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Perfect QRQC - The Basics

De
196 pages

Recent quality problems have led to many recalls of products in the automotive as well as in the food and pharmaceutical industries, among others. Consequences have been often dramatic, both from a human and financial point of view.
QRQC (Quick Response Quality Control) is a major innovation in the field of Quality management. It is combining management and attitude in order to solve in a simple and logical way most of the production and functional problems.
Valeo, one of the world leading equipment suppliers has been using QRQC for over 10 years. QRQC had allowed the Valeo Group to change its quality measurement scale from PPM (Parts Per Million) to PPB (Parts Per Billion).
The QRQC approach relies on two pillars:
• The San Gen Shugi attitude, based on the “3 real” principles which aim at going to the “real place (Gen-ba), with the “real parts” (Gen-bustu) and the real data/facts (Gen-jitsu)
• A management activity composed of 4 steps: Detection, Communication, Analysis and Verification

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PERFECTQRQC The Basics
Hakim Aoudia & QuintinTesta Foreword by Jacques Aschenbroich
PERFECTQRQC The Basics
Hakim Aoudia,graduated from the Commercial Institute of Nancy (France). He is an expert in the field of Quality management, particularly in the automotive industry. After having spent a few years in the United States, he held several Quality Management positions at Valeo for over ten years. He is now working as Group Environment, Safety, Health & Quality Director at Faiveley Transport, one of the worldwide leaders In the railway industry. He can be reached at: hakim.aoudia@maxima.fr
Quintin Testa, graduated from the Instituto Tecnológico de Monterrey in Mexico. An expert in the eld of quality and pro ductivity, he has joined Group Valeo in 2003 where he is Group Quality Director.
infos/nouveautés/catologue :www.maxima.fr
8, rue Pasquier, 75008Paris. Tél. : + 33 1 44 39 74 00 – Fax : + 33 1 45 48 46 88
© Maxima, Paris, 2011.ISBNPDF Web:978 2 81880 6814
Tous droits de reproduction, traduction, et d’adaptation réservés pour tous pays.
Table of contents
Foreword by Jacques Aschenbroich, CEO of Valeo Group ..............................................................
Introduction..............................................................................
1.1. 1.2. 1.3.
2.1. 2.2. 2.3. 2.4. 2.5.
1. What is QRQC? Why?...............................
Quick Response: Speed of reaction....................... Quality Control: Rigour and Verication ............... Perfect QRQC ................................................................
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17 22 24
2. The San Gen Shugi Attitude.72..............
The “3Real” Principle ................................................ 29 Genba, real place ...................................................... 30 Genbutsu, real parts .................................................. 33 Genjitsu, real data ...................................................... 36 TheRoleoftheManagerintheSan Gen Shugi Attitude ............................................. 38
3. QRQC Step 1, Problem Solving.......
3.1. The Fundamental Principles behind QRQC Step 1 ................................................................. Detection....................................................................... Communication............................................................ Analysis.......................................................................... Veriîcation.....................................................................
Table of contents
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43 44 50 54 59
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3.2. QRQC Applications in Production .......................... 62 Line................................................26................................. ฀ •฀APU:฀Autonomous฀Production฀Unit.......................... 77 Plant............................................................................... 87 Safety............................................................................. 98 Suppliers........170................................................................ 3.3.฀ QRQC฀Applications฀in฀Support฀Functions............ 116 Logistics......................................................................... 116InformationSystems........42..1.......................................... 3.4.WarrantyQRQC............................................................ 133 3.5. QRQC in Projects ......................................................... 144
4. Logical thinking........................................... 155
4.1. Objectives....................................................................... 157 4.2.TheFundamentalPrinciples........157............................. CharacterizetheProblemwith5W2H........158.............. ฀ •฀Analyze฀the฀Sorting฀Operations................................. 162 ComparisonUsingFTA................................................ 164 FindtheRootCause:The5Why...............180............. 4.3.Keypoints...................................................................... 184
