main root cause(s) (2/2)

Supplier has to select at least 1 root cause type

When a root cause is … All data related to the

selected… corresponding root cause becomes
mandatory and must be filled by the
supplier

It is possible to select several root causes

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April 2006
Upload of attachments
For a selected root cause
Attach photos/schemas for “Bad part” and “Good part”

Attach photos/schemas for ”Process before” and “Process after”

Once LLC is completed, click on “Submit

Analysis Check Act” to submit to Valeo

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April 2006
Examples of Lesson Learnt Card
To display the LLC when completed, click on “Lessons Learnt Card”

It will display a LLC file in PDF format

The LLC is a way to

Have a global view of the incident
Capitalize experience

Check the following slides to see examples of LLC

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April 2006
Example of LLC on Occurrence
WHAT WAS THE PROBLEM? (5W + 2H) WHAT IS THE CAUSE?
What happened? PROCESS\Packing
Fork lift damaged bulk package
Why is it a problem?
Products damaged To be able to read label, pallet was oriented in a
When did it happen ? way that could potentially cause damage to parts
17 March 2006 during fork lift maneuvers
Who has detected it ?
Cars International
Where has been detected?
Overseas shipping area
How has it been detected?
Visual inspection at reception
How many ?
3 pallets out of 7
BEFORE AFTER
Physical pallet issues

No standard to define location of label on the pallet. If Label is systematically put on package length so that fork
the pallet 2 is aligned along the wrong side, the fork lift lift can take packages on side A
taking pallet 1 damages the packaging and parts of
pallet 2
Bad Part Process Before Good Part Process After

(broken)

WHAT WE LEARNED
ITEM (Control Factor) METHOD CRITERIA

Label position Visual check by Logistic operator Label put systematically on side A

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April 2006
Example of LLC on Non-detection
WHAT WAS THE PROBLEM? (5W + 2H) WHAT IS THE CAUSE?
What happened? PROCESS\Test and measurement equipments
Wrong part assembly (cap of wiper arm)
Why is it a problem?
Part not corresponding to the right vehicle Visual check of parts, not physical.
When did it happen ? Part reference on package not checked at start of
19 March 2006 shift
Who has detected it ?
Autocars, inc.
Where has been detected?
Customer line
How has it been detected?
Not possible to mount part on vehicle
How many ?
29
BEFORE AFTER
Mix of part numbers Gauge added to check if cap is the appropriate

Part checked visually

Bad Part Process Before Good Part Process After

WHAT WE LEARNED
ITEM (Control Factor) METHOD CRITERIA

Diameter of cap Place cap in gauge Cap fits to gauge

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April 2006
Example of LLC on Management
WHAT WAS THE PROBLEM? (5W + 2H) WHAT IS THE CAUSE?
What happened? STRUCTURE
Delivery of mixed parts (T5 found in container of B5)
Why is it a problem?
T5 do not have the same specifications as B5 Mix of references during sorting operations (due to
When did it happen ? internal issue)
22 April 2006
Who has detected it ?
EuropAuto GMBH
Where has been detected?
End of line
How has it been detected?
Abnormal noise
How many ?
36
BEFORE AFTER
Mix of references

Two references processed in the same area, as One reference sorted at a time and in the same
allowed by work instructions. Non-standard area. Barcode check to verify product, packaging
process not managed like standard process and label (same as standard process)

Bad Part Process Before Good Part Process After

(mixed references) (single reference)

WHAT WE LEARNED
ITEM (Control Factor) METHOD CRITERIA
Number of references
1 reference sorting at a time and Adequation between part, packaging,
simulteneously packed in the same
barcode check label
area
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April 2006
 APPENDIX – Detail of available root causes
OCCURENCE NON-DETECTION MANAGEMENT
1st Level 2nd Level 1st Level 2nd Level 1st Level 2nd Level
Part /components
Process / tools design
Software Non-respect of validation phases
DESIGN Hardware DESIGN Test coverage SYSTEM (none)
Specifications QAPp not-sufficient
QAPp
Late modification
Insufficient QAP process
Disrespect of process parameters/instructions
Maintenance / Tool breakdown
Not capable process
Men Non-respect of Control Plan
Rework / downgraded process Lack of self control
PROCESS Organization PROCESS Training of operators STRUCTURE (none)
Flow organization Test and measurement equipments
Start of production / batch exchange 5S not applied
Worn out tools
Unauthorized process modifications
Raw material / component use
Packing
Design
Manufacturing
Incoming inspection
COMPONENT Validation COMPONENT SKILL (none)
Tier 2 QAPp not sufficient
Counterfeit
Identification
STRATEGY (none)

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April 2006