仕入先名 Date 2023/ 06 /16

83 期 品 質 改 善 計 画 書
承認 確認 作成
(2023年7月期～2024年6月期) Viet Nam Schlemmer Yu Da Zhi
Dao Duc
Nguyen
Van
Phong
Vuong

1．82期と83期品質クレーム推移＆対比（登録･発生･調査） ※異議受託になるまでカウントとして下さい。 2．82期クレーム結果総括

82 期実績と 83 期目標と実績比較
5
Y Y
H E 不良发生原因
4
V
-
客户 V
-
Q T
N V
2 4
3 81 0 0
期 N Abnormality mis-
% % o
件数

不良类型 handling
82 a 20% I
m
2 s
不良流出原因 p

期 s Improper change r
o
Y e Other point management p
e
H m r
V
White crack of 60% 20%
1 -
b base lock i
n
l
s H y
20%
Other
s
p
e
P Deformation 60%
c
20%B t
0 4 S Broken
i
Abnormality
o
mishandling
7月 8月 9月 10 月 11 月 12 月 1月 2月 3月 4月 5月 6月 0 B 40%
n
20%

% 2 m
e
0 t
h
% o
d
2
0
%
7月 8月 9月 10月 11月 12月 1月 2月 3月 4月 5月 6月 合計 目標
81期 0 0 0 0 1 2 0 1 1 2 1 2 10
82期 0 1 0 1 1 0 0 0 0 1 1 0 5
83期目標 0 0 0 0 0 0 0 0 0 0 0 0 0 【総括】
83期 0 0 0

3．82期クレーム詳細（2022年7月期～2023年6月期）
発生先 クレーム内容 責任場所(発生工程) 責任場所(流出工程) 発生原因 流出原因
№ 月度 管理№ 品番 発生対策 流出対策
区分 詳細名 重点不具合 その他 内外製 会社名 内外製 会社名 4M 詳細 4M 詳細
检查客户寄回的不良样品及越南诗兰姆
储存的样品，产品卡窗都存在类似发白
痕迹，卡窗对配后产生白痕迹但没有发 1.
生断裂现象。此位置性能检查结果为合 联络客户，对于这种情况建议正
8 7276-6659-0W - White crack of base 格 （参考性能检测结果）。 常使用 / /
1 矢崎工場 YEV-TV lock
社内 Schlemmer Viet Nam 社内 Schlemmer Viet Nam Method
因产品与进胶点结构，从开始量产到现 2.
在，产品注塑成型时客户投诉的卡窗位 优化魔具，改善客户联络卡窗扣
置都存在原料熔接痕。产品初期管理时 合后发生发白痕迹现象
，产品卡窗扣合后也存在类似现象，但
性能检测结果合格无发生断裂现象。

The bubbles position for which

1. 不合格品再现时，必须用很大的力量 you contacted us is the
突然行动产品局部结构才发生与客户类 shrinkage hole, which has no
似的
破损现象。 effect on the function and can
此局部结构为检验作业指导书中重点检 be used normally.
2 10 7271-2296-3W 矢崎工場 YEV-TV 駒折れ Broken 社内 Schlemmer Viet Nam 社内 Schlemmer Viet Nam 查内容。产品在越南诗兰姆生产履历无 Reason: Because the product / /
发生类似破损现象。越南诗兰姆各生产 structure is too thick. During the
、运输工序没有存在发生破损风险。 molding process, when the
2.产品结构较厚，生产过程很难避免产
material cools inside, it shrinks
品里存在点气泡现象。客户联络气泡现
象没有影响产品外观、性能。 and forms holes; this is an
unavoidable phenomenon.

