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IQB 05 – Quality Fire Wall

Purpose:
Quality Fire Wall is a control applied to 100% of the parts before delivery, in order to protect our
customer from not capable processes.

Process Users
Actors
 Firewall Supervisor - will manage and schedule people resources, materials and handling,
 Quality Firewall leader – will determine the parts to pass through the quality firewall, will
update QPS/Quality Alert regarding any customer issues, will prepare boundary parts, will
train Firewall operators,
 Firewall operators, will check the parts,

Process Owners
 Plant Manager will sponsor the activity providing resources, people, surfaces, handling
equipment,
 Quality Manager will supervise efficacy and efficiency of Firewall.

Initiating Inputs:
 Customer PPM and written concerns are out of targets,
 Safe Launch activity during Ramp up process must implement a Fire wall for all new parts and
components,
 New processes, launches or transfers when capabilities and readiness have never been
demonstrated,
 Suppliers for cross dock parts not achieving PPM targets,
 Suppliers in a risk situation, important headcounts reductions, economics difficulties, or
savage process transfers to other supplier facilities or countries

Outputs:
 Firewall layout/workstations/stock area,
 Firewall QPS/ Quality Instructions,
 Firewall daily TPPA / Customer PPM weekly TPPA,
 Firewall audit (see attachment 1)

Definitions
 8D process - is a collection of 9 disciplines that go to make a systematic problem solving
process known as 8D Methodology. The process is used globally within Visteon and mirrors
similar processes from other OEM’s.
 (ERA) Emergency Response Actions - actions in place to protect/isolate your customer from
the symptom whilst you investigate the causes of these symptoms, until Interim Containment
Actions are implemented and validated
 (ICA) Interim Containment Actions – actions in place to isolate the effects of the problem from
the customer until Permanent Corrective Actions PCA) are implemented and validated
 TPPA - A TPPA, also know as a ‘Four Panel’ chart, is a one page chart that will show the
trend of something that is measurable, with detail behind the trend and actions to correct
issues, TPPA is an Acronym for Trend Paynter Pareto Action.
 Quality firewall list of parts – is the list of part# that systematically must pass through the
firewall, the list is daily updated by quality

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General rules:
 Initiation conditions, (see initiating inputs paragraph),
 A Fire wall can be considered as an ERA or ICA not solving the source of the problems,
unless is accompanied by a strong action plan based on TPPA and a full 8D package,
 Don’t apply a firewall approach whenever defects are a few, very specific, and escape points
well identified, in these cases reinforcing final control of escaping workstations is a better and
cheaper solution.
 Don’t include or mix, rework or mock-up operations into the firewall workstations,
 Firewall must be placed out of the sight of the assembly line operators, to prevent loose of
their quality awareness, trusting that someone else is checking their work after them.
 Quality Function will define and update a “Quality Firewall List of Parts” to pass through the
firewall, this list will be in line with initiating conditions,
 Quality Firewall List of Parts will be distributed to logistics and production,
 Firewall control instructions will be aligned with “IQB 04 Self-Inspection and Final Control”,
 Remove conditions, parts will be remove from the Firewall whenever the next 2 conditions
happen:
1. 5000 consecutive checked parts are good, or 1 week production without defects,
2. 8D report is completed or strong containment (Poka-Yoke) has been implemented and
validated.
 Firewall operators will use pace-boards to record rejections; they will react upon certain
rejection threshold defined in the plant,
 Firewall failures will be feedback immediately to upstream process by the quality leader or the
firewall supervisor,
 Firewall supervisor will prepare a daily TPPA summary of rejections by part#
 Firewall supervisor will discuss with upstream assembly process Leaders, Quality &Process
Engineers main issues and actions, the team will agree:
 New parts to include in the “Quality Firewall List of Parts”,
 New actions to reinforce TPPA,
 Parts to remove from the “Quality Firewall List of parts”,
 Quality firewall leader will be informed on time by Customer Engineers of any customer
rejection, or written concerns, the Firewall Quality leader will prepare Quality Alerts, updated
QPS, and weekly TPPA with customer PPM,
 Mislabelling Issues are critical in firewalls, rules to relabeling, remove labels, print, mark etc.
have to be defined and applied, according Mislabelling best-practices in the region,
 Don’t check two different part numbers at the same time in the same workstation; this is a risk
for mislabelling.
 Put specific marks for OK checked parts leaving the firewall, recommended to stick the
operator number and date, use a small sticker applied in each single part,
 Use boundary parts approved by customers and quality alerts, to train and provide clear
criteria decision to operators about what is good, and what is no good,
 Use Versatility Matrix process to manage people skills and training,
 Operators must be trained daily about last customer alerts and problems,
 LPA must be applied in firewalls areas to confirm people follows operation standards,
 Once implemented the FW, it must be validate by auditing following IQB 04 A Attachment 1,
Firewall Audit, apply corrective actions to solve any non-conformity,

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Procedure:

Responsibility Flowchart Notes/Deliverables

Inputs:
Quality Manager
see initiating inputs list
Plant manager 1. Firewall decision
Outputs
Quality Firewall List of Parts,
Resources allocation (people,
surface, workstations, lighting, etc.)

Documents/People training
Firewall Supervisor 2. FW implementation Inputs:
Quality Leader
Quality Firewall List of Parts,
Process Engineers
Outputs
Firewall Layout implemented
FW CCAR QPS Final Control instructions
Improvement
Plan
Boundary parts & Pictures
Pace boards record forms
Firewall TPPA
Firewall Customer TPPA
Audit Versatility matrix / training records
RED
To validate implementation a
Firewall audit following Attachment
GREEN
1 must to be done with green
assessment.

Rejections feedback on Upstream

Operator
3. Firewall working process (reaction threshold)
Inputs:
Yes Quality Firewall List of Parts,
Rejects? QPS Final Control instructions
Boundary parts & Pictures
Pace boards record forms
3.1 Feedback
Upstream Outputs
Process Pace boards records

Firewall: Feedback to Upstream process

Supervisor leaders,
4. Team board daily meeting Decision to remove or include new
Quality Leader
parts in the FW see “initiation” or
Upstream Process: “removal” conditions
Supervisor Inputs:
4.1 Customer
Quality Leader Daily TPPA on rejections
Risk? Customer TPPA weekly
Yes
8D
No
Outputs
Quality FW List of Parts, Update
END TPPA update
8D update

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Support Documents in the Fire Wall Workstation

Pictures with the

control path (Eye
path sequence)

QPS (Quality
Process Sheet)
Detailing each one
of the 16 control
points

Pace-board hourly
rejections record,

Daily TPPA


Versatility Matrix

Weekly OEM TPPA

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Firewall pictures/Examples

Berlin FW for Door

Panels,

With RED light &

Siren

Firewall Layout
example

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List of Records
Pace board records
Daily FW TPPA results
FW Versatility matrix / training records
FW LPA Audit results

Attachments
IQB 05 A - Attachment 1, Firewall Audit

References
IQB 04 Self inspection and Final Control

Originator
Jordi Lopez

Record of Revision:
Date Description of Change
1/6/2011 New Instruction
6/8/2011 Added Initiating Inputs, Safe Launch activity
must apply a Fire Wall for all new parts
20/2/2013 Included Firewall audit assessment IQB 05 A,
in step 2, and attachment 1 audit document
(translated and adapted document from
Renault Firewall audit)

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