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S upplier Q uality R e-engineering
A ssessment M anaging team activity
September 9 ,2004
~ Improvement activities In component quality with supplier ~
Photo by Defense Agency (H.P.)
2
1. Background (Customer’s view)
Those discrepancies were preventing high aircraft working rate
Those discrepancies were preventing high aircraft working rate
Component discrepancies had not been decreasing
Component discrepancies had not been decreasing
< before SQRAM
activity>Project A Delivered Discrepancy trend
component
others
2000 2001
To reduce
component discrepancies
was a pressing need
3
2. Background (Supplier’s view)
< The in-house sales ratio of an aerospace section at suppliers> A sales ratio is very
small
A sales ratio is very
small
・ Top managements did not feel big interest ・ Suppliers could not make improvement activities, even if they wanted to do because of an insufficient resources・Motivation had not been growing up
・ Top managements did not feel big interest ・ Suppliers could not make improvement activities, even if they wanted to do because of an insufficient resources・Motivation had not been growing up
50 100%~
10 50%~
0 10%~
What should be carried out
to the suppliers of such a situation?
MHI went into a supplier and activated quality
improvement activities
4
Team establishment (2004 FY ~ )
Team establishment (2004 FY ~ )The deputy
GM, manufacturing
Supplier 13
companies( 2002FY )
LeaderDirector , Procurement
SecretariatQA ManagerQA Assistant
Manager
Materia l Depar
tment
Production
Department
Engineering
research Departm
ent
Engineering
Department
Service Departm
ent
Quality Assuranc
e Departm
ent
3. Organization
SQRAM team
Sub-LeaderDirecto
r , QualitySupplier quality control team
SQRAMSQRAMSSupplier upplier QQuality uality RRe-e-
engineering engineering AAssessment ssessment MManaging teamanaging team
MHI and each supplier promote this activity by
forming a scrum
5
Between only focal points
External Go into a manufacturing process / organization
Instruction
by MHI
Experience of only in each company
Each company shares its knowledge
Knowledge
source
passive voluntaryPosition
Low motivation (less understanding for the usage and importance of components)
Improvement in consciousness (from mechanics to managers)
Consciousness
formerly SQRAM
Broad communication
Communication
supplier
MHI supplier
MHI
4. Aim of SQRAM activityACTIVITY
Knowledge Share activitiesPeriodical general meeting to
invite all suppliers
Enlighten educational activities
MHI provides opportunities of education which targeted from the mechanics to managers of a supplier
Individual meeting with each company ・ Activity at MHI ・ Activity at supplier
The improvement activities
(each company)
As an leading company in aerospace industry
① Raising component
quality
of all involved
suppliers
② Develop spirit of
working
together
6
4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
Kick/ off interim Final Kick/ off interim Finalgeneral meeting ▼ Report Report Report Report Project A (51) ▼ (32) ▼ (35) ▼ (56) ▼ ▼
Project B ▼ (37) ▼ (31) ▼ (47) ▼ ▼
Project C ▼ (21)
(36)▼ (7) ▼ (6) ▼ ▼
MHI Training ▼ (74) ▼ Pilot lecture
The improvement3.activities
Individual meeting
2003FY2002FY
Knowledge Share1.activities
Improvement2.activities
16times 15times 26times
5. Schedule
Supplier 274
MHI 168
( ) shows attending supplier number
Supplier 65
MHI 170Supplier 97
MHI 83
7
Plan by each companyPlan by each company
General Mtg (Interim report)General Mtg (Interim report)
Implementing each company’s plan
Implementing each company’s planIndividual Mt
gIndividual Mtg
General Mtg (Final report)General Mtg (Final report)
General Mtg (Plan presentation)
General Mtg (Plan presentation)
StepStep
Implementing each company’s plan
Implementing each company’s planIndividual Mt
gIndividual Mtg <Scene of the General
Meeting>
6-1 share of supplier’s action (1/2)6. Activities
8
ResultResult
(1) showed MHI’s initiatives for the suppliers
(2) let the suppliers have the consciousness of the importa
nce of quality
(3) boosted the concern of each company’s top manageme
nt
(4) provided suppliers with trigger of self PDCA managemen
t
(5) shared each company’s good points and failure experien
ce
(6) stimulated each other
(1) showed MHI’s initiatives for the suppliers
(2) let the suppliers have the consciousness of the importa
nce of quality
(3) boosted the concern of each company’s top manageme
nt
(4) provided suppliers with trigger of self PDCA managemen
t
(5) shared each company’s good points and failure experien
ce
(6) stimulated each other
6-1 share of supplier’s action (2/2)
9
Confirm each company’s detailed plan and status
Confirm each company’s detailed plan and status
Confirm purpose and member
Confirm purpose and member
Listen desiresListen desires
Discuss quality
improvement
Discuss quality
improvement
Check “3-Gen” together(onsite, products,
actualities)
