7 STEPS OF PS – # NUMBER

Detached brackets
Gustavo Velázquez Alvarez
Quality Engineer

QC
12-01-2019
7 STEPS OF QC PROBLEM SOLVING
Overview
STANDARDIZE AND
ESTABLISH CONTROL 7
CHECK RESULTS
6
CONSIDER AND
IMPLEMENT THE
SOLUTION
5
CAUSE ANALYSIS
4
PLAN ACTIVITIES
3
UNDERSTAND THE
SITUATION, TREND
AND SET TARGETS
2
CHOSING THE
PROBLEM
TO SOLVE
1
Plant Name 2
 CHOOSING THE PROBLEM TO SOLVE
Prioritization
Reference Period
QA MATRIX 2018
12 Month Rooling

A B C D Resume TIMMING STATUS

CLASSIFICATIO

Process Impact

START DATE
Incoming material
Product Model

N AA-A-B-C
Date added to

FREQUENCY
Defects Mode

Priority Index

Project leader
Resident Report
Sub Defects

Project code
Assembly Final

END DATE
Root cause
A*B*C*∑D
QA Matrix

SEVERITY

Workstation

CLOSED
CHECK
Customer

Estatus
4M+1D
Rework

PLAN
COST
Rank

GP12

ACT
150

300

Line

DO
Field

∑D
Line

10

25

75
1

5
1 06/02/2019 S140534 Dimensional Tube out of spec (RT02 Reduction) 5 5 4 25 25 2499.9 18.450% PZEV Material 8 EXH069 A. Miranda 06/02/2019 09/03/2019 Act 0 0 0 x 0

2 06/02/2019 S158970 Dimensional Bracket out of scpec (RT02 Reduction) 5 4 4 25 25 1722.5 31.162% Rear 4 Material 8 EXH070 A. Miranda 06/02/2019 09/03/2019 Act 0 0 0 x 0

3 05/02/2019 S159164 Welding ROD burnthrough 5 3 4 25 25 1480.4 42.087% Front E6D Design 8 EXH067 R. Valle 05/02/2019 08/03/2019 Do 0 x 0 0 0

4 12/02/2019 S145089 Dimensional Closed Thread Central 5 3 4 25 25 1247.5 51.294% Front 1 Machine 8 EXH066 R. Valle 12/02/2019 15/03/2019 Do 0 x 0 0 0

5 14/02/2019 S160497 Identification Blanking parameters standarization 4 2 4 25 25 767.5 56.958% PZEV Method 8 EXH068 G. Velazquez 14/02/2019 17/03/2019 Do 0 x 0 0 0

6 15/01/2019 S155220 Welding Canning envelope burnthrough 4 2 4 3 25 28 817.0 62.988% PZEV Design 8 EXH066 G. Velazquez 15/01/2019 15/02/2019 Do 0 x 0 0 0

Thread out of specification (minor

7 16/05/2018 S158969 Identification 4 2 4 3 3 87.5 63.634% Central 3 E6D Machine 8 EXH051 R. Valle 16/05/2018 16/06/2018 Check 0 0 x 0 0
diameter)

8 17/11/2018 S155653 Dimensional Lack of brackets 4 2 4 3 3 87.4 64.279% HE 3 Machine 5 EXH075 R. Valle 17/11/2018 18/12/2018 Check 0 0 x 0 0

9 13/01/2018 S155217 Appearance Incorrect Expansion Process 4 2 4 3 3 87.4 64.924% HE 1 Man 5 EXH003 G. Velazquez 13/01/2018 13/02/2018 Check 0 0 x 0 0

10 21/01/2018 S155217 Welding Detached bracket 4 2 4 3 3 87.3 65.568% Rear 2 Method 5 EXH009 M. Sierra 21/01/2018 21/02/2018 Check 0 0 x 0 0

11 10/02/2018 S155217 Dimensional Burnthrough in outlet pipe 4 2 4 3 3 87.3 66.212% HE 1 Machine 5 EXH012 G. Velazquez 10/02/2018 13/03/2018 Check 0 0 x 0 0

12 13/02/2018 S155217 Dimensional Duplicated traceability 4 2 4 3 3 87.2 66.856% HE 1 Method 5 EXH013 G. Velazquez 13/02/2018 16/03/2018 Check 0 0 x 0 0

13 27/04/2018 S152697 Identification Rack wrong identification 4 2 4 3 3 87.2 67.499% Central 2 Method 8 EXH042 R. Valle 27/04/2018 28/05/2018 Do 0 x 0 0 0

Canning marking with incorrect

14 31/05/2018 S158475 Identification 4 2 4 3 3 87.1 68.142% HE 3 Method 8 EXH060 G. Velazquez 31/05/2018 01/07/2018 Check 0 0 x 0 0
nomenclature

HOT END L3

STRATIFICATION PER DEFECT (BASED ON THE M SELECTED

HOT ENDBEFORE)
L1 & L2

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 3
 CHOOSING THE PROBLEM TO SOLVE
Detached Brackets
PROBLEM CORRECT SITUATION

PROBLEM DESCRIPTION
The part could not be assembly due to the lack of brackets (Detached
Brackets)
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 4
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA The analysis was made on Hot End area, Line #3 Operation 40
Go to the Shop
Floor The analysis on the Op 40 was made on booth welding fixture sides

GEMBUTSU The issued parts present lack of brackets and displaced brackets against welding
Examine the
object seams

GENJITSU In MM EXH Toluca the rework has been increase due to lack of welding on the
Check the facts brackets
and figures and Parts has been discover without brackets

GENRI The basic conditions on the equipment has been validated (Machine Parameters,
Refer to the Personal Trained, Torch position, Brackets supports condition and Material
theory Load on Welding fixture (brackets))

GENSOKU
Follow the The welding process and the basic conditions on the equipment has been
Operating validated against the standards
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 5
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop
Floor

GEMBUTSU
Examine the
object

GENJITSU
Check the facts
and figures

GENRI
Refer to the
theory
Welding Fixture Op. 40
GENSOKU Line #3 and #4
Follow the
Operating
Standard Side 1 and side 2

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 6
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA PART NO OK
Go to the Shop
Floor

GEMBUTSU
Examine the
object

GENJITSU
Check the facts
and figures

GENRI
Refer to the
theory

GENSOKU
Follow the
Operating
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 7
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop PART NO OK PART OK
Floor

GEMBUTSU
Examine the
object

GENJITSU
Check the facts
and figures

Lack of bracket
GENRI
Refer to the
theory

The issued parts present lack of brackets and displaced

GENSOKU
Follow the brackets against welding seams
Operating
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 8
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop PART NO OK PART OK
Floor

GEMBUTSU
Examine the
object

GENJITSU
Check the facts
and figures

GENRI Lack of bracket

Refer to the
theory

The issued parts present lack of brackets and displaced

GENSOKU
Follow the brackets against welding seams
Operating
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 9
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop
Floor

GEMBUTSU
Examine the
object

GENJITSU
Check the facts
and figures

GENRI
Refer to the
theory

GENSOKU
Follow the In MM EXH Toluca the rework has been increase due to lack of welding on
Operating
Standard the brackets
and Parts has been discover without brackets on Hot End #3
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 10
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop
Floor

GEMBUTSU
Examine the
object

GENJITSU # ITEM CHECKED STANDARD CONDITION

Check the facts 1 Machine Parameters According SOP
and figures
All the personal working on the plant must
2 Personal Trained be trained according the SOP and
GENRI acceptance criterial
Refer to the 3 Torch position According torch alignment gauge
theory
All screws must be tight, free of damage
4 Brackets supports
and without worn out
GENSOKU Material Load on Welding
Follow the 5 According SOP
Operating fixture (brackets)
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 11
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop
Floor # ITEM CHECKED STANDARD CONDITION Status
All the personal working on the
1 Personal Trained plant must be trained according the OK
GEMBUTSU SOP and acceptance criterial
Examine the
object Method of material Load
2 on Welding fixture According SOP OK
(brackets)
GENJITSU 3 Machine Parameters According SOP OK
Check the facts
and figures
4 Torch position According torch alignment gauge OK
Brackets supports All screws must be tight, free of
5 No OK
conditions damage and without worn out
GENRI
Refer to the
theory