发生原因：产品结构原因，该部位一直 1.全检时取下工装，产品OK，因未
存在变形问题，产品注塑后定型，全检 1./重新确认水路接法，验证成型 经过充分定型，在运输过程中回
时取下定型工装。送样产品注塑时间与 工艺 弹变形。
3 2 7171-6612 矢崎工場 YHV-HP - Deformation 2次外注 Schlemmer Ningbo 2次外注 Schlemmer Ningbo Method 全检时间间隔长，定型时间久，效果好。 2.重新检讨水路设置，必要时使用 Man 对宁波诗兰姆工程师培训，收到
2.宁波诗兰姆未对越南诗兰姆反 问题点时的确认方法和注意事项
YHV发现的不良批次后注塑时间与全检 3D打印水路 馈的变形问题点详细确认，导致
时间间隔短，定型时间不充足，效果不 流出。
佳。

经过确认在YHV-QN发生的不良样品和
客户的信息确认不良发生在20230331
批次。发生NG的箱子排列在同一托盘
上属于YQN230409单据送到YHV-QN（
2023/4/15）。检查发生不良的箱子，箱
外有变形、破开，箱内有凹陷痕迹。检查
4 4 7276-6142-3W 矢崎工場 YHV-QN 駒折れ Broken 社内 Schlemmer Viet Nam 社内 Schlemmer Viet Nam 发现1pcs断裂，碎片还存在在箱子里。 / / /
破裂位置是检查指导书重点检查位置
箱子坠落验证发现破裂形状与客户投诉
相似
结论：发生破裂的原因是由于检查完成
后坠落
调查在VSA制造工序没发生产品坠落，
所以没有发生破裂的风险
 通过确认不良样品和库存返工信息，确
定发生不良批次是20230303批
次。20230309批次是在越南装配的。当 全检工段检查指导书未符合。尽
时，装配机刚转移到越南，在装配与调 管指导书已标志着Busbar装配位
整的过程中。 置但用较大圆形标识，而且颜色
在装配机设置期间仍然有客户的订单， 标志与其他位置也没有区别。此 更改检查指导书，添加每个装配
5 5 7271-2587-30 矢崎工場 YHV-HP 部品欠品 No assembly BSB 社内 Schlemmer Viet Nam 社内 Schlemmer Viet Nam Machine 为了满足订单，VSA一边验证完善装配 设置完整零件装配机，装配机已 Method 位置的详细图片以及每个位置的
外，该位置的名称未记录是
机设置一边装配产品。因为产品在装配 安装完好，2023.4开始稳定运营 Busbar装配位置，而是装配槽位 单独测试要求。Busbar装配的位
机未设置完好装配，所以发生漏装现象 置用颜色不同的箭头标记
而没有发现。 置导致操作人漏检，流出NG产品
装配机已安装完好，2023.4开始稳定运 。
营，从4月到现在装配的批次没发生不
良。
4．反省・課題 5．課題及び弊社品質目標達成に向けた活動方針

Quality 1. 无流出严重不良到 YAZAKI 各装配工厂

【4M】 【反省点】 【課題点】
2. 与 T 82 相比减少了 20% 不良数量
target

Method 重新对宁波工程师进行培训，收到问题点时的确认方法和注意事项
宁波工程师没有向子公司通知异常信息

► Plan for T83 :

对现场工人进行培训，提高处理异常、变化点的能力， 继续保持已量产零件稳定
生产
Method
新装配设备刚刚转移到越南，未安装设定完整 完整设定装配设备

Method None None

To raise knowledge of worker at factory-
Trainer of system department

On going
Method 装配BSB的产品在越南是第一次开发的，所以检验指导书
增加了对带有 BSB 装配的产品进行操作和检查方法的验证。
中的检查方法还没适合。

