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QSB Quality System Basics & Q7 tools in practice

QSB Quality System Basics & Q7 tools in pracice

Introduction
QSB is a kit of tools and methods which provide a fast response in
the case of claim. It also avoids our customers getting defective
parts.
1. Fast reponse
2. Control of nonconforming products
3. Standardized work
4. Standard operator training
5. Risk Reduction (RPN)
6. Error proofing verification
7. Layered Audits
8. C.A.R.E
9. Lessons learned

Corrective action

Preventive action

QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

is a system that standardizes reactions to significant internal and


external quality failures,
a fast reponse meeting shall be held daily to review the significant
quality concerns gathered by Quality,
is a communications meeting,
meeting not a problem solving
meeting. It can be a 10 - 20 minute stand up meeting held on the
shop floor or in a production conference room,
is a manufacturing review meeting owned by manufacturing
and supported by Quality, Engineering, Maintenance, etc
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QSB Quality System Basics and Q7 tools in pracice

Introduction
1. Fast reponse

At the Fast Response meeting, leadership shall

Designate a leader (owner) for each concern/issue.


Assign owner report out for next meeting

Owners shall be responsible for assuring all problem solving


and exit criteria are met in a timely manner.
Owner report out shall include updates on the following:

Fast Response Tracking Sheets


Standardized Work Instructions
Problem Solving Form(s)
PFMEA
Control Plan
Layered Audit
Workforce Notification
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QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

Report out to Leadership is scheduled on the Fast Response


tracking form as deemed necessary.
The Fast Response Tracking form should be part of a visual
management system. The format should be displayed as large
as is practical in the meeting area.

QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

QSB Quality System Basics & Q7 tools in pracice

Introduction
2. Control of nonconforming products

QSB Quality System Basics & Q7 tools in pracice

Introduction
3. Standardized work

QSB Quality System Basics & Q7 tools in pracice

Introduction
4. Standardized operator training

QSB Quality System Basics & Q7 tools in pracice

Introduction
5. Risk reduction (RPN) operator training

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QSB Quality System Basics & Q7 tools in pracice

Introduction
6. Error proofing verification

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

Extract from DC specific requirements for use with ISO TS 16949

QSB tool # 6 Error proofing verification

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

Extract from DC specific requirements for use with ISO TS 16949

QSB tool # 2 Control of nonconforming products


QSB tool # 1 Fast reponse

QSB tool # 9 Lessons learned

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QSB Quality System Basics & Q7 tools in pracice

Introduction
8. C.A.R.E CUSTOMER ACCEPTANCE REVIEW & EVALUATION

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QSB Quality System Basics & Q7 tools in pracice

Introduction
9. Lessons learned

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

19

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

20

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Run
chart

Inspection
chart

Pareto
analysis

21

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Pareto
analysis

Histogram

22

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Pareto
analysis

Histogram

Ishikawa
diagram

23

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Pareto
analysis

Histogram

Ishikawa
diagram

5 why
analysis

24

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Pareto
analysis

Histogram

Ishikawa
diagram

5 why
analysis

Action plan

25

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Pareto
analysis

Histogram

Ishikawa
diagram

5 why
analysis

Action plan

26

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Pareto
analysis

Histogram

Ishikawa
diagram

5 why
analysis

Action plan

27

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Ishikawa
diagram

5 why
analysis

Action plan

28

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

29

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

30

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

31

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

32

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

8-D-Report

33

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

8-D-Report

QSB 1
Fast response
(Fast Response is the tool
monitoring all other
activities)

34

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

35

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

36

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

37

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

38

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

39

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

40

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

41

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

42

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

5 why
analysis

Action plan

Action plan

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

PFMEA

43

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

8-D-Report

PFMEA

44

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

8-D-Report

PFMEA
QSB 6
Error proofing
Verification

45

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

8-D-Report

PFMEA
QSB 6
Error proofing
Verification
Controlplan

46

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

PFMEA
QSB 6
Error proofing
Verification
Controlplan

47

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

48

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

49

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

QSB 5
Risk reduction
RPN

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

50

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

QSB 5
Risk reduction
RPN

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 8
C.A.R.E.

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

51

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools
Record failures

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

QSB 5
Risk reduction
RPN

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 8
C.A.R.E.

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

52

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

QSB 5
Risk reduction
RPN

8-D-Report

Squeeze & picture failures

Pareto
analysis

Histogram

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 9
Lessons
learned

Record failures

QSB 3
standardized
work

QSB 4
Standard oper.
training

QSB 8
C.A.R.E.

QSB 7
Layered audits
PFMEA
QSB 6
Error proofing
Verification
Controlplan

53

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice


The basic 7 quality tools

Control
chart

Inspection
chart

Squeeze & picture failures

Pareto
analysis

Histogram

Internal failure
or customer
complaint

QSB 2
Contr. of
NC products

QSB 5
Risk reduction
RPN

Find out root cause & solutions

Ishikawa
diagram

Action plan

5 why
analysis

Action plan

QSB 9
Lessons
learned

Record failures

QSB 3
standardized
work

8-D-Report

The process state


of the green
colored boxes is
indicated here

QSB 4
Standard oper.
training

QSB 8
C.A.R.E.

QSB 7
Layered audits

PFMEA
QSB 6
Error proofing
Verification
Controlplan

54