GENSOKU
Follow the
Operating
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 12
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
SOP SOP SOP-001 Revisón 02

GEMBA STANDARD OPERATION PROCEDURE

S155217 (PZEV)
EPP PAG. 1/2 Data 20/03/19

Go to the Shop
Descripción de la operación: Núm Producto: S152826 (THRIFT) T. Cíclo Clasificación de Características
S158475 (PZEV THRIFT)
150 Seg. TM, S Significativa (Crítica) R Referência Report
Operación 40 Versión: Hot End Pzev

Floor
67 Seg. TH
Metodología de Pilar Línea Puesto Unidad Operativa
Documentos
WO - Organización del lugar de trabajo E XH A US T WE LD IN G OP 40 PZEV Aplicables

1 S152826 (PZEV THRIFT) S152826(THRIFT) S155217 (PZEV)

2 3

GEMBUTSU S151144
S140542
S140520 S140522 S140530

Examine the Descripción de la Operación Medios Descripción de la Operación Medios Descripción de la Operación Medios

object Revisar que tengamos material surtido para

poder proseguir con el proceso de soldado.
Visual
Máquina
Tomar una pieza del riel con ambas
manos de alimentación de la OP 30
Visual
Máquina
Con las dos manos colocar las piezas en
el herramental, así como el Upper Bracket
S140530 x3, Low er Bracket S140522 x2,
Manos/Visual
Máquina
(En caso contrario avisarle al supervisor y revisar que el Lambda Sensor Boss Bracket S140520 x7 y el Outlet Flange
correspondiente, para que pueda Máquina soldadura N000090 contenga su respectivo Máquina soldadura S151144, S140542 que se van a soldar. Máquina soldadura
proporcionar el material f altante). Op40 tapón. Op40 (No olvidar que el sensor boss Op40
contenga su tapón ).

6 5 4

GENJITSU
Check the facts
and figures Descripción de la Operación
Una vez finalizada la operación,
Medios
Visual
Descripción de la Operación Medios
Manos/Visual
Descripción de la Operación
Ajustar las palancas del
Medios
Manos/Visual
liberamos la pieza con cuidado y Una vez ajustado el material y con herramental hasta que las piezas a
Máquina las piezas ya colocadas, Máquina soldar estén tocando la superficie Máquina
proseguimos a checar que se haya
generado una soldadura uniforme proseguimos a presionar el botón del manifold de la OP30. Los
alrededor de las piezas. Máquina soldadura verde para proseguir con la Máquina soldadura sensores del herramental deben Máquina soldadura
To ma r e n c ue nt a q ue e s t e p ro c e s o e s p unt o Op40 soldadura. Op40 detectar que las piezas estén bien Op40
i mp o rt a nt e p a ra c a l id a d
colocadas.

Nombre Emisor / Área/ Firma Superior Inmediato Gerente de Área Gerente de Seguridad

GENRI Enrique Rosales/Ricardo Ramirez F. Leónides/ O. Jiménez / J. Zarco O.Quijano Abraham Irak García

Refer to the
ITEM ACTUAL RESTORED
theory # CHECKED
STANDARD CONDITION
CONDITION (Y/N)
All the personal working on the plant must
GENSOKU 1 Personal Trained be trained according the SOP and OK NO
Follow the acceptance criterial
Operating Method of material
Standard 2 Load on Welding According SOP OK NO
fixture (brackets)

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 13
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5G
GEMBA
Go to the Shop # ITEM CHECKED STANDARD CONDITION Status
Floor
3 Machine Parameters According SOP OK
GEMBUTSU 4 Torch position According torch alignment gauge OK
Examine the
object Brackets supports All screws must be tight, free of
5 No OK
conditions damage and without worn out

GENJITSU
Check the facts
and figures

GENRI
Refer to the
theory

GENSOKU
Follow the
Operating
Standard

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 14
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5W1H
PROBLEM DESCRIPTION Rework of Maniverter due to lack of brackets
WH What does the problem look like? What product, Rework of Maniverter p.n. S160497 due to lack of brackets
AT machine, material was being used? What size? from Op. 40
When did the problem occur? When in the
WH sequence of operation; startup, continuous
January 12th, 2019 during second shift
EN running, intermittent problem, shutdown,
changeover?

WH Where did you see the problem? Where on the Hot End Line #3
ERE equipment or material did you see the problem? Operation 40
Who can effect it? Everyone? Or is it less of a
WH problem for some individuals or teams? (If so,
Line 3 Welder and Operator from Op. 40
O what info can they offer?) Is it skill related? Is
there a “knack”?
Which trend or pattern does the problem have?
WHI E.g. Is the problem more frequent on Monday
mornings? After a change-over? Which direction
The parts present lack of brackets from the welding seam #32
CH does the problem happen in? (Note: Not many and #47
problem are truly random!)

HO How is the state of the equipment changed from

the optimal? How many times does the problem
The welding fixtures present wear out on the cavity brackets
W occur? support (pins and holes) and loose screws on the supports
Rework of Maniverter p.n. S160497 for lack of brackets from
REVISED PROBLEM OR Op. 40 due to welding fixtures present wear out on the cavity
PHENOMENON DESCRIPTION brackets support (pins and holes) and loose screws on the
supports
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 15
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5W1H
PROBLEM PHENOMENON

Lack of bracket

Loose tooling
During the clamping the tooling moves and
is cause that the brackets be out of position
and the torch could not weld properly

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 16
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
5W1H
PROBLEM PHENOMENON

Lack of bracket

Worn brackets support

During the material load if the supports
present worn out the brackets could move,
lose position or fall down

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 17
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
Interim Actions
RESPONSIBL
# ACTION (Y/N) WHEN STATUS
E
RED ALERT (INFORMATION ABOUT CLAIM) - WAS IT COMPLE
1 SENT TO THE PLANT?
YES Gustavo Velázquez 12/01/2019
TE
BLOCKING STOCKS IN ALL LOCATIONS AND COMPLE
2 SELECTION IN ALRU
YES Gustavo Velázquez 12/01/2019
TE
POKA-YOKE / ERROR PROOF - DOES IT WORK COMPLE
3 PROPERLY?
NO Daniel Alcantara 12/01/2019
TE
COMPLE
4 ADDITIONAL CONTROL (GP12) - IS IT INTRODUCED? YES Gustavo Velázquez 12/01/2019
TE
VERIFICATION OF FINISHED GOODS ON THE WAY TO COMPLE
5 CUSTOMER, LETTING KNOW THE CUSTOMER
YES Gustavo Velázquez 12/01/2019
TE
100% SORTING AT THE CUSTOMER - WAS IT COMPLE
6 INTRODUCED?
YES Gustavo Velázquez 12/01/2019
TE

7 SUPPLIER CLAIM - WAS IT ISSUED? NO NA NA NA

NEXT SHIPMENT DATE VERIFICATION, CONFIRMATION

COMPLE
8 OF THE DATE OF FIRST GOOD DELIVERY TO THE YES Gustavo Velázquez 13/01/2019
TE
CUSTOMER

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 18
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
Interim Actions
Containment Reports

Internal WIP Material

Warehouse Parts inspected: Customer
Parts inspected: 630 180 Warehouse
Parts Ok : 630 Parts Ok : 180 Parts inspected: 612
Part NOK: 0 Part NOK: 0 Parts Ok : 612
Part NOK: 0
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 19
 UNDERSTAND THE SITUATION/TREND AND
SET THE TARGETS
Target Setting
Brackets Rework Hours KPI
14 12
12 10
HOURS PER WEEK

MEASUREMENTI
10 8
8

KP UNIT OF
6
6
4 4
2 2
0 0
Wk 47 WK 48 WK 49 WK 50 WK 51 WK 52 WK 1 WK 2 WK 3 BEFORE TARGET

Rework Hours TIME

SMART TARGET
Is it Is it
Is it
Is it SIMPLE ? MEASURABLE ACHIEVABLE Is it TIMED ?
REALISTIC ?
? ?

