Quick Response in Quality Control

It is a tool in quality control which consists

of automatically stopping the production
equipment or production line in case of a
malfunction or a defect in order to
prevent defects from being produced
further.
It is based on a Japanese concept known
as San Gen Shugi. It has three
components-
Genba- Real Place
Genbutsu- Real Parts
Genjitsu- Real Data
It also takes inspiration from the Japanese
practice named jidoka, which is one of the
two pillars of manufacturing at Toyota.
The main object required for QRQC is
quick and efficient communication.
There are three
How does it help?
Helps to detect a problem earlier
Avoids the spread of bad practices
A level of human intelligence is
transferred into automated machinery
Improvement in productivity
No defective products produced
Where does it apply?
It has various different applications in
different segments of supply chain which
includes-
Project management
Manufacturing
Logistics
How QRQC is done?
Step 1- Problem Detection
Step 2- Problem Communication
Step 3- Problem Analysis
 Step4- Problem Verification
Different steps involved in QRQC

Preparatory work upstream

1. Define performance indicators of
the process
2. Define influent factors of the
process
3. Define the reaction rule in case of
defectiveness
Detection of the default
4. Point of a performance indicator
observed by the operator of the line
5. Stop the manufacturing line
6. Isolate defective products
QRQC treatment
7. Verifying that each influential
factor respects the standard
 8. Readjust the influential factors
which does not respect the standard
9. Restart the manufacturing to verify:
conform influential factors and
conform products
10. Ok: Identify and treat the causes
of non- detection of drifts
Non ok: Initiate the 8-D
The 8D- eight disciplines
D0: Plan: Plan for solving the problem
and determine the pre-requisite.
D1: Use a team: Establish a team of
people with process/product
knowledge.
D2: Describe the problem: Who,
what, when, where, why
D3: Define and implement actions to
isolate any problem
D4: Determine and verify root causes
and escape points
D5: Verify permanent corrections
 D6: Define and implement corrective
action plan
D7: Prevent recurrence
D8: Congratulate the team