Understanding QRQC

The QRQC
Quick Response
Quality Control
What is important to know
before speaking QRQC
“Quality is one of the biggest weakness of

manufacturing companies”
It is necessary to recognize it
“A change of Culture is necessary based on

San Gen Shugi”
What is San Gen Shugi ?
“Every one needs to apply QRQC”
What is QRQC ?
2 December 13
Property of Valeo - Reproduction prohibited
San Gen Shugi
San means "3"

Gen means "real" or "actual"
Shugi means "ideology“
3 December 13
The 3 “Gen” are:

1. Real Place (Gen-ba) on shop floor
“Genba” means going down on the shop floor to discover the real
place and the root causes of problem
2. Real Parts (Gen-butsu) with real bad parts

Applying “Genjitsu” means being realistic, not idealistic.
3. Reality (Gen-jitsu) with data

“Genbutsu” refers to real parts, and the way of dealing with non-
conformance.
4 December 13
Understand QRQC
5 December 13
Understand QRQC
Detection
QRQC
Verification MEETIN Communication
G
Analysis
6 December 13
Understand QRQC
Understand what is QRQC
Why QRQC is required for Valeo ?

– Key word : “What have you improved yesterday ?”
– Concept :
QRQC has been put in place to counter main
weaknesses
It should be always done, based on San Gen Shugi
7 December 13
Understand QRQC
Iceberg concept:
You see
this 1) RED Box:
Detection Collect each bad part
Bring it to QRQC meeting
Is the Red box available at all
You don’t see places?
this
Red Box is not a garbige can!
QRQC
MEETIN
Never say that « the G
2) You can detect a defect
problem is small » only if you have a reference
3) Detection is based on part (master part / good part)
4) What « COMPARISON »
methodology / You compare the NG part to:
means / tools are If a part is claimed to be a
-A master sample / part NG part, ask yourself:
available to detect a -A drawing / specification
NG part ? -A standard Golden rule1: « It is Not Good
-Boundery samples … based on what ? »
8 December 13
1st step : Caracterization and 5W2H
- Problem is described
WHAT ? - The parameter of the subject have to be delimited
- Separate the subject in several items if necessary
- Define the necessary people for this subject
WHO ? - Tracability : which operateurs, which shift…
- Status : trained operator …
- Localisation : internal / external, exact place
WHERE ? - Where the defact was created ?
- Where the defect was detected ?
- Date
WHEN ? - Periodicity / Frequency of this defect
- Missing information, events …
- How did it happen ?

HOW ? - Bad / weak detection …
- Quantity in defect, quantity found non-conform, cost dor the rework,

number of lots concerned…
HOW MANY ? - Number of cavities, Number of days with this defect
- Information on non conform parts declaration, test report
- Define the reasons and hypothesis
WHY ? - History
- Look and compare with equivalent parts
9 December 13
Understand QRQC
Detection
QRQC
MEETIN Communication
G
10 December 13
Understand QRQC
4) Golder rule3: For every defect / problem, do

you have the 5W-2H ?
If the answer is « No », you cannot go further!
3) Defect should be
identified: identify each NG
part to make it obvious QRQC
(sticker, marker, label…) MEETIN Communication
G
2) Keep the memory about the issue: 1) Don’t hide the problem, inform
-Record the issue on a record sheet somebody: Your manager ,Quality …
-Keep the data available at all times
Bring the issue to the QRQC meeting
-Every one should have access to the
data Golden rule2 : « You see something, You
say something !»
11 December 13
Understand QRQC
Detection
QRQC
MEETIN Communication
G
Analysis
12 December 13
Understand QRQC
3) Use again Golden rule1:

« It is Not Good based on
2) Compare the NG parts to a what ? »
GOOD part (visualy,
based on data)
4) Perform the analysis on obvious
What is different ? items and on hypothesis:
(compared to master part, Use 4M factor matrix and find root
drawing, specification…) QRQC causes on:
MEETIN -Non detection
G
-Occurence
1) Understand the problem !
-Use the 5W-2H 5) Decide what are the
information corrective actions to implement:
-Golden rule4:
« speak with data! » Analysis -Immediate and short term
actions
(never say :
maybe, we think that …!) -define: Who, what when ?
13 December 13
Understand QRQC
Detection
QRQC
G
Analysis
14 December 13
Understand QRQC
1) Validate that the 2) Measure the impact of

corrective actions are: corrective actions:
-Efficient Containment action
implemented here
-Sufficient 6
Containment action
5
implemented here
4
3 Validation
2
QRQC
Verification MEETIN
G
1
0
Day1 Day2 Day3 Day4 Day10 Day30
3) Put in place audits to verify that the

4) If the problem still corrective actions are:
occure, you have to go -still in place & implemented
back & challenge the
-Respected
previous step « Analysis »
15 December 13
Understand QRQC
Detection
QRQC
G
Analysis
16 December 13
Understand QRQC
Detection
QRQC
G
Analysis
17 December 13

Understanding QRQC

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Understanding QRQC

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The QRQC

“Quality is one of the biggest weakness of

“A change of Culture is necessary based on

San Gen Shugi

San means "3"

The 3 “Gen” are:

2. Real Parts (Gen-butsu) with real bad parts

3. Reality (Gen-jitsu) with data

Understand what is QRQC

Why QRQC is required for Valeo ?

It should be always done, based on San Gen Shugi

- How did it happen ?

- Quantity in defect, quantity found non-conform, cost dor the rework,

4) Golder rule3: For every defect / problem, do

3) Use again Golden rule1:

1) Validate that the 2) Measure the impact of

3) Put in place audits to verify that the

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