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 20
 PLAN ACTIVITIES
Team Definition – WCM Radar Chart - BEFORE
Gustavo Velázquez Justino Mendoza Daniel Alcantara Jose Luis Zarate
Maintenance
Quality Engineer Process Engineer Production Supervisor
Coordinator
1 1 1 1
8 5 2 8 5 2 8 5 2 8 5 2

3 3 3 3
7 1 3 7 1 3 7 1 3 7 1 3

Cinthia Colin Enrique Rosales RADAR CHART

6 4 6 4 6 4 6 4
Financial
5
analyst PP&C
5
# TOOLS
5
R
5
1 5G 5
2 5W1H 4
3 4M1D 4
4 5 Whys 4
1 1 7 Steps of problem
5 4
8 5 2 solving
8 5 2
6 QA Matrix 4
3 3 7 PM 5
7 1 3 7 1 3 8 AM 5

6 4 6 4
5 5
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 21
 PLAN ACTIVITIES
Team Definition – Technical Radar Chart AFTER
Gustavo Velázquez Justino Mendoza Daniel Alcantara Jose Luis Zarate
Maintenance
Quality Engineer Process Engineer Production Supervisor
Coordinator
1
8 5 2

3
7 1 3

6 4
Cinthia
5
Colin Enrique Rosales RADAR CHART
Financial analyst PP&C # TOOLS R
1 Quality Maintenance 5
2 X – Matrix 4
3 PPA 3
4 5QF0D 2
5 Tooling Design 3
6 4
7 5
8 3

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 22
 PLAN ACTIVITIES
Timeline of the Project
PROJECT TIMELINE
PHAS WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK
TIME
E 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
PLAN
STEP
1 ACTU
AL
PLAN
STEP
2 ACTU
AL
PLAN
STEP
3 ACTU
AL
PLAN
STEP
4 ACTU
AL
PLAN
STEP
5 ACTU
AL
PLAN
STEP
6 ACTU
AL
PLAN
STEP
7 ACTU
AL
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 23
 CAUSE ANALYSIS
4M1D
MATE MACHI
RIAL NE
2 Op 40- Inductive sensor wrong setting

Brackets Out of 3 Worn out tooling brackets supports Lack of

1 specification
(dimensionaI) 4 Loose screws in brackets supports brackets
5 Worn linear actuator arrow
on
Maniverte
r
PM Calendar do not considere
6 remplace the brackets supports
and nest
Personal doesn´t Op 40 tooling design is not
Lack of spare parts for worn 9 enough robust to avoid
follow the SOP 11
7 brackets nest Support, Max and damage on the sensors during
Min not defined 1 Personal not trained the perform
0
AM don´t consider the Lack of flow regulator effort
frequency of tightening 12
8 for clamping system
frequency of Op40 Welding
METH fixture DESIG
OD MAN N

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 24
 CAUSE ANALYSIS
4M1D Confirmation - MATERIAL

4M1D CONFIRMATION TABLE - MATERIAL

RESULTS COMPLE
RESPONSIB
ID POTENTIAL ROOT CAUSE CHECK TION NOTES
NOK OK LE
DATE

Brackets Out of The components were Gustavo

12-01- Velázquez Component
1 specification measured without any 2019 Alvaro s OK
(dimensionaI) dimensional deviation Miranda

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 25
 CAUSE ANALYSIS
4M1D Confirmation - MACHINE

4M1D CONFIRMATION TABLE - MACHINE

RESULTS COMPLE
POTENTIAL ROOT RESPONSI
ID CHECK TION NOTES
CAUSE NOK OK BLE
DATE
The Sensor is not correct setting Is necessary
Op 40- Inductive 13-01- Daniel
2 because it allow start cycle with 2019 Alcantara
adjust one
sensor wrong setting sensor
the brackets displaced
Daniel
The brackets support present Is necessary
Worn out tooling Alcantara
13-01- replace some
3 damage due to lack of damaged
brackets supports 2019
Justino
supports worn
components replacement out
Mendoza
Daniel
Some screws are loose due to The AM do
Alcantara
Loose screws in 13-01- not consider
4 lack of tightening of tooling on 2019 the tightening
brackets supports Jose Luis
AM Calendar activity
Zarate
Daniel
Alcantara
Worn linear actuator 13-01-
5 The linear actuator
arrow 2019
Justino
Mendoza

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 26
 CAUSE ANALYSIS
4M1D Confirmation - METHOD

4M1D CONFIRMATION TABLE - METHOD

RESULTS COMPLE
RESPONS
ID POTENTIAL ROOT CAUSE CHECK TION NOTES
NOK OK IBLE
DATE
PM Calendar do not
Reviewing the PM Calendar
considere remplace the 14-01- Daniel
6 is not consider the frequency
brackets supports and 2019 Alcantara
of bracket nest replacement
nest
Lack of spare parts for Tool crip stock do not Daniel
Alcantara
worn brackets nest considere the maximun/ 14-01-
7
Support, Max and Min minimus of brackets nest 2019
Justino
not defined spare parts Mendoza

AM Calendar don´t Juan L.

Reviewing the AM Calendar
consider the frequency 14-01- Zarate
8 is not consider the frequency 2019
of tightening frequency
of bracket screws tightening Cesar Sosa
of Op40 Welding fixture

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 27
 CAUSE ANALYSIS
4M1D Confirmation - MAN

4M1D CONFIRMATION TABLE - MAN

RESULTS COMPLE
I RESPONS
POTENTIAL ROOT CAUSE CHECK NO TION NOTES
D OK IBLE
K DATE

The Operator make the Melina

activities according the Gutierrez
Personal doesn´t follow
9 SOP, analysis was made on 14-01-2019
the SOP Gustavo
all the lines and all the
Velázquez
shifts
The Operator were audit Melina
according the Skill matrix Gutierrez
1
0
Personal not trained and all the personal is 14-01-2019
Gustavo
trained according the Velázquez
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O P 1 0 .S O L D A D

TE
LA T A

A M

D O D E
ROB L EAD
I DAD

L Y
O P 6 0 . E N S A

ERT ER
OG
O P 2 0 . S O LD A

L
ES

D U R A
AR 2 2-ma
C IA

O P 3 0 . S O L D A
r-16

A D U R A
J
S E N S O R B O

60 01 AI
M
37 ES

D E M A N IF U

N E S
4

D E B R A C K E T S
O P 4 0 . S O LD A
3x

D U R A

M B L E D E
O P
W
E LD
I
3 x3

D E M A N IF U
EMM ERAD NG
1
A NU OR
EL
MAR

S S
1

B A D E
TI N 0 -en

CA N N IN G
E Z B US e -17
FU G A

O P 5 0 . P R U E
6 00

O D E
155 TAM

Y
O P 6 0 . E N S A
2 AN
TE 4 OP E R

O P 10 .S O L D A

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D U R A
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A

PR O T E C C IO
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4 ON E

S E N S O R B O
AN

D U R A
DOR S D E

D E M A N IF U L
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D E M A N IF U
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D E B R A C K E T S
R AB

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6

S S
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CA N N I N G

B A D E
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O P 1 0 .S O L D A D
RAD

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GERA

PR O T E C C I O N
OR
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L Y
O P 6 0 . E N S A
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1

