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© Autoliv, Inc. All Rights Reserved. / INTERNAL
Zero Defect Culture
Brian Hyde, Plant Manager
Autoliv ASP - Ogden, Utah
May 2016
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 2
Mono or stereo vision system
Inflatable curtain airbag
Passenger airbag
Pedestrian protection
Night driving assist
Satellite sensor Driver assist radar
Knee airbag
Pelvis restraint cushion
Steering wheel
Driver airbag
Side impact sensor
Electronic control unit and
Brake control/ESC
Side airbag
Seatbelt systems
Rear-side airbag
Far-side airbag
Battery disconnect
switch
Extra safety belt
Anti-whiplash system
Dynamic spot light
Bag-in-belt
Complete Safety System Supplier
Blind spot radar
Integrated child seat
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 3
Our Customers - All Major Vehicle Manufacturers
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 4
Zero Defects – Corporate Policy Deployment
Design robust
products Buy flawless
components Manufacture
flawless products Verify conformity of
products
Product & Process
Development
Production System Supplier
Management
After Delivery
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 5
Why Zero Defects?
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 6
What is a Defect?
Zero Defects is defined as meeting all the
criteria listed below:
No Customer nonconformance
No Supplier nonconformance
No Scrap
No Dropped parts on floor (Scrap)
No Lot Acceptance testing nonconformance
No Rework, Retest, Reprocessing
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 7
There is one thing more important than Zero Defects – JIDOKA! • It is critical to recognize and praise someone that
stops production when they find a problem or
potential problem.
The goal is NOT to report Zero Defects,
The goal IS to find and fix root cause of Defects to
achieve Zero.
JIDOKA
While inspecting housings for the 5C, Brad noticed the dog bone was abnormal. Brad notified his AMT who contacted the PQE. The housings were from totes of material that were on sort but had not been picked
up from the cell’s material rollers.
GREAT CATCH BRAD!
Containment action documented in Dispatch
Dispatch #: _____814416_
Root cause: Man / Machine / Method / Measurement / Material
Quality Manager Signature______________ ___________________
Brad Weir 5C / Swings
Date found: [2/4/16]
Jidoka Example – Recognition for Stopping
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 9
Purpose of Zero Defects Activities
Employee development
Improve team work across multiple sections of the company
Break the “PPM” thinking and achieve “EVENT” thinking
Eliminate complacency of current condition
Make quality personal for everybody
Pursue real root cause elimination for each defect
Get rid of mindset of “having a few defects is normal”
Change from inspection mindset to prevention mindset
Deliver perfect parts to the customers (external / internal)
Eliminate the blame game. Move from “their problem” to “our
problem”, we need to work through it either way.
Develop a Team that believes Zero Defects is possible.
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 10
Zero Defects
“Land of Uncomfortable”.
The Zero Defects Journey On our zero defects journey,
we will be tempted to turn around and go back.
What message do
we send if we turn
around?
How many will
follow us the next
time we do
something new?
We MUST be
committed to
drive towards
True North, learn
from our actions
and continue to
improve!
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 11
Many Organizations have “Islands” of
Quality Improvement Activity
Poka Yokes
– Design
Process &
Supplier
MPS
Compliance
SAPQP
Design for
Robustness
& Reliability
Red Bin
Processes
Variation
Reduction
Projects
Master FMEA
Development
Line/Design
Workshops
Regional
Problem
Matrix
PFMEA
Go,See&Fix
Standardized
Work
QE
Development
Process
Design
Reviews Problem
Solving Skills
AS 51 Supplier
Performance
Improvement
Change
Point
Control
Jidoka -
Proactive
and
Reactive
NQC
Reduction
Global
Yokoten
Meetings
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 12
The “Aligned” Road to
Zero Defects
DESIGN ACTIVITIES/TOOLS
Design
Reviews
Master
DFMEA
Development
Design for
Robustness
& Reliability
Design Poka
Yokes
PROCESS ACTIVITIES/TOOLS SUPPLIER
ACTIVITIES/TOOLS
MPS
Compliance Jidoka -
