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  • Case Study Rajeev

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    yatin rajput
    118 vizualizări1 pagină
    This case study describes efforts to reduce defects from automotive suppliers by 50% for a major Indian automotive components manufacturer. The company worked with suppliers to establish an "Oobeya Room" for better problem solving, ensured no defective parts left suppliers through "Protect The Customer" processes, identified key quality variables through a QA Matrix, facilitated root cause analysis and solutions, and implemented daily visual management to highlight abnormal conditions. As a result, defects received by the customer were reduced from 60% to 10% within 4 months and sustained at low levels for an additional 2 months, with learnings captured in supplier-specific sustenance manuals.

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    This case study describes efforts to reduce defects from automotive suppliers by 50% for a major Indian automotive components manufacturer. The company worked with suppliers to establish an "Oobeya Room" for better problem solving, ensured no defective parts left suppliers through "Protect The Customer" processes, identified key quality variables through a QA Matrix, facilitated root cause analysis and solutions, and implemented daily visual management to highlight abnormal conditions. As a result, defects received by the customer were reduced from 60% to 10% within 4 months and sustained at low levels for an additional 2 months, with learnings captured in supplier-specific sustenance manuals.

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    © All Rights Reserved
    Descărcați ca PDF, TXT sau citiți online pe Scribd
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    118 vizualizări1 pagină

    Case Study Rajeev

    Încărcat de

    yatin rajput
    This case study describes efforts to reduce defects from automotive suppliers by 50% for a major Indian automotive components manufacturer. The company worked with suppliers to establish an "Oobeya Room" for better problem solving, ensured no defective parts left suppliers through "Protect The Customer" processes, identified key quality variables through a QA Matrix, facilitated root cause analysis and solutions, and implemented daily visual management to highlight abnormal conditions. As a result, defects received by the customer were reduced from 60% to 10% within 4 months and sustained at low levels for an additional 2 months, with learnings captured in supplier-specific sustenance manuals.

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    © All Rights Reserved
    Descărcați ca PDF, TXT sau citiți online pe Scribd
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    din 1

    Enhancing Manufacturing Capability Case Study

    Reducing defects at OEM line by 50%


    The Company
    One of India’s leading Automotive component manufacturing company, diversified their capabilities by
    introducing Suspension products, Transmission products and Brake systems.
    The Problem
    The Company’s Business need is to get “Defect free products” from all Suppliers in ‘Required Quantity’ at
    ‘Right time’ (JIT: Just in Time). This will enable building long-term partnership between OEMs and suppliers
    through:
    • High level of satisfaction with bought out components
    • Aligning Sourcing Strategy with the “Organisational Vision 2020”
    At a Glance
    The Approach
    • Gemba walk to understand the Supplier manufacturing processes.
    Customer
    • Establishing ‘Oobeya Room’ to improve information exchange via visual One of the Largest auto
    means, thereby allowing better understanding the Problem followed by component Company in
    Problem solving by CFT leading to improved performance in overall. India.
    • Initiated ‘Protect The Customer [P.T.C]’ concept by ensuring no defect
    leaves the supplier company. Problem
    • Handholding the suppliers at Gemba to understand the Key Process High Customer complaints
    variables having high significant impact on Defects through ‘QA Matrix’. due to bought out parts
    • Facilitated each Supplier for Structured Root cause analysis and solution
    implementation.
    • Validating the Special processes like Powder coating, Plating, Welding Solution
    etc.… • Basic condition improved
    through DWM
    • Probable defects analysis
    through QA Matrix &
    FMEA.
    • 3 Pillars Implementation
    (i.e.) Quality, Process &
    Sustenance Management.

    Outcome
    • PPM level reduced.
    • Inhouse Rework reduced.
    • Productivity Improved.
    • Machine capability
    • Improved.
    • Zero PPM achieved with
    • Daily Visual Management [DVM] is designed such a way to see what is few suppliers
    under control and what isn’t. This system highlighted abnormal condition
    right away so that anyone will know when to take action.
    The Result
    Defects at Customer end has been reduced from 60% to 10% in 4 months time line and sustenance was
    demonstrated for next 2 subsequent months.
    Supplier specific “Sustenance manual” capturing all the Learning by each Supplier team in this journey has
    been documented and submitted to Customer

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