5. True  False? Questions and Answers........................ 186
Conclusion ................................................................................ 189 Abbreviations ........................................................................... 193 Photo credentials.................................................................... 193 Bibliography............................................................................. 195 Acknowledgments.................................................................. 195
Perfect QRQC
Foreword
oday฀more฀than฀ever฀before,฀quality฀control฀is฀an฀essential฀ requirement฀ for฀ automakers฀ and฀ end฀ users.฀ Vital฀ for฀ for ReTcent฀ vehicle฀ recalls฀ have฀ reminded฀ us฀ of฀ the฀ importance฀ of฀ ging฀ a฀ brand’s฀ reputation,฀ it฀ represents฀ a฀ daily฀ challenge.฀ maintainingtheutmostvigilancetopreventdefectsthatweighheavilyonourbusinessandourbottomline.
These฀issues฀can฀also฀have฀a฀severe฀impact฀on฀the฀brand฀image฀ and฀ the฀ hard-earned฀ trust฀ between฀ an฀ automaker,฀ their฀ end฀ users฀ and,฀ of฀ course,฀ their฀ suppliers.฀ They฀ affect฀ every฀ link฀ in฀ the฀chain.฀And฀never฀more฀so฀than฀today,฀when฀our฀customers฀ are,฀ quite฀ rightly,฀ increasingly฀ demanding,฀ all฀ over฀ the฀ world. The฀tools฀and฀methods฀we฀use฀to฀guarantee฀top฀quality฀for฀our฀ products฀should฀therefore฀adhere฀to฀the฀same฀standards฀on฀all฀ continents,allcountries,etc.
Valeo฀is฀a฀leading฀automotive฀supplier,฀working฀with฀the฀world’s฀ foremost฀ automakers.฀ It฀ launched฀ its฀ total฀ quality฀ drive฀ seve ral฀years฀ago,฀largely฀based฀on฀QRQC฀(Quick฀Response฀Quality฀ Control).฀ This฀ approach฀ to฀ our฀ work฀ processes,฀ guided฀ by฀ the฀ pragmatism฀ of฀ the฀ San฀ Gen฀ Shugi฀ principles฀ (the฀ three฀ reals:฀ real฀place,฀real฀parts,฀real฀data)฀should฀be฀seen฀as฀a฀mindset,฀a฀ guiding฀path฀for฀all฀Group฀employees฀to฀adopt฀the฀right฀reexes.฀ It฀is฀a฀vital฀part฀of฀our฀growth฀strategy.฀
Quality฀ is฀ essential฀ to฀ foster฀ trust,฀ and฀ we฀ need฀ it฀ not฀ only฀ to฀ satisfy฀ and฀ loyalize฀ our฀ customers,฀ but฀ also฀ to฀ conquer฀ new฀ markets.฀ Because฀ of฀ its฀ standard฀ approach,฀ QRQC฀ also฀ allows฀ us฀ to฀ maintain฀ a฀ consistent฀ level฀ of฀ quality฀ on฀ all฀ our฀ markets,฀
Foreword
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whatever฀ the฀ different฀ practices฀ and฀ cultures.฀ This฀ method฀ is฀ supporting฀ our฀ growth฀ in฀ emerging฀ countries,฀ especially฀ China฀ and฀India,฀which฀form฀one฀of฀the฀Group’s฀strategic฀growth฀priori ties.฀So฀QRQC฀has฀made฀an฀important฀contribution฀to฀the฀record฀ level฀of฀new฀orders฀taken฀in฀2010฀and฀2011,฀providing฀a฀concrete฀ illustration฀of฀our฀ability฀to฀meet฀our฀customers’฀expectations฀in฀ terms฀of฀innovation,฀delivery฀and฀costs฀as฀well฀as฀product฀quality฀ andreliability.
Perfect QRQC,฀by฀Hakim฀Aoudia฀and฀Quintin฀Testa,฀who฀kindly฀ invited฀me฀to฀write฀this฀preface฀and฀to฀whom฀I฀am฀grateful฀for฀ their฀work,฀demonstrates฀the฀drive฀to฀share฀the฀best฀knowledge฀ and฀ practices฀ in฀ our฀ Group.฀ The฀ authors฀ are฀ leading฀ Quality฀ specialists:฀Hakim฀Aoudia฀is฀Quality฀Director฀in฀the฀Comfort฀and฀ Driving฀Assistance฀Systems฀Business฀Group฀and฀Quintin฀Testa฀is฀ GroupQualityDirector.Theirbookisnotedioustechnicaltome,but฀ a฀ clear,฀ informative฀ presentation฀ of฀ the฀ method฀ applied฀ at฀ Valeosince2002,inkeepingwiththespiritofthe5Axes.
Since฀the฀beginning฀of฀the’90s,฀Valeo฀has฀deployed฀the฀5฀Axes฀ methodology฀ on฀ all฀ its฀ sites:฀ Involvement฀ of฀ Personnel,฀ Valeo฀ Production฀ System,฀ Constant฀ Innovation,฀ Supplier฀ Integration฀ and฀Total฀Quality.฀This฀system฀has฀made฀a฀considerable฀contribu tion฀to฀the฀enhancement฀of฀our฀operational฀excellence.฀In฀order฀ to฀ ensure฀ the฀ continuous฀ improvement฀ of฀ its฀ performance฀ in฀ this฀îeld,฀Valeo฀then฀deployed฀QRQC,฀adapting฀it฀to฀its฀organiza tion.฀The฀aim฀of฀this฀initiative฀was฀to฀deal฀with฀problems฀more฀ quickly,฀ more฀ rationally,฀ and,฀ therefore,฀ more฀ efîciently,฀ based฀ on฀four฀core฀principles:฀detection,฀communication,฀analysis฀and฀ veriîcation.฀QRQC฀is฀applied฀on฀all฀our฀sites฀worldwide,฀and฀in฀ all฀strategic฀areas:฀production,฀quality,฀projects,฀purchasing,฀war ranty,logistics,safety,etc.
Our฀performance฀may฀be฀good,฀but฀it฀also฀reminds฀us฀that฀we฀ are฀ not฀ perfect.฀ QRQC฀ remains฀ relevant.฀ It฀ has฀ demonstrated฀ its฀ effectiveness฀ ever฀ since฀ it฀ was฀ deployed฀ at฀ Valeo.฀ We฀ now฀ have฀to฀develop฀this฀approach฀by฀embedding฀it฀more฀deeply฀in฀ our฀projects,฀so฀that฀our฀processes฀and฀products฀are฀even฀better฀
Perfect QRQC
designed.฀ And฀ we฀ should฀ remember฀ that฀ Quality฀ is฀ not฀ just฀ a฀ technical฀issue฀but฀a฀management฀one,฀and฀that฀it฀concerns฀us฀ all,฀from฀the฀top฀management฀to฀the฀shopoor,฀as฀Hakim฀Aoudia฀ andQuintinTestashow,withalltheauthorityoftheirexpertise.
Foreword
Jacques Aschenbroich CEO, VALEO
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