Proactive
and
Reactive
PFMEA
Go,See&Fix
Zero Defect
Workshops
WORMPIC
Reduction
Red Bin
Process
Master
PFMEA
Development
Standardized
Work
Process
Poka
Yokes
SAPQP
Supplier
PFMEA
Go,See&Fix
Supplier
Design
Reviews
AS 51
Supplier
Performance
Improvement
Supplier
Poka
Yokes
Foundation “ROADBED” elements
Change Point Control Divisional Read Across Global Yokoten Reviews
Line/Design Workshops Practical Problem Solving Skills MPS Disciplines, Std Work,
Six Sigma (Variation Reduction) Tool Set QE Development Process-QE101/201/301 Certification
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 13
Zero Defect Workshop Methodology
Establish team and workshop plan / structure
Ensure robustness of
previous corrective actions
Solve current problems
Anticipate potential problems
– PFMEA Go & See & Fix
Active Yokoten
<LEVEL 1>Design
Pokayoke
<LEVEL 2> Mechanical Pokayoke
<LEVEL 3>Mechanical Inspection in Process
<LEVEL 4>Manual
Inspection in Process
<LEVEL 5>Mechanical Inspection
in Line
<LEVEL 6>Manual
Inspection in Line
<LEVEL 7>Sampling
Inspection
Stronger Weaker
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 14
Autoliv Zero Defects Workshop
Ma
na
ge
me
nt R
evie
w
Validation of
Completed Actions
Review of Open
Action Items
Celebrate Zero
Defects as Cell
Achieves Zero
Defects at 15
Working Days
Continue to Find
Actions to Improve
Pre-Analysis
• Objective of
Workshop
• Collection and
Review of
Past Data
• Review of
Current Data
• PFMEA
Review
• Jidoka
Review
• Scrap Review
• Audit Reviews
Kic
ko
ff/D
isco
ve
ry
Se
t O
bje
ctive
/Actio
ns
Ma
na
ge
me
nt R
evie
w
Workshop
• Discovery
Day 1
• Set Objective
• Brainstorm
• Create Actions
Day 2
• Complete
Actions
Day 3
• Training
• Validation of
Actions
• Yokoten
Follow-Up
AOA Zero Defects Workshop
Formation of Teams
Design Team
John Spader
Naoki Morita
Falon Welch
Marcus Barney
Kodey Kunz
KC Atkinson
Process Team
Larry Hunsaker
Ryan Bradley
Harley Erickson
Layne Layton
Keith Bingham
Craig Standing
Maritza Weaver
Equipment Team
Don Fenton
Jann Albio
Derek Farr
Adam Montoya
Colby Sycamore
Standard Team
Josh Barneck
Connie Hammon
Carla Lopez
Sandra Aparicio
Ryan Zampedri
Kevin Figuerora
Tyson Smith
Antonio Espinoza
Cross-functional Teams:
• Manager
• Safety Engineer
• Quality Engineer
• Supplier Quality Engineer
• Design Engineer
• Industrial Engineer
• Customer Representative
Team Members from ALL shifts:
• Production Associates
• Production Cell Team Leaders
• Maintenance
Workshop Groups
AOA Zero Defects Workshop
Day 1 Brainstorming – Focus Ideas
Review of Quality Issues Customer concerns, Lot Acceptance tests, Scrap, Historical Corrective Actions and
Jidoka.
Review of Design Issues Design – DFMEA, Customer concerns
Prototype – Limit Testing issues, Scrap
Review of Process/Production Issues Jidokas w/Corrective Action, First Time Quality, Yokotens, 8Ds
Review of Equipment Issues Drawings, PFMEA, JBS/Control Plan, SC/CC/CIP
Equipment downtime, Work orders, Machine Mod Sheets
Review of Standard Work/Motion Workshops Review of past workshops – what needs updated
AOA Zero Defects Workshop
5S Cell information: Living Pareto
© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 18
Scrap Collection for Review
AOA Zero Defects Workshop
Day 1 Brainstorming – Focus Ideas
Go and See Activities Design and Process Teams PFMEA Go and See Document Review
Review of each machine in the cell
Supplier Issues Potential Drawing updates
Interface between Customer and Autoliv drawing
Equipment Team Review of each sensor on each process
Review of automation/programing on each process
Standard Work/Motion Team Review past improvements – Is the improvement still effective?
Focus on standard motion to eliminate current scrap
Review video of standard motion
AOA Zero Defects Workshop
Day 1 Brainstorming – Focus Ideas
E – Easy
W – Workshop
L – Long-Term
AOA Zero Defects Workshop
Days 2 & 3 Drive Actions to Success
The Goal is to accomplish as many action during the workshop as possible. Easy Actions
Day 1
41 Submitted, 41 Complete - 100%
Day 2
17 Completed
Workshop Actions
25 Actions – 60% complete
Set Priority
10 became long-term actions
Long Term Actions
Day 1 – 40 actions
Day 2 – total 50 actions
Plan to accomplish Weekly follow-up until actions complete
AOA Zero Defects Workshop
Post Workshop Follow Up
All Defects are treated as a Crime
Scene.