On going
【Managementとしての反省点】 【Managementとしての課題点】

On going

6.改善計画/実績表
計画/実績
クレーム件数 対象(品番,工程)
№ 重点不具合 具体的取り組み(方策) 目標値 責任者 寄与度 ※別紙要 年 2023年 2024年 結果
月 7月 8月 9月 10月 11月 12月 1月 2月 3月 4月 5月 6月
計画
実績
計画
実績
計画
実績
計画
実績
計画
実績
流出累積目標
メーカークレームの流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
計画
2
実績
計画
実績
計画
実績
流出累積目標 0 0
重点不具合の流出クレーム目標と実績 流出累計実績 0 0
評価 OK OK
計画 0 0
100% 阮文旺 所有装配巴斯巴零件的产品（
设定完整零件装配机
1个产品） 実績 0 0
3
漏装巴斯巴零件
計画 0 0
改变方法，增加了对每个BSB组件装配位置进行详细检查的要 所有装配巴斯巴零件的产品（
100% 阮文旺
求，并且装配位置用特别的颜色箭头标记
1个产品） 実績 0 0
流出累積目標 0 0
重点不具合の流出クレーム目標と実績 流出累計実績 0 0
評価 OK OK
計画 153 153
4 装配后卡窗发白 检查所有卡窗位置，装配后发生裂纹时优化排气系统。 100% 阮文旺 所有带有卡窗的产品
4 装配后卡窗发白 检查所有卡窗位置，装配后发生裂纹时优化排气系统。 100% 阮文旺 所有带有卡窗的产品
実績 153 153
流出累積目標
重点不具合の流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
5
計画
実績
計画
実績
流出累積目標

不具合の流出クレーム目標と実績 流出累計実績
評価
 83th term Quality Improveme
1. Customer claim transition & comparison on 82th term and 83th te
※Please count until dispute arising out.

Result of comparison between 82th term and

5

3
Count

0
July Aug Sep Oct Nov Dec Jan Feb Ma

July Aug Sep Oct Nov Dec Jan

81th term 0 0 0 0 1 2 0

82th term 0 1 0 1 1 0 0
83th target 0 0 0 0 0 0 0
83th term 0 0

3．Detail of claim which occurred on 82th term (July period of 2022

Found at Claim detail
Period
№ Control № Part number Internal/
of month Place name Critical issue
External

1 8 7276-6659-0W 矢崎工場 YEV-TV -

2 10 7271-2296-3W 矢崎工場 YEV-TV 駒折れ

3 2 7171-6612 矢崎工場 YHV-HP -

4 4 7276-6142-3W 矢崎工場 YHV-QN 駒折れ

 5 5 7271-2587-30 矢崎工場 YHV-HP 部品欠品

33

34

35

4．Review・Problem

【4M】 【Review】

Ningbo engineers do not deploy abnormality information to train NBS engineers on c

Man
the agency received.

Newly assembly equipment delivered, not yet installed

Machine Set up as
completely
 Material None

The assembled product BSB is a new item that has been

Increasing validation of o
Method exploited for the first time. The test method in the inspection
which assembled with BSB
instruction is not suitable.

【Review as Management】 【Problem as Mana

※Training NBSLM engine
※ Information is not deployed fully between Ningbo and agency. need to determine the v
attention

※The test method is not suitable ※Increasing validation o

products which assemble

№ Critical issue Detail action (Plan)

Target and result of NG escape claim w

2
 Target and result of NG escape claim

Set up component assembly machine completely

Assembly without BSB

3 The change methods, adding detailed inspection requirements for
component
each
BSB component assembly positions and assembly positions are
marked with separate arrow colors

Target and result of NG escape claim

White reef base lock after Checking all of base lock position, optimized mold escape when cracks are
4 assembly detected after assembly

Target and result of NG e

Target and result of NG e

rovement Plan (July 2023～June 2024)

rm and 83th term (Registry･Occurence･Investigation) 2．Customer claim resul

【Chart of claim occurred location】

n 82th term and 83th term

82th
term
83th
target
83th
term

an Feb Mar Apr May June

Feb Mar Apr May June Total Target

1 1 2 1 2 10
0 0 1 1 0 5 【Summary】
0 0 0 0 0 0
0

period of 2022 ～ June period of 2023)

Claim detail Responsible company (process of occurrence) Responsible company (process of esc
In-house production or In-house production or
Other Company name Company na
produced by other produced by other

White crack of base

lock
社内 Schlemmer Viet Nam 社内 Schlemmer Vie
 Broken 社内 Schlemmer Viet Nam 社内 Schlemmer Vie

Deformation 2次外注 Schlemmer Ningbo 2次外注 Schlemmer Ni

Broken 社内 Schlemmer Viet Nam 社内 Schlemmer Vie

 No assembly BSB 社内 Schlemmer Viet Nam 社内 Schlemmer Vie

5．Problem and improve

Quality
【Problem】
target
ain NBS engineers on check method and alerts for problems
ceived.