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CA N N IN G
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I
N DO OR
RA NT 4 4
1 2- 5
ES
M j u l -1 4 4
6
ON 7 4
6 00 7 DRAG 4 5 ok
59 ON 6
4 WEL
D IN
OPE 4 5 4
ok

JUA RA 4 4
6
N D DOR 5
E 4 ok

FU G A
DI
O S 4
TO 3 0-j u 4 4 5
RRE n -
1 7 4
6 0 S FL O 4 4
0 596 RES 4 5
4 SUP
OPE 4 5 E R VI
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6 0 E L 4 C ION
01 4 ENO 4 4 4 OP ER
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ROJAS 4
OR 4 4 CE
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AND 03 -en I ACI
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4
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ANA 4 4 24
J ES S DOR 4 4
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RAMI 1 4 RT IFI
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6 001 99 NCHEZ 4
4 4 4 4
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IED

A 4 4 4
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2077 IA 4 4 T IF I
4 4 4 ED

OPE 4 4 4 4
RAD 4 4 20
J OSE OR 4
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5 OK
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4 5
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4
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60 0 1 NI
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78 4 4 TIF
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6 001 20 SA R -18 4 4 CER
5 CO 4 4 T I
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4 4 4 D

O P 4 4 4
ARM E RADO 4 4 20
4

O D A S L A S O P
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6 0 4
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CER
TIF
2 3 4 IE D
AYUD 4
3

C I O N E S
JO SE A NT 4
AN T E 4 24
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60 01 3 71 CON 4 4 CER
T IF
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D
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NCO -1 8 4 4
60 0 1 AG 3 CER
46 UI 3 4 4 T I
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D

3 4

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ALL -1 7 4 5
6 00 150 END 4 4 CERT
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IF I
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4 4
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60 0 0 4 CE R
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7 4 4
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4
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TIF
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IF I
MA ED
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TO R
CHAVE
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n o v 4
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L F RAN R
C I
S CO, 22 -may 4 3.0
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6 00 159 SE AN 4 C E
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5 TO IE D
NI
O 4
SOL
DA D 18
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CAN 4.
0
O, 2 4-j u 4 4
6 0 VALENT l -17 C
01 ERT
893 IN 4 4 IF I
ED

SOL 4 4
DA D 0
ROBERT OR
4 4
OM 4.0
EJI 4 4 4
6 0 A RI V C
01 E RA ER
T IF
895 4 4 IE D

SOL 4
DA D 4 4 0
JOS OR
E 4 4 4 # DI V/0!
AL CA 20 -no
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6 001 A 4 4 # D
9 IV
44 /0
!
4
SOLD
ADO 4
ERI C R 4
K AL F # D
ONSO 2 0 4 I V/0!
--NOV
H ID 4
6001 A LG
-17
4 #D IV /0
317 O
4 OK
!

SOLD 4
ROLAN ADO 4
DO R 4
J U
A RES 4 4
60 0 J UAR
1 5 8 ES 4
8 4 4
O K
O R SOLD 4
TI Z
D EL A DOR 4
ANGEL ok
, D AV 19 -j u 4 4
D
I n- 17
4 4
OK
SOLD 4
ADOR 4
4 4
07 -ag 4
o-17 4 4
4
O K
4 4
4 4
4
4 4
4
4 OK
4
4
4
4
4
4
O K
4
4
4 4
4
4
4
4
4
4 OK
4
4
4
4
4 OK
4
4
4
4
4
4
O K

4
4
4 OK
4
4

OK

OK

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 28
 CAUSE ANALYSIS
4M1D Confirmation - DESIGN

4M1D CONFIRMATION TABLE - DESIGN

RESULTS COMP
LETIO RESPONSI
ID POTENTIAL ROOT CAUSE CHECK NO NOTES
OK N BLE
K DATE
Op 40 tooling desing is
not enough robust to Justino
The sensors are damage Is necessary
avoid damage on the Mendoza /
11 due to the current design make an
sensors and the brackets Daniel
improvement
because it allow damage Alcantara
cavities during the
perform
Is necessary
implement a
Lack of flow regulator The clamping effort is not Justino
flow
Mendoza /
12 effort for clamping controlled but it doesn´t Daniel
regulator in
system affect to the root cause order to
Alcantara
avoid the
loose screws

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 29
 CAUSE ANALYSIS
4M1D - Results
MATE MACHI
RIAL NE
Op 40- Inductive sensor wrong
2
setting

1
Brackets Out of
specification 3 Worn out tooling brackets supports
Lack of
(dimensionaI) 4 Loose screws in brackets supports brackets
5 Worn linear actuator arrow on
Maniverte
r
PM Calendar do not considere
6 remplace the brackets supports
and nest
Personal doesn´t Op 40 tooling desing is not
Lack of spare parts for worn 9 enough robust to avoid
follow the SOP 11
7 brackets nest Support, Max and damage on the sensors during
Min not defined 1 Personal not the perform
0 trained
AM don´t consider the Lack of flow regulator effort
frequency of tightening 12
8 for clamping system
frequency of Op40 Welding
METH fixture DESIG
OD MAN N

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 30
 CAUSE ANALYSIS
Tools Selection

ROOT CAUSE ANALYSIS – TOOL

SELECTION
LOSS
I Tool to be
ATTACKE SUGGESTED TOOL NOTES
D use
D
5WHYS (REACTIVE APPROACH
QUALITY WITH CUSTOMER) IT MEANS THAT THE PROBLEM
1 8 STAGES OF INCOMING CANNOT BE SOLVED BY YOU. YOUR
MATERIAL MATERIAL (PREVENTIVE SUPPLIER WILL HAVE TO SOLVE IT.
APPROACH WITH CUSTOMER)
IF YOU REALIZE THAT THE ISSUE IS RELATED TO AMCHINE, ATTACK IT
USING THE

2
QUALITY
MACHINE 7 STEPS OF QUALITY
MAINTENANCE
3
QUALITY METHOD FLOW CHART
FLOW CHART AVAILABLE IN THE
METHOD NEXT SLIDES

QUALITY
4 TWTTP / HERCA -
MAN

5
QUALITY 5 WHYS
5 WHYS AVAILABLE IN THE NEXT
DESIGN SLIDES-

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 31
 CAUSE ANALYSIS
Tools Selection

Lack of brackets on
Maniverter

MACHI METH DESIG

NE OD N

7 STEPS OF METHOD 5 WHYS

QUALITY FLOW CHART
MAINTENAN DOE
CE

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 32
 7 STEPS OF QUALITY MAINTENANCE
ALL Q POINTS ISCORE
5 ON QUESTION 5 OF
5QF0D
7
CHECK AND IMPROVE
ZERO DEFECT
CONDITION
6
DEFINITION OF ZERO
DEFECT CONDITION 5
RESTORE NEW
QUALITY
PARAMETERS
4 ZERO
ACHIEVED
REVEAL UNKNOWN
QUALITY
PARAMETERS: PPA / 3
DOE
RESTORING THE KO
QUALITY
PARAMETERS
2 ZERO
ACHIEVED
QUALITY
PARAMETERS OK/KO 1
Plant Name 33
 RESTORE THE QUALITY PARAMETERS
QUALITY
# PARAMETER KO
STANDARD CONDITION ACTUAL CONDITION STATUS

Without damage and

1 Bracket support worn out Damage Restored
worn out
CONDITION KO CONDITION RESTORED

Internal cavity Internal cavity

shape worn out shape OK

ROOT CAUSE DEFINITIVE COUNTERMEASURE

THE WORN OUT ON THE BRACKETS
THE WORN OUT BRACKETS SUPPORTS
SUPPORT AFFECT DIRECTLY THE
WERE REMPLACED AND CONSIDER THE
POSITION OF ALL THE COMPONENTS AND
REPLACE OF DAMGED ON THE PM
THE PRESENCE OF BRACKETS