Team Lead and Maintenance are
notified of Defect to be investigated.
The Team also performs a weekly
review of open actions to achieve
Zero Defects Date: 12/9/2014 Facilitator Location: Cell 65
Status
Assigned Target Completed
1L. Hunsaker / A. Montoya Shave down the B-Pillar tooling on hardware.
12/09/14 12/09/14 12/09/14Shave tooling.
4
2M. Barney Take unused bolt out of tape scanner on bag fold.
12/09/14 12/09/14 12/09/14Remove unused bolt.
4
3M. Barney Install bolts and locknuts on tape dispensers on
bag fold. 12/09/14 12/09/14 12/09/14Added bolts and locknuts.
4
4
Naoki Why is the Pillar ramp / Loom flap there?
12/09/14 12/09/14 12/09/14
So the cushion rolls down the loom flap
during deployment instead of the bracket. 4
5J. Spader Move stamp position on cushion.
12/09/14 1/5/2015Supplier to keep stamp out of throat area
minimum of 50 mm. 2
6Naoki Part # 620711800H/01H - Add SC to tox process
12/10/2014 1/7/2015 1
7
Naoki Due some pressure testing in order to remove SC
on C- fold- Drawing part # 6256572 12/10/2014 1/15/2015 1
8L. Hunsaker / A. Montoya Cushion mounting brackets not meeting sensors.
12/09/14 01/30/15Submit a work order to redesign tooling.
1
9Naoki Evaluate brackets drawings for burrs called out
and add sharp edges not acceptable. 12/10/2014 1/30/2015 1
10
Naoki Part# 617064700A - change to 628960900B-
Caution needs to be place at current position. Do
not change.
12/10/2014 1/30/2015 1
11
Naoki Part #626079700B- Increase length on tape to
help holding the cushion roll, since this tape is
going over the bracket and the cushion and this
area is the thicker area.
12/10/2014 TBD
This needs be evaluate and be agreed by
Nissan
1
12Naoki Pillar ramp / Loom flap to hard to fold over at
hardware & Tape keeps coming apart. 12/09/14Use longer tyvek tape.
1
Comments/Updates Closure Criteria
(Who, What and How)
Keith B.
Action
Number
Person responsible for
item completion
Method
(Description of Action required)
Dates
Action 50% Completed22
New Action Assigned0
Action in Process1
Action 75% Completed3
Action 100%Completed4 Action Verified5
AOA Zero Defects Workshop
Weekly Management Review
Achieved Goal of 15 consecutive
days of Zero Defects
Current number of days at Zero
Best continuous run of Zero
Total cumulative days of Zero
AOA Zero Defects Workshop
Design Team
Benefit:
Reduced chance of label peeling during
transportation from vendor, Torque and
Cushion Fold.
Before
Zero Defects Design Improvements
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement:
Cushion Barcode has poor adhesion, and is
prone to damage, ie. Tearing, rolling,
folding, etc.
1. Move location of cushion label
2. Add second stitch
1. Proposal to move cushion label 7 mm away
from housing initiated.
2. Rotate printing 90 degrees and add second
stitch to secure cushion label
Benefit:
Reduced chance of broken bridges during
folding operation
Before
Zero Defects Design Improvements
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement:
Cushion wrap bridges break during folding
operation.
1. Work with vendor to control cutting process
2. Increase bridge width from 2.5 mm +1.5/-1
3. Standardized knacks at torque and folding
operations across all associates to reduce
tension on bridges via JBS
1. Negotiations/understanding of vendor
constraints initiated.
2. Proposal to revise bridge specifications initiated.
3. Complete.
Drawing changes in
process
1 2 3 4 5 6
AOA Zero Defects Workshop
X61A – Holes tearing •Scrap is being created because of forcing / stretching wrappers to engage stud holes circled below.
