WABCO TEAM MEMBERS

• Mr. Amiya Kumar – Site Leader

• Mr. Amit Kumar Singh – Site Quality Leader

• Mr. Kundan Kr. – Value stream leader

TML TEAM MEMBERS

• Mr. Shyam Kishore

• Mr. Vinay Rai

WCSQ AUDITORS
• Mr. Kunal Mehta

• Mr. Utkarsh Aroakar

WCSQ JOURNEY

WABCO Confidential and Proprietary 1

WCSQ ROAD MAP

WABCO Confidential and Proprietary Information - For internal use only

Assessment done by
TML team for WCSQ
Certification
Dec’15
Pre assessment
Internal assessment done by tml and
Internal assesment done by tml gaps closed the issue.
done and identified
find and closed Nov’15
the improvement.
WABCO internal Sep’15 and Nov’15
training to all Sep’15 – Oct’15
WCSQ concerned
Training by Aug’15
TML team
WCSQ Kick off Aug’15
@ WABCO by
TML top
management .
July ‘15

2
WCSQ BOARD IN SHOP FLOOR

WABCO Confidential and Proprietary Information - For internal use only

Plant level WCSQ
Plan Vs Actual
displayed in Central
Board

3
1. QUICK RESPONSE TRACKING
QRTB for external & Internal Issues Daily/Monthly monitoring

WABCO Confidential and Proprietary Information - For internal use only

Since Nov15 no external issues.

4
CLAIMS INFO/LESSON LEARNED
Display of BAD parts for claims
in shop floor entry for awareness

WABCO Confidential and Proprietary Information - For internal use only

QUALITY ALERTS

5
COST REDUCTION PROJECTS - 2015

WABCO Confidential and Proprietary Information - For internal use only

Achieving 11%
conversion cost
productivity

6
2.CONTROL OF NCP MATERIALS
Rework Procedures in Lines CFT for Process scrap reduction

WABCO Confidential and Proprietary Information - For internal use only

Identification in parts

7
3.QUALITY GATE - VERIFICATION
QUALITY GATE With Good BAD QUALITY GATE DRM & MONITORING
Photo and Bench inspections

WABCO Confidential and Proprietary Information - For internal use only

8
4. STANDARDIZED OPERATION
OPERATING STANDARD IN STATIONS CT & BOTTLENECK DISPLAY IN STATION

WABCO Confidential and Proprietary Information - For internal use only

WASTE REDUCTION – 3S Concept

9
 4. STANDARDIZED OPERATION
INCOMING MATERIAL STORAGE WITH CLEAR 5S and FIFO CONTROL

Dedicated trolley for finished goods

WABCO Confidential and Proprietary Information - For internal use only

 Pick me first ,second etc concept in raw materials and finished goods storage.
 KANBAN SYSTEM followed by SAP and bar code to be pasted as per pull.

10
5. STANDARDIZED OPERATING TRAINING
ANNUAL TRAINING PLAN FOR OPERATORS

WABCO Confidential and Proprietary Information - For internal use only

 Operator certification done for CTQ stations.
 WB & YB Certification provided to operators
after completion of QR6S Projects.
 Monthly Award system for best
suggestions/Kaizen
6 .POKA YOKE VERIFICATION
CENTRALISED POKA YOKE
MONITORING SYSTEM

WABCO Confidential and Proprietary Information - For internal use only

VISUAL MONITORING OF PY IN
POKA YOKE REVIEW & MONITORING STATION ITSELF

12
7. LAYERED AUDIT
LAYERED AUDIT PLAN & MONITORING FINAL LAYERED AUDIT NCS STATUS

WABCO Confidential and Proprietary Information - For internal use only

NCs DETAILS
8. RPN RISK REDUCTION
MONTHLY PLAN FOR RPN REDUCTION O/S MATRIX FOR IMPROVEMNT

WABCO Confidential and Proprietary Information - For internal use only

PY IMPLEMENTATION AS PER PLAN

14
 9. CONTAMINATION CONTROL
KAIZEN FOR CONTAMINATION CONTROL

WABCO Confidential and Proprietary Information - For internal use only

15
 9.CONTAMINATION CONTROL
CONTAMINATION CONTROL PROCEDURES WITH FREQUENCY AND RASCI

WABCO Confidential and Proprietary Information - For internal use only

16
10. SUPPLIER CHAIN MANAGEMENT
SUPPLIER RATING - COMBINED INDIVIDUAL SUPPLIER SCORE CARD

WABCO Confidential and Proprietary Information - For internal use only

17
10. SUPPLIER CHAIN MANAGEMENT
SUPPLIER AUDIT PLAN VDA 6.3 process audit report

WABCO Confidential and Proprietary Information - For internal use only

SUPPLIER PERFORMANCE MONITORING

18
 10. SUPPLIER CHAIN MANAGEMENT

WABCO Confidential and Proprietary Information - For internal use only

19
 FACILITIES TO SUPPORT QUALITY
ULTRASONIC CLEANING PROCESS FOR MILIPORE TESTING FOR CLEANED PARTS
CRITICAL PARTS AND TRACKING FOR EFFECTIVENESS

WABCO Confidential and Proprietary Information - For internal use only

20
FACILITIES TO SUPPORT QUALITY
LIFE CYCLE TEST FOR PARTS IN SALT SPRAY TEST FOR
ENDURANCE LAB CHECKING PLATING QUALITY

WABCO Confidential and Proprietary Information - For internal use only

IMPREGENATION PROCESS TO AVOID CASTING POROSITY

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 QUALITY FIRST WORKSHOP -
TARGET REVIEW IN DRM 4

QUALITY IS AN
ATTITUDE

WABCO Confidential and Proprietary Information - For internal use only

Consolidated
actions
 SIX SIGMA CULTURE
QR6S ( QUICK RESPONSE SIX
Function Wise Certification percentage
SIGMA ) YB+WB certification trend
120%
100%
100% 93%

WABCO Confidential and Proprietary Information - For internal use only

77%
80%

60% 50% 50%

40%

20%
0%
0%
VS Site Quality PAM LPO HR IT

• Total running GB six sigma projects = 7.

• 4 People certified in GREEN BELT.
• All Trained GB are indulge on GB
projects

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 REACTIVE & PROACTIVE ACTION
Robust Firewall- WIN Packing modification Process Up gradation

Carton Boxes
(Before)

WABCO Confidential and Proprietary Information - For internal use only

Manual assembly process

Bulk packing
(After)
Prevention pokayoke with feed back tightening control

100% Recyclable Bins

Champion nominated to ensure

effective firewall for all parts
Testing standardization in-line with Stainless steel bin for easy to clean
customer testing – 100% Automatic ok punch for testing completion

Align, detect, assign, resolve and improve 24

WORKSHOP ON BEHAVIOR

Workshop on
Behavior

WABCO Confidential and Proprietary Information - For internal use only

organized and
prepared “TO
DO LIST” for
improving our
behavior

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TPM – QM INITIATIVES

WABCO Confidential and Proprietary Information - For internal use only

JH

KK PM

SHE QM

E&T

2015 YTD
plan
23 12
1200 978
98.5 98.1
1200 878
Setting the goals…
 WIN 2.0 INITIATIVE

WABCO Confidential and Proprietary 27

WABCO Confidential and Proprietary 28