► Plan for T83 :

Training to increa
factory to mainta

Set up assembly equipment completely

 None

ncreasing validation of operations and checking methods for products

hich assembled with BSB component.

Problem as Management】
Training NBSLM engineers: when there is a problem , engineers
eed to determine the validation method and the items to pay
tention

Increasing validation of operations and checking methods for

oducts which assembled with BSB component.

6.Improvement pla
Contribution of Target (Part No., Process)
Target value In charge person
claim content ※Need another sheet

scape claim which is arisen by Car maker

G escape claim which is critical issue

All products with BSB

100% 阮文旺 component assembly ( 1
part)
equirements for
All products with BSB
positions are 100% 阮文旺 component assembly ( 1
part)

G escape claim which is critical issue

pe when cracks are

All of products have base
100% 阮文旺
lock position

result of NG escape claim

result of NG escape claim

 Company name

Viet Nam S

er claim result summary on 82th term

occurred location】

Y Y
H Customer E
V V
- -
Q T
N V
2 4
0 0
% % N
o h
W

Y Defect typei
H a
s
t
e
V s
e c
- m
b
r
a
H Deformation
20%
l
y
c
k
P
B o
4 S f
B
0 2
Broken
40% b
% 0
%
a
s
e

l
o
c
k
2
0
%

company (process of escape) Cause of NG occurrence

Company name 4M Detail

Check the defect sample returned by the customer and the
keep sample at Schlemmer Vietnam have the same status,
after assembling the cover lock has white marks but no
cracks. The functional test results for this position are
satisfactory (refer to sheet "functional test")
Due to the product's structure and the inlet gate line's
Schlemmer Viet Nam Method structure when molding, the product has always a weld-line at
the cover lock position as customer's information from the
beginning of mass production until now. There is also a white
marks status after assembling in the initial verification, and
functional test results for this position are satisfactory with no
cracks.

Schlemmer Viet Nam
Schlemmer Ningbo Method
Schlemmer Viet Nam
1.We reproduce the defect and must use a large force of
sudden impact so that the clamp position could occur a defect
such as you contacted.
The clamp position is the key inspection point in the
inspection instruction.
There was no similar breakage condition in VSAP's production
history.
The same risk of breakage does not exist in the production
and transportation stages of VSAP.
2.Because the product structure has a large thickness, small
bubbles are unavoidable during production. The condition of
small bubbles, about which you contacted us, will not affect
the product's appearance and usability.
3.The inventory sort results did not detect deformed products.
The defect position is the key inspection point in the
inspection instruction. Using foam padding after improving the
packing method. The product was not deformed during the
inspection process at VSAP. At VSAP, there is no risk of
deformation defects during the manufacturing process.
due to the part structure, this area always suffers
deformation. After molding, parts are shape-cured,and the
curing jigs are removed at the time for final inspection.The
time interval from injection molding to final inspection is long
enough to get a good shape curing result. The NG lot found in
YHV had a short time interval from injection to final inspection
to cure the shape, so it is not effective enough.
After confirming the defective products at YHV-QN and your
side information, we confirm that the defect occurred in lot
no. 20230331.
Boxes with NG products are placed on the same pallet
delivered to YHV-QN on April 15, 2023 at invoice no.
YQN230409.
Check the product box that occurred defect, noticed that the
box's outside appearance had deformation marks, was
cracked, and the inside had dent marks.
During inspection, one product was discovered to be broken,
and there was a broken piece of defective product in the box.
The broken position is a key point in the inspection instruction.
Carry out the product box drop test, and discovered a broken
condition similar to the defect you contacted.
Conclude: Cause of broken due to dropping after the product
has been completed inspection.
Re-investigation of the stages at VSAP, no dropped product ,
no risk of break at VSAP
 After confirming the defective products and inventory sorting
information, we confirm that the defect occurred in lot no.
20230309.
Lot no. 20230309 was assembled in Vietnam Schlemmer. At
this time, the assembly equipment has just transferred in Viet
Nam and are in the process of installation and adjustment.
During the completion of the assembly equipment installation,
there are still orders from customers, to meet urgent orders
Vietnam Schlemmer has conducted both verification of
Schlemmer Viet Nam Machine assembly equipment installation completion and products
assembly to meet the needs of customer's order.
Because the product was assembled when the assembly
equipment was not complete installed,
there was a missing assembly condition that the assembly
equipment did not detect.