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 34
 RESTORE THE QUALITY PARAMETERS
QUALITY
# PARAMETER KO
STANDARD CONDITION ACTUAL CONDITION STATUS

Without damage and

2 Bracket support worn out Damage Restored
worn out
CONDITION KO CONDITION RESTORED

Sensor cavity
worn out Sensor Ok

Locator pin worn Locator pin ok

out

Magnet OK
Lack of magnet

ROOT CAUSE DEFINITIVE COUNTERMEASURE

THE WORN OUT BRACKETS SUPPORTS
THE WORN OUT ON THE BRACKETS
WERE REPLACED, THE MISSING MAGNETS
SUPPORT AFFECT DIRECTLY THE
WERE INSTALLED AND CONSIDER THE
POSITION OF ALL THE COMPONENTS AND
REPLACE OF DAMAGED SUPPORT ON THE
THE PRESENCE OF BRACKETS
PM

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 35
 RESTORE THE QUALITY PARAMETERS
QUALITY
# PARAMETER KO
STANDARD CONDITION ACTUAL CONDITION STATUS

3 Loose screws Tight screws Loose Screws Restored

CONDITION KO CONDITION RESTORED

ROOT CAUSE
Loose screws on welding fixture
DEFINITIVE COUNTERMEASURE
Magnet OK
THE WORN OUT ON THE BRACKETS
THE WORN OUT BRACKETS SUPPORTS
SUPPORT AFFECT DIRECTLY THE
WERE REMPLACED AND CONSIDER THE
POSITION OF ALL THE COMPONENTS AND
REPLACE OF DAMGED ON THE PM
THE PRESENCE OF BRACKETS

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 36
 RESTORE THE QUALITY PARAMETERS
Results
R
3
R
2 KPI
R
KPI 1 12
14
10
12
KP UNIT OF MEASUREMENTI

8
10

MEASUREMENTI
8 6

KP UNIT OF
6 4
4
2
2
0
0

ET
RE

ER
Wk WK WK WK WK WK WK 1 WK 2 WK 3 WK 4 WK 5 WK 6 WK 7 WK 8 WK 9

RG

FT
FO
47 48 49 50 51 52

A
BE

TA
TIME
TIME

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 37
 CHECK POINT
ZERO ALL Q POINTS ISCORE

ACHIEVED
5 ON QUESTION 5 OF
5QF0D
7
?
Y CHECK AND IMPROVE

ES
ZERO DEFECT
CONDITION
6
Move to Step 5
DEFINITION OF ZERO
DEFECT CONDITION 5
RESTORE NEW
QUALITY
PARAMETERS
4
REVEAL UNKNOWN
QUALITY
PARAMETERS: PPA / 3
DOE
RESTORING THE KO
QUALITY
PARAMETERS
2
QUALITY
PARAMETERS OK/KO 1
Plant Name 38
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL COMPLETIO
ID ACTION DUE DATE
E N DATE

Cesar Sosa /José

A Tighten the loose screws on the welding fixture Luis Zarate
03/03/2019 03/03/2019

Review the PLC sequence and fix in the

B Daniel Alcantara 03/03/2019 03/03/2019
necessary case (Op.40 x 4)
C Replace the Inductive sensors damage Daniel Alcantara 11/03/2019 11/03/2019
Replace the worn out brackets supports (cavities
D Daniel Alcantara 11/03/2019 11/03/2019
and pins)
E Tightening of screws on Op. 40 tooling Daniel Alcantara 03/03/2019 03/03/2019
Restore basic conditions on the Op 40, replace
the handles
F Daniel Alcantara 03/03/2019 03/03/2019
•Make the mapping of the clamping status on
all Op 40
Make the validation of the tooling - presence of
G flow regulators Daniel Alcantara 03/03/2019 03/03/2019
(Op.40 x 4)
Implement the flow regulator for the clamping
H system Daniel Alcantara 11/03/2019 12/03/2019
(Op.40 x 4 x 2)
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 39
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL COMPLETIO
ID ACTION DUE DATE
E N DATE

Performer the AM / PM program on the tooling

Op. 40
I José Luis Zarate 28/02/2019
•Make the SO´s / TAG´s for specialties
activities
Replace of missing and wear out magnets
J Daniel Alcantara 11/03/2019
(Op.40 x 4 x 2)
Validate the linear actuator arrows physical
K Daniel Alcantara 03/03/2019
condition
L Replace the damaged linear actuator arrows Daniel Alcantara 17/03/2019
New design for the front and back bracket
M Justino Mendoza 11/03/2019 12/03/2019
supports
New brackets support manufacturing for Op40
N Mauricio Mendez 31/03/2019
Welding Fixtures
New brackets support implementation on Op40
O Daniel Alcantara 07/04/2019
Welding Fixtures

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 40
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL COMPLETIO
ID ACTION DUE DATE
E N DATE

Performer the AM / PM program on the tooling

Op. 40
I José Luis Zarate 28/02/2019
•Make the SO´s / TAG´s for specialties
activities
Replace of missing and wear out magnets
J Daniel Alcantara 11/03/2019
(Op.40 x 4 x 2)
Validate the linear actuator arrows physical
K Daniel Alcantara 03/03/2019
condition
L Replace the damaged linear actuator arrows Daniel Alcantara 17/03/2019
New design for the front and back bracket
M Justino Mendoza 11/03/2019 12/03/2019
supports
New brackets support manufacturing for Op40
N Mauricio Mendez 31/03/2019
Welding Fixtures
New brackets support implementation on Op40
O Daniel Alcantara 07/04/2019
Welding Fixtures

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 41
 Tight screws (according

x
x x marks)

x
FREE OF CONDENSATION

STEP 0
CONMUTATION

x
20 - 30 ms
TIME ANSWER

x
SENSOR WITHOUT BYPASS

SENSOR &CABLE FREE OF

DAMAGE AND BURNS x

Plant Name
X-Matrix

DIAMETER
4.5 mm± 0.5
x

BRACKETS PIN
mm
LOCATORS
DEFECTS

PRESENCE OF MAGNET AT

STEP 1
x
x

Machine:
BRACKET SUPPORTS

PHYSICAL INTEGRITY
x
x
x
x
x
x
x

(WITHOUTWORNOUT, CRAKS,

Root Cause:
Phenomena:
BENDING, LEAKAGES)

Defect Mode:
TORCHHOLDER WITHOUT
x

BACKLASH

TORCH ALIGNEDWITH MACHINE

x

TCP
x

STEP 2
GAS FLOW 40-60 CFH
x

TOTAL LENGTH 48.5 mm

INTERNAL NOZZLE
x

13 mm
DIAMETER

GAS CONDUCTOR HOLES FREE OF

x

SPATTER
x
x
x
x

FASTENNING GAP 0 mm

STEP 3
Welding Fixture
GAS CONDUCTOR HOLES FREE OF
x

SPATTER

TIP INTERNAL
x

1.2 mm
DIAMETER

PARAMETER VALUE

CONDITIONS

Welding fixtures loose

OPTIMAL

STEP 4
Bracket out of position
TORCH

NOZZLE

MACHINE
MAGNETS

INSULATOR

DEFECT MODE
COMPONENTS
CONTACTTIP
GAS DIFFUSER

Lackof bracket / Detached

CLAMP CILINDER
WELDINGFIXTURE
MAINSUPPLYGAS

ABNORMAL
INDUCTIVESENSORS

BRACKETS SUPPORTS

PHENOMENA

DESCRIPTION SKETCH
LOCATORPINS ONBRACKETSUPPORT

VALVECLAMP CILINDER SY3000/ 5000

ESTABLISH THE CONDITIONS FOR ZERO

ARC WELDING WITH

x
x

VARIATIONON
POSITION

STEP 5 VARIATIONONSTICK
x
x

OUT

TORCH NECK WITH

x
x

SHORT CIRCUIT

LOWGAS FLOWAT
x
x
x
x

THE PROCESS POINT

Lack of Brackets/ Brackets out of position

Non-thight screws on welding fixture device

LEAKAGES INSYSTEM
STEP 6
x
x
x
x

GAS CIRCUIT
x
x

x
x
x
x

SUPPORTS DISPLACED
x
x
x

TOOLINGLOOSE
42

WRONGCOMPONET
x

STEP 7

DETECTION
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
QM-Matrix

GROUP MACHINE PNEUMATIC ELECTRIC TOOLING MIC WELDING SYSTEM

MACHINE GAS
VALVE INDUCTIVE PIN MAGNE WELDING TORCH GAS NECK GAS CONTACT
COMPONENT FRL LOCATOR FIXTURE
TORCH REGULATOR NOZZLE DIFUSE DIFFUSER TIP
BLOCK SENSOR T HOLDER TORCH
R

