Theme: Reduce

number of miss locations

Sub theme:

Reduce number of miss locations in connector #10 for Toyota Rear Door

Site name: SEWS-R TARNAVENI

Team members:
Stroia Alexandru
Bacriu Nicoleta
Dan Victoria
Lucaci Iulian

Customer
REAR DOOR

Our products are

BACK DOOR

ENGINE

YFA FLOOR

VERSO FLOOR

YFA IP

FRONT DOOR

We have regular meetings

to discuss quality
problems.
Create plan to set target
for improvement.

Summary of activity

1. THEME selection complete

2. Preparation of activity plan complete
3. Clarification of problem and target settings complete
4. Understanding of current conditions complete
5. Factor analysis complete
6. Countermeasures development complete
7. Countermeasures implementation complete
8. Confirmation of effects complete
9. Standardization complete
10.Establishment of control complete
4

Step 1: THEME selection

WORK SHOP LAYOUT

Team
meetin
g area

Study
Area

Step 1: THEME selection

1st Pareto diagram

After we have collected all defects for all facilities, we identify the line with
the highest number of defects.
All defects / facility
120%

2500
2140
2000

100%
1825
80%

1500

1439
60%

1000

Quantity

40%

Percent

566
500

399366
290
239
168168129125
11911585 78
60 48 44

20%
15 8 4 2 1 1 1 1 1 1 1 1 1

0%

Facilities
6

Step 1: THEME selection

2nd Pareto diagram
All defects pareto
1400

120%

1244
1200

100%

1000
80%
800

We analyze deeper
all issues and get to
the conclusion that
the highest number
of defects are misslocation.

600

Quantity

482
400

Percent
40%

20%

200
102
0

60%

52 48
23 7
15 36 25 17 20

6 22 9

All defects

0%

Step 1: THEME selection

The current situation was considered based on the following criteria:
productivity, number of defects and customer annoyance.

0
points
Customer

2
points

1
point

Productivit
y

Defects

Customer

Total

Toyota

Suzuki

2
8

Step 1: THEME selection

We investigated also the customer

concerns

Checking all customer concern for current month we identified:

3 x Customer concerns, rank R (Liability of defect related to Customer);
1 x Unofficial concern, rank C (Verso Floor 1);
2 x Unofficial concern, rank D (Verso Floor 1 and 2);
1 x Official concern , rank B(+) (Rear Door). in connector #10

Step 1: THEME selection

In order to identify the worst line applied criteria for all Toyota line
facilities.

0
points
Line

Productivit
y

2
points

1
point
Defects

Customer

VERSO FLOOR
ENGINE 1.0
ENGINE 1.3
ENGINE 1.4
ENGINE 1.5

Total
2

The Rear Door line

facility was chosen
because of
annoyance customer
concern.

1
1
2
2

REAR DOOR YARIS

BACK DOOR YARIS

FRONT DOOR YARIS

1
10

Step 1: THEME selection

Miss-location pareto by connector
50
45

120%
44
100%

40

Based on score we decided to chose as facility

Most of the
line:
Rear Door.
Quantity
Percent
misslocations
Considering
on
that the most common defect is missRear Door
location we choose this defect to be our theme.
line are in
Connector
Connector
Connector
Connector
connector
#
Majority
of miss-locations
are
in
connector
#10
20
271
10
270
10
but we focus on LA*P / LA*GR because of the
customer concern.
35

80%

30

27

25

60%

20

17

15

12

10

40%
20%

5
0

30
25

Quantity

Miss-location
pareto byby
wires in
Misallocation
connector #10

wires

0%

120%

Most of miss-locations are

between wires BR/BR &
LA*P/LA*GR

100%

20

80%

15

60%

10

40%

20%

0%

Percent

11

Step 2: Preparation of activity plan

Steps to follow

WEEK 28

WEEK29

WEEK30

Actual
Resolved
WEEK31

WEEK32

WEEK35

WEEK3638

WEEK3840

1. THEME selection
2. Preparation of
activity plan
3. Clarification of
problem and target
settings
4. Understanding of
current conditions
5. Factor analysis
6. Countermeasures
development
7. Countermeasures
implementation
8. Confirmation of
effects
9. Standardization
10. Establishment of
control
11.Reporting

12

Step 3: Clarification of problem

Mislocation of LA-P/LA-GR of wire in connector #10

OK

NOK

13

Step 3: Target setting

Target: Eliminate number of miss-locations

in connector #10, LA-P & LA-GR wires

Reducing defects to zero

Mislocation / connector
44
45
40
35
27

30
25

17

20

12

15
10

Connector
Total
10
Connector
20
Connector
270
Connector
271

#
#
#
#

5
0

14

Step 3: Clarification of problem

Compone
nt Store

Lead
Stor
e

Test
electric

Tapeback
1

Audit 2

Packing

Trolley

Marking
wires

Process Description

PB &
tube insertion

Gromme
t
Greasing

Audit 1

Assy + Clip

Tape-back
2

Electrical test detects insertion

and continuity nonconformities
WHY DO WE SHIP
MISLOCATED HARNESS ???

15

Step 3: Clarification of problem

Electrical Test can only
detect correct insertion and
continuity

The wire color can

not be detected

16

Step 3: Clarification of problem

Intervie
w with
operator
s

In order to have a clear

view over the problem we
interviewed the operators
and checked our internal
records.