The assembly equipments has been completely installed and

put into operation stably from April 2023.
Shipments assembled from April to present have no defects.

m and improvement action for achieve our quality target.

1. No occurrence serious errors to the assembly plants of YAZAKI
2. . Reduced the number of errors by 20% compared to the period 82

► Plan for T83 :

Training to increase ability solve abnormality, change point and raise capacity for workers at produ
factory to maintain stability of component which carry on mass production
 On going

On going

On going

provement plan / Result table

Plan/Result
Year 2023
Month Jul Aug Sep Oct Nov
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
NG Escape
cumulative
target
NG Escape
cumulative
result
Evaluation
Plan
Result
Plan
Result
NG Escape
cumulative 0 0
target
NG Escape
cumulative 0 0
result
Evaluation OK OK
Plan 0 0

Result 0 0

Plan 0 0

Result 0 0

NG Escape
cumulative 0 0
target
NG Escape
cumulative 0 0
result
Evaluation OK OK

Plan 153 153

Result 153 153

NG Escape
cumulative
target
NG Escape
cumulative
result
Evaluation
Plan
Result
Plan
Result
Plan
Result
Plan
Result
NG Escape
cumulative
target
NG Escape
cumulative
result
Evaluation
y name Date 2023/ 08 /14
Approve Confirm
Viet Nam Schlemmer Yu Da Zhi
Dao Duc
Phong

I
m
p
r
o
p
e
r

c
h
a
n
g
e A
b
A p
b n
Occurrence cause
n
o o
i r
o n
r m
t
m a
a m l
l a i
i I t
n
t m
Out-flow cause y
Other a
y p
W 60% g
e r m
m m o i
i e p s
s n e h
h t r
a a
2 n
n Other
0 i d
d 60%
% n
l l
s i
i
n p n
g e g
2 c 2
0 t 0
% i %
o
n

m
e
t
h
o
d
2
0
%

NG escape root cause

Measure for preventing recurrence Measure for preventing NG
4M Detail

1.Contact the customer to suggest a normal use for

this status.

2.Optimize mold and improve white marks status / /

after assembling at the customer's information
position.
The bubbles position for which you contacted us is
the shrinkage hole, which has no effect on the
function and can be used normally.
Reason: Because the product structure is too thick. / /
During the molding process, when the material
cools inside, it shrinks and forms holes; this is an
unavoidable phenomenon.

1. Jigs were removed at the time

1.re-check the waterline connection method and
verify process parameters
Man
2.review the waterline setting again, and use 3D
printing waterline if necessary
for final inspection. The parts
were OK. But their shape was
not cured so sufficiently that it train NBS engineers on check
deformed again during transport. and alerts for problems receiv
2. NBS did not inform VNS of
this deformation in detail,leading
to escape.

/ / /
 At the full inspection process,
the initial inspection instructions
were not appropriate.
Although the inspection
instruction manual has markings Revised the inspection instruc
the busbar assembly position, manual. Added images show
The assembly equipments has been completely but the markings are large and each assembly position and r
installed and put into operation stably from April the color of the markings has no separate inspection of each p
Method
2023. distinction from other positions. Busbar assembly position ma
In addition, the position's name separate colored arrows to inc
is not recorded as busbar worker attention.
assembly position, but as
assembly groove position, as a
result, the worker inspects
omissions and flows out NG
product.