CONMUTA TIP
CONDENS PRESENCE WITH OUT GAS INTERNAL CLEANN Fastenning Fastenning
PARAMETER TION TIME
DETECTION
INTEGRITY DIAMETER PRESENCE INTEGRITY
BACKLASH
ALIGNED LENGTH INTERNAL
ATION
ANSWER FLOW DIAMETER ESS GAP GAP
DIAMETER

STANDARD FREE FREE ALIGNED

FREE OF
ON / OF OF WITH WITH FREE OF
REFERENCE VALUE CONDENS 25 MS 4.5 mm PRESENCE
BACKLASH MACHINE 50 CFH 48.5 mm 13 mm SPATTER
0 mm 0 mm 1.2 mm
ATION OFF DAMAG DAMAG
TCP
E E
FREE OF
TOLLERANCE ± 5 MS NA NA ± 0.5 mm NA NA NA NA ± 10 CFH ±0.5 mm ± 0.5 mm NA 0 0 1.2 - 1.5 mm
QM-Matrix CONDENS
Visual
MEASURING TOOL Visual Cronometer Visual Visual Vernier Visual Visual Visual Visual Visual Visual Visual Visual Visual Visual (tip
change)
Every Every Every Every Every Every 45 Every Every 45
FREQUENCY Daily Montly Weekly Daily Weekly Weekly
Shift Shift Shift Shift Shift Shift PIECES Shift Shift PIECES
CHECK
RESPONSABILITY [AM / PM] AM PM AM AM PM AM AM AM PM AM AM AM AM AM AM AM

STANDARD DOCUMENT AM SOP SMP AM SOP AM SOP SMP AM SOP AM SOP AM SOP SMP AM SOP AM SOP AM SOP AM SOP AM SOP AM SOP AM SOP

Q POINT
Q16 Q16 Q16 Q4 Q9 Q11 Q7
HIGH H H H H H H H
IMPACT MEDIUM M M M
LOW L L L L L L

The new Critical Characteristics (Q points) were defined and

included at the AM and PM calendar in order to have a
preventive approach at the process
STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 43
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
Q-Points – AM and PM Calendar

Q4 Q7

Q11 Q16
STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 44
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
Q-Points – AM and PM Calendar

QR4

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 45
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
5 Questions for 0 Defects - MACHINE
The settings are defined and shared (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 Are the settings defined? A method to check the settings is defined (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3
The settings are easy to see without special
access or tools (5pt) 5 5 5
Difficult to adjust/set (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Is the machine easy to adjust to return
2
to specified range?
Easy to adjust/set (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Adjustment is automatic (5pt)

During the normal production (1pt)

Are the equipment settings varying

3
outside the specification range?
Only at set up / start (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Exceptionally (5pt) 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
Low probability of seeing it (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
The periodic inspection system is able to detect
4 Is the equipment variation detectable?
the variation (3pt) 3 3 3 3 3 3 3 3 3 3 3 3
Continuous monitoring ensuring immediate alert
(5pt) 5 5 5 5
Difficult, requiring specialized technical skills and
high downtime (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Is it easy to bring the equipment
5
settings back into specification?
Easy, once a person is qualified (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Automatic adjustment (closed loop) (5pt)

TOT Before 0 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7

TOT After 0 19 17 21 21 17 17 17 17 19 17 17 17 17 19 17 17

INSERT HERE YOUR Q

FACTOR RESULT

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 46
 CAUSE ANALYSIS
4M1D Root Cause Confirmation - METHOD

4M1D ROOT CAUSE CONFIRMATION TABLE - METHOD

RESULTS COMPLETI RESPONSI
ID POTENTIAL ROOT CAUSE CHECK
NOK OK ON DATE BLE

PM Calendar do not Reviewing the PM Calendar is

Daniel
7 considere remplace the not consider the frequency of 14-01-2019
Alcantara
brackets supports and nest bracket nest replacement

Daniel
Lack of spare parts for worn Tool crip stock do not considere Alcantara
7 brackets nest Support, Max the maximun/ minimus of 14-01-2019
and Min not defined brackets nest spare parts Justino
Mendoza

AM Calendar don´t consider

Reviewing the AM Calendar is Juan L. Zarate
the frequency of tightening
8 not consider the frequency of 14-01-2019
frequency of Op40 Welding Cesar Sosa
bracket screws tightening
fixture

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 47
 CAUSE ANALYSIS
Method Flow Chart Analysis
ANALIZ
E METHOD ISSUES
CAUSES
IS THERE A
MAKE NEW
WORK N SOP
STANDARD?

Y
IS THE WORK
STANDARD
APPROPRIAT
E?

Y
WAS THE
STANDARD
BEING
FOLLOWED?

Y
WORKING IMPROVE THE AM AND PM
CONDITIONS ARE
CALENDAR
INADEQUATE

KAIZEN

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 48
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL COMPLETIO
ID ACTION DUE DATE
E N DATE

Include on the AM Calendar the tightening of

A screws activity for welding fixtures Op 40 with Jose Luis Zarate 03/03/2019 03/03/2019
weekly frequency (Q points)
Define the max and min quantity for spare parts
B Justino Mendoza 09/03/2019 09/03/2019
available at tool crip for welding fixtures Op 40
Supply and ensure the existence of the spare
C Daniel Alcantara 15/03/2019 18/03/2019
parts for Op 40 Welding fixtures at Tool crip
Include on the PM Calendar review and replace
D the brackets supports damaged or worn out for Daniel Alcantara 05/03/2019 05/03/2019
welding fixtures Op 40

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 49
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
Q-Points – AM and PM Calendar

Q4 Q7

Q11 Q16
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 50
 THE CONDITIONS FOR ZERO DEFECTS
Q-Points – AM and PM Calendar

Q4

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 51
 CONDITIONS FOR ZERO DEFECTS
Q-Points – AM and PM Calendar

Q7

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 52
 CONDITIONS FOR ZERO DEFECTS
Q-Points – AM and PM Calendar

Q11

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 53
 CONDITIONS FOR ZERO DEFECTS
Q-Points – AM and PM Calendar

Q16

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 54
 CONDITIONS FOR ZERO DEFECTS
Q-Points – AM and PM Calendar

QR4

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 55
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
5 Questions for 0 Defects - METHOD
A=1
AM PM
B=3 Operations
C=5 Op 40 Op 40
Before After Before After

A There is no standard. 1 1
Is the standard (work instructions) A standard exists, but lacks detail and it’s
1 B
clearly defined? not visual yet.

There is a detailed VSOP (the document is

C at least 80% Visual) that all operators 5 5
should find easy to understand.

A It is not possible.

It is possible to follow the standard as

2
described?
B It is possible, but difficult. 3 3

C It's easy to follow . 5 5

A It is non sufficient, high risk of error. 1 1

It is effective, but a margin of error still
3 Is the standard effective? B
exists.

