GEs Control Level Evaluation

Process introduction

CLE process 5/28/2013

What CLE is ?
workout method
resolve quality issues / implement proactive quality

process mapping focused on describing critical to quality parameters for each process step (output and input CTQs). the way to identify weak points of process which have to be improved to assure part/product quality

focused team of experts

identify process steps / inputs / outputs develop and execute an action plan to improve

Six Sigma approach

systematically reduce the Cost of Quality

CLE process 5/28/2013

What is the benefit?

To minimalize internal scrap cost by implementing mistake-proof solutions at the very begining of process. Indicators Product criticality, Sourcing and Product Management startegy. Main focus on residential & protective product vendors. Risk factors & actual quality performance

Resolve systemic supplier, customer and sites quality issues with high quality costs. Find-out process control gaps in order to have process more foolproof.

CLE process 5/28/2013

Philosophy why CLE?

Cost Of Quality vs. where/when the defect is likely to be detected.

The most effective and less costly is to detect and solve isses at design stage. Some issues detected during manufacturing can be solved or the risk can minimalized by implementing change in design.

CLE process 5/28/2013

Program principles

CLE process 5/28/2013

Control Level - definition

When all CTQs are identified its time to determine appropriate Control Level for each of them.

Control Levels:
L1 : Poka-yoke you can not make a mistake No bad products, no scrap/warranty costs L2 : Early warning alarms before you make a mistake You have the chance to prevent bad products
L3 : Operator dependency it is documented what is wrong, but you have to check. Mistakes can (and will) happen

L4 : Unknown level you dont know, you dont control Disasters (can) happen...
CLE process 5/28/2013

Control Level outcome & expectation

All parameters clasified as CTQ should have assigned appropirate Control Level (CL). There are 4 possible CLs: L1 (foolproof) , L2, L3 and L4 (no control)

Program target: L1L2% equal or greater than 80%

CLE process 5/28/2013

How to control a process?

Example: making tea at home
who is your customer? what does he/she wants?

what are the critical things to your success?

what are your process steps? outputs? inputs?

how can you control?

CLE process 5/28/2013

Control level example

Tea making: the water is boiling - output (water heating process step): water is at 100C
Control Level L1 Poka-yoke Example Closed heating system (like in an espresso machine): - it doesnt let out water below or above boiling point - when you press the button you always receive water at 100C - you can not make a mistake here Electric water kettle: - red light means water is heating up - loud click & red light turns off means water reached 100C - early warning system: decision about the output (100C) is independent from you and it has a clear signal but if you pour out water while the light is on, you will make a mistake (making a cold tea) Heating water in a cooking pot: - you have received a training: water is boiling when bubbles appear - you must constantly check, and make a decision if small bubbles are good enough or wait a bit more for large bubbles to appear

L2 Early Warning

L3 Operator Dependent

L4 Unknown

You dont know... ... that you need water at 100C / you think any warm water will do
CLE process 5/28/2013

The CLE workout

identify process steps / inputs / outputs
classifying workstations setting up priorities

develop and execute an action plan to improve

Define
DP0: Initiate need for CLE

Measure
DP1: Data preparation

Analyse

Improve
DP3: project execution, goal attinment

Control
DP4: sustained quality levels

DP2: the CLE workout (this step)

CLE process 5/28/2013

CLE Process Steps

Prioritize DP0
DP1
GE team + Supplier
1 DAY

SELECT SUPPLIERS for SWAT event DEFINE: o Prepare audits plan, assign SQE. o Choose exact products to be evaluated At supplier site
Remotely

Supplier involvement

MEASURE: Data Preparation ANALYSE: o Supplier Workout o Detailed Action Plan o Resource Commitment

DP2

On site

Quick Fixes/Final Firewalls CTQ requirements Action Log - Prioritized Scorecard Quality Metrics Goals/Benefits/Schedule Required Funds

DP3 DP4

2 DAYS remotely

IMPROVE: o Project Execution o Monthly Pulsing o Goal Attainment o Consultation sessions CONTROL: Sustained Quality Levels

Validate Results with Scorecard Long Term Control Plan

GE team + Supplier

Validate Long Term Control

CLE process 5/28/2013