AKI
riod 82

city for workers at production

To raise knowledge of worker at factory- Trainer of

system department
 To raise knowledge of worker at factory- Trainer of
system department

n/Result
2024 Result
Dec Jan Feb Mar Apr May Jun
Date 2023/ 08 /14
Make

Nguyen Van
Vuong

A
b
n
o
r
m
a
l
i
t
y

m
i
s
h
a
n
d
l
i
n
g
2
0
%

Measure for preventing NG escape

/
 /

ain NBS engineers on check method

nd alerts for problems received.

/
Revised the inspection instructions
manual. Added images show details of
ach assembly position and required
eparate inspection of each position.
usbar assembly position marked with
eparate colored arrows to increase
worker attention.
Result
 Y Y
客户 次数 H E
V 客户 V
YEV-TV 2 -
Q
-
T
N V
YHV-HP 2 2 4
0 0
% %
YHV-QN 1

Y
H
V
-
H
P
4
0
%

不良类型 次数
White crack of base lock 1
Broken 2
N
Deformation 1 o 不良类型
a
No assembly BSB 1 s
s
e
m White crack of
b base lock
l 20%
y
Deformation
B
20% S
B
2 Broken
0 40%
%
合计 19

不良发生原因 次数
不良发生原因
Abnormality mishandling 1
Improper change point management
1
Abnormality mishan-
Non-compliance 0 dling
20%
Other 3 Improper change
Other point management
合计 10 60% 20%
 不良流出原因 次数
Improper inspection method 1
Abnormality mishandling 1 A
b
n
o
I r
m

Improper WI
不良流出原因 m
p a
r l
o i
p t
e y
r

Other 3
m
i i
n s
s h
p a
Other e n
60% c d

合计 10
t
i
o
n
l
i
n
g
2
m 0
e %
t
h
o
d
2
0
%
 Y
E
户 V
-
T
V
4
0
%

te crack of
ase lock
20%

Broken
40%

生原因

lity mishan-
dling
20%

Improper change
point management
20%
 A
b
n
o
I r
原因 m m
p a
r l
o i
p t
e y
r
m
i i
n s
s h
p a
e n
c d
t l
i i
o n
n g
2
m 0
e %
t
h
o
d
2
0
%
 Customer Times Y Y
H E
Customer
YEV-TV 2 V V
- -
Q T
YHV-HP 2 N V
2 4
YHV-QN 1 0
%
0
%

Y
H
V
-
H
P
4
0
%

Defect type Times

White crack of base lock 1
Broken 2
Deformation 1
N W

No assembly BSB 1 o

a
Defect type h
i
t
s e
s
e c
m r
b a
l c
Deformation
y k
20%
B o
S f
B
2 b
0 Broken a
% 40% s
e

Total 5 o
c
k
2
0
%

Occurrence cause Times I

m
p
r

Abnormality mishandling 1
o
p
e
r

c
h

Improper change point management 1

a
n
g
A e
b
Occurrence cause
n p
o o

Non-compliance 0
r i
m n
a t
l
i m
t a
y n
Other

Other 3
a
60% g
m
i e
s m
h e
a n
n t
2

Total 5
d
l 0
i %
n
g
2
0
%
 Out-flow cause Times
Improper inspection method 1
A

Abnormality mishandling 1 b
n
o
r
m
a

Improper WI
I l
m
Out-flow cause i
p t
r y
o
p m
e i

Other 3 Other
r

i
n
s
h
a
n
60% s d
p l

Total
e

10
i
c n
t g
i 2
o 0
n %

m
e
t
h
o
d
2
0
%
 Y
E
mer V
-
T
V
4
0
%

W
type h
i
t
e

c
r
a
c
k

o
f

b
ken a
% s
e

l
o
c
k
2
0
%

I
m
p
r
o
p
e
r

c
h
a
n
g
A e
b
e cause
n p
o o
r i
m n
a t
l
i m
t a
y n
a
m g
i e
s m
h e
a n
n t
d 2
l 0
i %
n
g
2
0
%
 A
b
n
o
r
m
a
I l
m
use i
p t
r y
o
p m
e i
r s
h
i a
n n
s d
p l
e i
c n
t g
i 2
o 0
n %

m
e
t
h
o
d
2
0
%