In 100% of cases, the quality is

C
guaranteed. 5 5
Standard is available, but not visible from
A
work station. 1 1
Standard is in work station and visible, but
INSERT HERE YOUR Q FACTOR
4 Where is the standard located? B
not in line of sight of the operator. 3
RESULT
Standard is in work station, is clearly
C visible, and is in line of sight of the operator 5
when performing their job.

Operator at work station not involved with

A
generation of standard. 1 1
Is the operator involved in standard Operator at work station reviewed and
5
definition?
B
approved the work instruction . 3 3
Operator was directly involved with the
C content of the standard and approved the
document.
Total 7 23 7 21
% 28.0% 92.0% 28.0% 84.0%

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 56
 CAUSE ANALYSIS
5 WHYS
Op 40 tooling design is not
DESIGN 11
enough robust to avoid damage
on the sensors during the
perform

PROBLEM 1- 2- 3- 4- 5-
DESCRIPTION WHY ? WHY ? WHY ? WHY ? WHY ?
Op 40 tooling
desing is not The sensors wire
The upper side of The design allow
the wire sensor do hit the wires The wires are The design do not
enough robust to are damaged at a
not have any heat during the load of exposed over the consider this
avoid damage on very low
or termal components on Op welding fixture failure mode
frequency
the sensors during protection 40
the perform

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 57
 CAUSE ANALYSIS
Part Analysis

Problem

Current Design

The curren design do not protect the

wire due to this the sensor damage
frecuency is high
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 58
 CONSIDER AND IMPLEMENT THE
SOLUTION
Countermeasures
RESPONSIBL COMPLETIO
ID ACTION DUE DATE
E N DATE

New design for the front and back bracket

A Justino Mendoza 11/03/2019 12/03/2019
supports
Justino Mendoza
B New design of upper brackets (type sensor) Daniel Alcantara
21/03/2019 21/03/2019

Implement and replace the new design for the

Justino Mendoza/
C front and back bracket supports on both welding Daniel Alcantara
12/04/2019 12/04/2019
fixtures sides on Op 40
Implement and replace the upper brackets Justino Mendoza/
D 29/03/2019 29/03/2019
inductive sensors for laser sensor Daniel Alcantara
E
F
G
H

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 59
 CONSIDER AND IMPLEMENT THE
SOLUTION
Countermeasures
NEW DESIGN OF FRONT AND REAR BRACKETS
SUPPORTS
A THIS IMPROVEMENT WILL HELP TO PROTECT THE WIRE, REDUCE THE
DAMGE DAMGE AND REDUCE THE COST OF SENSOR SPARE PARTS

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 60
 CONSIDER AND IMPLEMENT THE
SOLUTION
Countermeasures
NEW DESIGN OF UPPER BRACKETS
B THIS IMPROVEMENT CONSIST IN REPLACE THE INDUCTIVE SENSOR FOR
LASSER SENSOR THE DETECT THE PRESCENCE OF BRACKETS BEFORE STAR
THE WELDING PROCESS

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 61
 ESTABLISH THE CONDITIONS FOR ZERO
DEFECTS
5 Questions for 0 Defects
A=1 Op 40
B=3 Operations Brackets
C=5 Welding
Before After

A Characteristic not identified.

Are the characteristics

The characteristics are known, but they may not satisfy
1 known to satisfy the B
the customer expectations.
customer?
The characteristics are known, and satisfy the customer
C
expectations. 5 5

Not completed prior to implementation or testing not

A
defined to satisfy the customer.

2
Has durability validation B
A shortened version was completed, but testing to satisfy
the customer is understood.
been completed?
Durability testing was developed knowing the customer
C
usage, and the testing was completed. 5 5

A No testing. 1
Has the new design
Prototype testing only; or, not on all models. Results
3 been evaluated in B
were favorable.
production? Production parts were evaluated on all variations of
C usage, and in sufficient quantity to see a good 5
representation. Results were favorable.

A No.
Are the limits of the
critical characteristics Through large sample size in testing or production, the
INSERT HERE YOUR Q FACTOR
4
known to satisfy the
B
limits satisfy the customer. RESULT
customer? Through analysis and testing, the limits are known to
C
satisfy the customer. 5 5

A Not Possible. 1
If a problem is
5
identified, is it possible B Very difficult both in cost and money.
to return to the
previous design level? C Not easy, but can be accomplished. 5
Total 17 25
% 68.0% 100.0%

STEP 0 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 62
 CHECK RESULTS
Timeline of the Project
PROJECT TIMELINE
PHAS WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK
TIME
E 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
PLAN
STEP
1 ACTU
AL
PLAN
STEP
2 ACTU
AL
PLAN
STEP
3 ACTU
AL
PLAN
STEP
4 ACTU
AL
PLAN
STEP
5 ACTU
AL
PLAN
STEP
6 ACTU
AL
PLAN
STEP
7 ACTU
AL
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 63
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL
ID ACTION DUE DATE STATUS
E
Cesar Sosa /José
A Tighten the loose screws on the welding fixture Luis Zarate
03/03/2019 100%

Review the PLC sequence and fix in the

B Daniel Alcantara 03/03/2019 100%
necessary case (Op.40 x 4)
C Replace the Inductive sensors damage Daniel Alcantara 11/03/2019 100%
Replace the worn out brackets supports (cavities
D Daniel Alcantara 11/03/2019 100%
and pins)
E Tightening of screws on Op. 40 tooling Daniel Alcantara 03/03/2019 100%
Restore basic conditions on the Op 40, replace
the handles
F Daniel Alcantara 03/03/2019 100%
•Make the mapping of the clamping status on
all Op 40
Make the validation of the tooling - presence of
G flow regulators Daniel Alcantara 03/03/2019 100%
(Op.40 x 4)
Implement the flow regulator for the clamping
H system Daniel Alcantara 11/03/2019 100%
(Op.40 x 4 x 2)
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 64
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL
ID ACTION DUE DATE STATUS
E
Performer the AM / PM program on the tooling
Op. 40
I José Luis Zarate 28/02/2019 100%
•Make the SO´s / TAG´s for specialties
activities
Replace of missing and wear out magnets
J Daniel Alcantara 11/03/2019 100%
(Op.40 x 4 x 2)
Validate the linear actuator arrows physical
K Daniel Alcantara 03/03/2019 100%
condition
L Replace the damaged linear actuator arrows Daniel Alcantara 17/03/2019 100%
New design for the front and back bracket
M Justino Mendoza 11/03/2019 100%
supports
New brackets support manufacturing for Op40
N Mauricio Mendez 31/03/2019 100%
Welding Fixtures
New brackets support implementation on Op40
O Daniel Alcantara 07/04/2019 100%
Welding Fixtures

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 65
 CONSIDER AND IMPLEMENT THE
SOLUTION
Kaizen Journal
RESPONSIBL
ID ACTION DUE DATE STATUS
E
Performer the AM / PM program on the tooling
Op. 40
I José Luis Zarate 28/02/2019 100%
•Make the SO´s / TAG´s for specialties
activities
Replace of missing and wear out magnets
J Daniel Alcantara 11/03/2019 100%
(Op.40 x 4 x 2)
Validate the linear actuator arrows physical
K Daniel Alcantara 03/03/2019 100%
condition
L Replace the damaged linear actuator arrows Daniel Alcantara 17/03/2019 100%
New design for the front and back bracket
M Justino Mendoza 11/03/2019 100%
supports
New brackets support manufacturing for Op40
N Mauricio Mendez 31/03/2019 100%
Welding Fixtures
New brackets support implementation on Op40
O Daniel Alcantara 07/04/2019 100%
Welding Fixtures

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 66
 CHECK RESULTS

Brackets Rework Hours KPI

14 12
12 10
10 8

MEASUREMENTI
HOURS PER WEEK

8 6

KP UNIT OF
6 4
4 2
2 0

ET
RE

ER
0

RG

FT
FO

A
BE

TA
Wk WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK WK
47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