•It was also discussed to reinforce the thickness of the material around the wholes
X61A – Proposed Change
•We are proposing that test and move hole
locations
2-5mm
Approx. 5mm
• Making this change will reduce scrap
from hole tear through and tearing
bridge seams
Zero Defects Design Improvements
AOA Zero Defects Workshop
Process Team
AOA Zero Defects Workshop
Stop, Call & Wait
Opportunity identified:
Reprocessing of part on tooling
AOA Zero Defects Workshop
Tools Used
5 Why Root Cause Analysis
Have to periodically reprocess part
Why? – Failing for cushion presence
Why? – Cushion isn’t being detected
Why? – Sensor doesn’t always see cushion
Why? – Sensor beam being partially blocked
Why? – Slot for sensor beam is blocking
Solution? – Widen slot for sensor beam
AOA Zero Defects Workshop
Results
Widened slot over sensor
Eliminated reprocessing defect
AOA Zero Defects Workshop
Dropped
Parts Opportunity identified:
Bands catching on each other, dropping to floor
AOA Zero Defects Workshop
Results
Cell team member created magnetized lid
- Catches loose bands as they’re coming out
- Also used as retrieval point for operator
Photo(s) before
and remarks
Benefit: Reduce/eliminate mini-wrap scrap
Before
Process Zero Defects
• On going SPC to stabilize process
Zero Defects Workshop – Presentation
After
Improvement: Stabilize Cushion Roll
Process through SPC
9181716151413121111
110
105
100
95
90
Observation
In
div
idu
al
Va
lue
_X=99.25
UC L=106.99
LC L=91.52
9181716151413121111
16
12
8
4
0
Observation
Mo
vin
g R
an
ge
__MR=2.91
UC L=9.50
LC L=0
1
111
1
1
1
1
1
1
1
I-MR Running Chart of Push Pin 11/3/14-
Benefit:
Before
Process Zero Defects
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement:
Cushion fold – Added guide to
bagfolder to keep cushion flap from
being caught in blade
Eliminate torn cushion wraps
AOA Zero Defects Workshop
Equipment Team CHUCK EDDY TECHNICAL SUPPORT LEAD
CHRIS JENSEN MACHINE BUILD SUPERVISOR
ELDEN SEVY MAINTENANCE TECH AUTOMATION
JEFF ORN AUTOMATION ENGINEER
GREG MCGHEE CELL ASSOCIATE
RICK GONZALES CELL ASSOCIATE
DENNIS THOMPSON PAB PROJECT MANAGER
Photo(s) before
and remarks
Benefit: Easier to identify proper pressure
settings for various air supply locations
Before
Photo(s) after
and remarks
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement: Installed Standard air gauges
on multiple regulators
Equipment Zero Defects
Before
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Wire damage from exposed wiring. Modified
tooling and re-routed wires to prevent
damage.
Equipment Zero Defects
Benefit: We can see problems before they
happen and correct them before causing
defects.
Before
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement: No Preventative Maintenance
specific to load cell and shunt valve
There is no PM for checking load
cell and shunt value
Detailed PM for load cell and
shunt value
Equipment Zero Defects
AOA Zero Defects Workshop
Standards Team
Benefit:
Multiple sensors allows operators to pull
tape from any location without wasting any.
If the tape shifts when replace roll won’t be
affected.
Before
Process Zero Defects
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Improvement:
Added multiple sensors on tape machines
to eliminate wasting unused tape.
Operators have to pull from right to left
otherwise machine feeds next row of
tape wasting the unused portion
Additional sensors allow operators
to pull tape in any combination
Before
Autoliv Proprietary Zero Defects Workshop – Presentation
After
Continued from last page:
Process Zero Defects
AOA Zero Defects Workshop
Safety Alert!
Opportunity identified:
Ergonomic strain from
water spider lifting
cushions into bin
Water spider position
designated as one of
the most difficult jobs by
plant physical therapist
AOA Zero Defects Workshop
Tools Used
5 Why Root Cause Analysis
Water spider getting hurt
Why? – Experiencing shoulder pain
Why? – Must lift cushions up and into bin
Why? – Bin walls are tall
Solution? – Cut out portion of rear wall to enable easier
access
Also standardized motion of
spider placing cushions into
bin
AOA Zero Defects Workshop
Results
Cut out rear
wall of
cushion bin
Ergonomic
strain
alleviated
AOA Zero Defects Workshop
Yokoten
Magnetic bandit lids – AOA Yokoten database
Visual aids for water spider – Yokoten to 6 other cells
Water spider safety issue – Yokoten to 6 other cells
AOA Zero Defects Workshop
Zero Defect Cells
Cell/Process Days 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Total
65 26 181
75 9 95
7C 6 75
Mld 29227 6 70
N4 3 7
44 2 10
Paint No AdPro 13 46
X1 7 62
7L 8 46
Mld 29222 4 33
NQ 6 90
NT 13 91
Mld RF 31 180
Mld R6 36 175
Mld R2 22 175
X5 7 40
NU 10 73
5S 4 27
Mld RG 14 84
Mld R7 31 125
Paint Dropped 8 19
56 3 6
5J 2 9
59 1 1
62 1 1
Total Days without Defects 1720
AOA Zero Defect Lines
1720 days
w/ zero
defects-
54% avg.
scrap
reduction
AOA Zero Defects Workshop
Creating a Zero Defect Culture where
“We Believe”