Check “3-Gen” together(onsite, products,
actualities)
StepStep
Discussed topics
Corrective actions, Preventive actions
Improvement of work instructions
FAI, Change management
Competence management and training
Visual management
Discussed topics
Corrective actions, Preventive actions
Improvement of work instructions
FAI, Change management
Competence management and training
Visual management
Professionals from both parties[tasks of MHI side] Engineer : coordinating engineering requirement Research : advising element techniques Manufacturing : Requesting from next process position Service : transmitting voices of final customers Procurement : coordinating contract matter Quality : advising quality improving
Professionals from both parties[tasks of MHI side] Engineer : coordinating engineering requirement Research : advising element techniques Manufacturing : Requesting from next process position Service : transmitting voices of final customers Procurement : coordinating contract matter Quality : advising quality improving
6-2. Improving of each company (1/2)
10
ResultResult
(1) Improved by reviewing source working ・ checked “3-Gen” by MHI each section’s professio
nals (recurrence prevention, similar discrepancy preve
ntion) ・ required reinforcing organization, if necessary ・ advised project management, schedule manage
ment, risk management etc
(2) Activated quality improving activities as unity ・ manufacturing process review and investigating
improving plan by both professionals ・ developed sense of unity by broad communicatio
n ・ act for actual (true) voice ・ learned mutually from other companies’ presenta
tion
(1) Improved by reviewing source working ・ checked “3-Gen” by MHI each section’s professio
nals (recurrence prevention, similar discrepancy preve
ntion) ・ required reinforcing organization, if necessary ・ advised project management, schedule manage
ment, risk management etc
(2) Activated quality improving activities as unity ・ manufacturing process review and investigating
improving plan by both professionals ・ developed sense of unity by broad communicatio
n ・ act for actual (true) voice ・ learned mutually from other companies’ presenta
tion
6-2. Improving of each company (2/2)
112001 2002 2003
could not find actual cause due to no reappearance at supplier(less information for reappearance)
could not find actual cause due to no reappearance at supplier(less information for reappearance)
frequent discrepancies for flight control computerfrequent discrepancies
for flight control computer
Could reappear at supplier and then finally solved the problem
Could reappear at supplier and then finally solved the problem
Collect MHI internal data and request customer to collect data
Collect MHI internal data and request customer to collect data
Picked up necessary information for reappearance (Flight situation, test situation)
Picked up necessary information for reappearance (Flight situation, test situation)
Example
1
Example
1
Non reappearance
items
With MHI
engineers
solved problem
by discussing in detail
stiffer relationship
12
Checked engineering requirement and production process in the individual meeting
Checked engineering requirement and production process in the individual meeting
Flight suspension due to control stick sensor discrepancyFlight suspension due to control stick sensor discrepancy
Found insufficient reflection of production know-how of an American license manufacturer
Found insufficient reflection of production know-how of an American license manufacturer
Example
2
Example
2
Onsite investigation with supplier member and MHI member (engineer, quality)
Onsite investigation with supplier member and MHI member (engineer, quality)
Reestablish improved production process
without nonconforming potential
Reestablish improved production process
without nonconforming potential
Traced back together
to original manufacturer
Ensured quality
production
13
polic
y
polic
y
actionaction
・ established nonconformance knowledge database・ share the data among all suppliers・ reflected nonconformance potential into design/production process in each company
・ established nonconformance knowledge database・ share the data among all suppliers・ reflected nonconformance potential into design/production process in each company
Nonconformance prevention for a coming project B(16 companies) ・ recurrence prevention for prototype nonconformance ・ nonconformance prevention in a change portion from prototype model to production model ・ deployed experienced nonconformance from project A
Nonconformance prevention for a coming project B(16 companies) ・ recurrence prevention for prototype nonconformance ・ nonconformance prevention in a change portion from prototype model to production model ・ deployed experienced nonconformance from project A
Example
3
Example
3
Frontloading by sharing
failure experiences
before production
Nonconformance
prevention
14
Result(audiences’ impression)