TIME
Rework Hours

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 67
 STANDARDIZE AND ESTABLISH CONTROL
Reactive
PILLA
R QUESTION DOCUMENT WHO ? WHEN ? STATUS
Justino 02/04/201
FMEA
Mendoza 9 100%
Gustavo
CONTROL 08/04/201
PLAN
Velázque 9 100%
z
ARE THE IMPROVEMENTS RELEVANTS IN TERMS OF QUALITY
QC ? QA NETWORK
Miguel 08/04/201
100%
Gabriel 9

Gustavo
Velázque 26/03/201
5Q0D
z 9 100%

José
22/02/201
DID WE CHANGE THE PROCESS ? IF YES  SOP / SWI Luis 9 100%
A Zarate

M DID WE CHANGE / ADD SOMETHING IN THE MACHINE THAT

AM
José 22/02/201
REQUIRES CLEANING, INSPECTION, LUBRICATION OR
CALENDAR
Luis 9 100%
REFASTENING ? IF YES  Zarate
DID WE CHANGE / ADD SOMETHING IN THE MACHINE THAT Daniel
PM 25/02/201
IS NOT CONSIDERED IN THE PM CALENDARD ? IF YES 
CALENDAR
Alcantar 9 100%
IS THE MAINTENANCE FREQUENCY WRONG ? IF YES  a
PM DID WE HAVE A STANDARD DOCUMENT THAT EXPLAIN HOW Daniel
25/02/201
TO DO THE MAINTENANCE OF THE COMPONENT ADDED TO SMP Alcantar 9 100%
THE MACHINE ? IF NO  a
Melina
DO WE NEED TO TRAIN THE OPERATORS ABOUT SOMETHING 26/03/201
PD NEW IN THE STATION ?
OPL Gutierre 9 100%
z
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7
Plant Name 68
 STANDARDIZE AND ESTABLISH CONTROL
5 Questions for 0 Defects - MACHINE
The settings are defined and shared (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 Are the settings defined? A method to check the settings is defined (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3
The settings are easy to see without special
access or tools (5pt) 5 5 5
Difficult to adjust/set (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Is the machine easy to adjust to return
2
to specified range?
Easy to adjust/set (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Adjustment is automatic (5pt)

During the normal production (1pt)

Are the equipment settings varying

3
outside the specification range?
Only at set up / start (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Exceptionally (5pt) 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
Low probability of seeing it (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
The periodic inspection system is able to detect
4 Is the equipment variation detectable?
the variation (3pt) 3 3 3 3 3 3 3 3 3 3 3 3
Continuous monitoring ensuring immediate alert
(5pt) 5 5 5 5
Difficult, requiring specialized technical skills and
high downtime (1pt) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Is it easy to bring the equipment
5
settings back into specification?
Easy, once a person is qualified (3pt) 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
Automatic adjustment (closed loop) (5pt)

TOT Before 0 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7

TOT After 0 19 17 21 21 17 17 17 17 19 17 17 17 17 19 17 17

INSERT HERE YOUR Q

FACTOR RESULT

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 69
 STANDARDIZE AND ESTABLISH CONTROL
5 Questions for 0 Defects - METHOD
A=1
AM PM
B=3 Operations
C=5 Op 40 Op 40
Before After Before After

A There is no standard. 1 1
Is the standard (work instructions) A standard exists, but lacks detail and it’s
1 B
clearly defined? not visual yet.

There is a detailed VSOP (the document is

C at least 80% Visual) that all operators 5 5
should find easy to understand.

A It is not possible.

It is possible to follow the standard as

2
described?
B It is possible, but difficult. 3 3

C It's easy to follow . 5 5

A It is non sufficient, high risk of error. 1 1

It is effective, but a margin of error still
3 Is the standard effective? B
exists.

In 100% of cases, the quality is

C
guaranteed. 5 5
Standard is available, but not visible from
A
work station. 1 1
Standard is in work station and visible, but
INSERT HERE YOUR Q FACTOR
4 Where is the standard located? B
not in line of sight of the operator. 3
RESULT
Standard is in work station, is clearly
C visible, and is in line of sight of the operator 5
when performing their job.

Operator at work station not involved with

A
generation of standard. 1 1
Is the operator involved in standard Operator at work station reviewed and
5
definition?
B
approved the work instruction . 3 3
Operator was directly involved with the
C content of the standard and approved the
document.
Total 7 23 7 21
% 28.0% 92.0% 28.0% 84.0%

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 70
 STANDARDIZE AND ESTABLISH CONTROL
5 Questions for 0 Defects - DESIGN
A=1 Op 40
B=3 Operations Brackets
C=5 Welding
Before After

A Characteristic not identified.

Are the characteristics

The characteristics are known, but they may not satisfy
1 known to satisfy the B
the customer expectations.
customer?
The characteristics are known, and satisfy the customer
C
expectations. 5 5

Not completed prior to implementation or testing not

A
defined to satisfy the customer.

2
Has durability validation B
A shortened version was completed, but testing to satisfy
the customer is understood.
been completed?
Durability testing was developed knowing the customer
C
usage, and the testing was completed. 5 5

A No testing. 1
Has the new design
Prototype testing only; or, not on all models. Results
3 been evaluated in B
were favorable.
production? Production parts were evaluated on all variations of
C usage, and in sufficient quantity to see a good 5
representation. Results were favorable.

A No.
Are the limits of the
4
critical characteristics B
Through large sample size in testing or production, the
limits satisfy the customer.
known to satisfy the
customer? Through analysis and testing, the limits are known to
C
satisfy the customer. 5 5

A Not Possible. 1
If a problem is
5
identified, is it possible B Very difficult both in cost and money.
to return to the
previous design level? C Not easy, but can be accomplished. 5
Total 17 25
% 68.0% 100.0%

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 71
 STANDARDIZE AND ESTABLISH CONTROL
Preventive
PILL DOCUMEN WHEN STAT ATTACH
AR QUESTION WHO ? NOTES
T ? US MENT
EE DID WE CHANGE SOMETHING IN THE MACHINE ? IF
MP INFO Microsoft Excel Adobe Acrobat

M YES  Macro-Enabled Worksheet

Document

EP DID WE CHANGE SOMETHING IN THE PRODUCT ? IF

EPM INFO Microsoft Excel
M YES  97-2003 Worksheet

IS THE SOLUTION IMPLEMENTED SOMETHING

BEST
FI INNOVATIVE THAT CAN BE IMPLEMENTED ALSO BY
PRACTICE
OTHER MM FACILITIES ? IF YES 

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 72
 STANDARDIZE AND ESTABLISH CONTROL
Expansion
EXPANSION MANAGEMENT

PILL
AR QUESTION WHERE ? WHO ? WHEN ? STATUS

Daniel
CAN THE IMPROVEMENT BE EXPANDED IN SIMILAR Hot End #1 , Alcantara /
FI AREAS ? IF YES  #2 and # 4 Justino
05/04/19 100%
Mendoza

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 73
 TEAM
WCM Radar Chart – End of the Project
Gustavo Velázquez Justino Mendoza Daniel Alcantara Jose Luis Zarate
Maintenance
Quality Engineer Process Engineer Production Supervisor
Coordinator
1 1 1 1
8 5 2 8 5 2 8 5 2 8 5 2

3 3 3 3
7 1 3 7 1 3 7 1 3 7 1 3

Cinthia Colin Enrique Rosales RADAR CHART

6 4 6 4 6 4 6 4
Financial
5
analyst PP&C
5
# TOOLS
5
R
5
1 5G 5
2 5W1H 4
3 4M1D 3
4 5 Whys 2
1 1 7 Steps of problem
5 3
8 5 2 8 5 2 solving
6 QA Matrix 4
3 3
7 PM 5
7 1 3 7 1 3
8 AM 3

6 4 6 4
5 5

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7

Plant Name 74