Miss
location records
sheet
Miss-locations
from our
database

Extract from training

manual

Rule of
insertion
17

Step 4: Understanding of current conditions

The operator
is using CPG
for connector
#271
It doesn't
have CPG for
connector
#10

Wires are
very close
to each
other

The operator
does not use the
diagrams, the
operator works
by memories

18

Step 4: Understanding of current conditions

All wires through

the grommet after
CPG on connector
#271.
before connector
#10

19

Step 4: Understanding of current conditions

All wires are
catched with the
hand there for is
difficult identify
lead colour for
connector #10.

Operator has
problems to identify
correct cavity
Operator does not
respect rule of
insertion.

The operator
holds incorrect
the connector
during insertion

20

Step 4: Understanding of current conditions

TIME STUDY REAR DOOR 2
1.8
1.6
1.4
1.2

1.097

Time
0.8
0.6
0.4
0.2
0

PB 1

PB 2

ASSY+CLIP

TEST ELECTRIC

OPERATION
TACT TIME = 1.097
TARGET = 410
82154-0D600 IS ALIKE 82154-0D620
MAX.
STATIO ACTUA NO. OUTPU
N
L TIME OPS. T
PB 1

1.341

336

PB 2

1.694

266

ASSY+
CLIP 0.967

130

WE HAVE 4 BOARDS FOR

ASSY+CLIP OPERATION

621

THS OPERATOR MAKES, ALSO,

TAPEBACK AND GROMMET
LUBRICATION

TEST
ELECT
RIC 0.725

We have 2 Pb

21

Step 4: Understanding of current conditions

Miss-location / code
20

18

18
14

15

11
7

10

5
0

OD600

OD620

OD630

OD700

OD710

OD750

From this graph we see that codes

occurred most miss-location
Miss- location occurred code
OD620

22

Step 4: Understanding of current conditions

Miss location/operators
4; 10%

A
6; 15%

12; 30%

7; 18%
11; 28%

From this we can see operators who had the

most mistakes.
We can see from this pie who had the highest
number of mistakes

B
C
D
E

23

Step 5: Factor analysis

Pre-block and lead
insertion
Misslocation
on
connector
#10 wire
LA-P/LA-GR

Operator
take the
wrong
wire and
insert in
connector

Operator
did not
check
marking
after tube
insertion

Operator
guessed
which
lead to
insert

PB10/1 is
very difficult
because
operator must
look very
closely to see
lead colours

Standardiz
ation work
was not
finish

Take
away
operator
guessing

LEGEND
Problem
Process
Facts
Activity
Countermeasur

24

Step 5: Factor analysis

Lay-up and tape
Introduce
buddy check
( visual
check for
these leads
con. #10)
Miss-location
on connector
#10 wire
LA-P/LA-GR

Operator
only lay-up
harness no
insertion

Other
operator
tapes

When
doesn't
check to
verify lead
colours

Marking
wires

LEGEND
Problem
Process
Facts
Activity
Countermeasur

25

Step 5: Factor analysis

Grommet attachment

Misslocation
on
connector
#10 wire
LA-P/LA-GR

Operator
takes the
wrong
wire and
insert in
connector

The
operator
does not
confirm
correct
insertion

Operator did
not read the
pre-block
diagram

The operator
hurries he
has to many
preparations.

Additional
training /
image
training

LEGEND
Problem
Process
Facts
Activity
Countermeasur

26

Step 5: Factor analysis

Miss-location
on connector
#10 wire
LA-P/LA-GR

The
operator
takes the
correctly
wire and
wrong
insert in
connector

The
operator
holds
incorrectly
connector
position

The wires
are mixed
after
grommet
attach

Installing
CPG for
connector # 10

LEGEND
Problem
Process
Facts
Activity
Countermeasur

27

Step 6: Countermeasures development

Countermeasur
e Proposal

Implementati
on time

Effects for
Quality

Easy to
impleme
nt

Cost

Mark lead correctly on B

end

Overall

11

Implementation new
Rule and standardization

10
Installing CPG for
connector #10

Retraining / image
training

1 points
2 points
3 point

10

We have implemented the items 1, 2 and

4 because the implementation was easy
and item 3 is under investigation for cost
and timing
28

Step 6: Preparation of Countermeasures implementation plan

Actual
Resolved
Countermeasures
implementation

Week
36

Week
37

Week
38

Week
39

Week
40

Week
40-44

1. Retraining /image training

2. Implementation of new Rule
and standardization
3. Mark lead correctly on B end
4. Installing CPG for connector
#10

29

Step 7: Countermeasures implementation

Plan

Do

Check

Support for
marking wires

Action
30

Step 7: Countermeasures implementation

Double check
on assy and
test electric for
connector # 10

Chec
k

Plan

Do

Action
31

Step 7: Countermeasures implementation

Creating
visual aid
for the
operator of
the PB

The
operator
was
retraining

32

Step 7: Countermeasures implementation

New work
instruction

Installing
CPG for connector #
10 next month

33

Step 8: Confirmation of effects

Defects after implemententation improvement

Week 37

Week 28
7

120%

100%

80%

Quantity

60%

percent

3
40%

20%

1
0

0%

Misslocation (LA*P/LA*GR)
in connctor #10
Defects
Sum defect

Procente %

70% pro

We can see that after the

implementation of
countermeasures defects were
reduced to zero in September

34

Step 9: Standardization

This created a double checking

for connector # 10 on assy and
electrical test. Will be done by
the operator from electrical test.

Created a visual
aid for the preblock operator
using connector
#10.
A new work instruction had
been created for marking
wires on placing them in
PB.
35

Step 10: Establishment of control

Checkpoint added in optional sheet

for compliance to ensure that they
comply with countermeasures

36

Safety first

Thank you
for
your
attention!

37