Result(audiences’ impression)
6-3 Enlightenment
MHI onsite trainingMHI onsite trainingTraining by inviting supplier mechanics to MHITraining by inviting supplier mechanics to MHI
Technical training (engineering): aircraft system and component
Plant observation :installation and usage of components
Interchange session :discussed for a theme in a small group
Technical training (engineering): aircraft system and component
Plant observation :installation and usage of components
Interchange session :discussed for a theme in a small group
Pilot lecturePilot lecture
MHI test pilot lectured his flight experience (mechanics and managers)
MHI test pilot lectured his flight experience (mechanics and managers)Attend lecture of an actual voice of pilot
Attend lecture of an actual voice of pilot
・ understood its functions and effeteness when failed of our component
・ understood jobs in MHI for our component
・ felt tension and severeness at final line and flight area
・ developed sense of unity by broad communication between persons in charge
・ understood its functions and effeteness when failed of our component
・ understood jobs in MHI for our component
・ felt tension and severeness at final line and flight area
・ developed sense of unity by broad communication between persons in charge
<Scene of the pilot lecture>
15
Example : Pilot lecture at supplier
factory
Example : Pilot lecture at supplier
factory<Message of Pilot>
・ “ People” is mostly a main cause of nonconformance
・ to make much of “feeling”
・ Never fly until consent on the flight affecting matter
<Message of Pilot>
・ “ People” is mostly a main cause of nonconformance
・ to make much of “feeling”
・ Never fly until consent on the flight affecting matter
<audiences’ impression> (74 attendees)
・ understood our component truly constitutes the aircraft
・ felt real tension
・ recognized we handle the pilot’s life
<audiences’ impression> (74 attendees)
・ understood our component truly constitutes the aircraft
・ felt real tension
・ recognized we handle the pilot’s life
Recognized
how our component is used
Developed sense of
responsibility and pride
16
7. Result (1/3)
<Project A : component nonconformance>
quantitative resultquantitative result
Work
errorDesign
error
Part
error
others
Non
reappearance
・ decreased component error in flight test ・ showing decreasing trend in flight test times
・ decreased component error in flight test ・ showing decreasing trend in flight test times
<company flight test times>
・ dramatically decreased component nonconformance(especially, design error decreased)・work error and part error
should be targeted to decrease from now
・ dramatically decreased component nonconformance(especially, design error decreased)・work error and part error
should be targeted to decrease from now
Surplus flight
times
Component error
Related result (@
MHI)
Related result (@
MHI)
2001 2003 2001 2003
17
7. Result (2/3)
(1) raised component quality in all suppliers ・ started moving to put in good quality at source ph
ase(2) Developed spirit of working together ・ synergy for common goal (good quality in final pro
duct) ・ each company’s independent participation
(voluntary action, constructive idea) ・ develop sense of unity by removing walls between
companies and between sections
(1) raised component quality in all suppliers ・ started moving to put in good quality at source ph
ase(2) Developed spirit of working together ・ synergy for common goal (good quality in final pro
duct) ・ each company’s independent participation
(voluntary action, constructive idea) ・ develop sense of unity by removing walls between
companies and between sections
improved final customer’s working rate by removing nonconformance potential and
raising dependability
Reliance from customers, then continuous contract
improved final customer’s working rate by removing nonconformance potential and
raising dependability
Reliance from customers, then continuous contract
18
7. Result (3/3)
Voices of
customers
Voices of
customers・「 Project A working rate has now been raising, we expect further effort for improvement to MHI 」
・「 We expect MHI this kind of essential activity indeed. We want to fully support this activity. 」
・ MHI was invited to make a presentation of this activity at a customer’s maintenance seminar.
(111 organization participated)
・「 Project A working rate has now been raising, we expect further effort for improvement to MHI 」
・「 We expect MHI this kind of essential activity indeed. We want to fully support this activity. 」
・ MHI was invited to make a presentation of this activity at a customer’s maintenance seminar.
(111 organization participated)
19
8. Continuous activity
Started SQRAM
Frequent nonconformance supplier ( 13)
ExpandedSQRAM
+ essential component ( 14 )
StartedSQRAM-Ⅱ
Back-shops(detail, assy) ( 25 )
2002 FY 2003 FY 2004 FY ~
ACT
Check
Check
Continue by
improving
Continue by
improving
CHECKPLAN ・ DO