zero defect culture - lean network defects - brian hyde...zero defect culture brian hyde, plant...

© Autoliv, Inc. All Rights Reserved. / INTERNAL

Zero Defect Culture

Brian Hyde, Plant Manager

Autoliv ASP - Ogden, Utah

May 2016

© Autoliv, Inc. All Rights Reserved. / INTERNAL / ALVcode-Initials-MMMYYYY / filename.pptx - 2

Mono or stereo vision system

Inflatable curtain airbag

Passenger airbag

Pedestrian protection

Night driving assist

Satellite sensor Driver assist radar

Knee airbag

Pelvis restraint cushion

Steering wheel

Driver airbag

Side impact sensor

Electronic control unit and

Brake control/ESC

Side airbag

Seatbelt systems

Rear-side airbag

Far-side airbag

Battery disconnect

switch

Extra safety belt

Anti-whiplash system

Dynamic spot light

Bag-in-belt

Complete Safety System Supplier

Blind spot radar

Integrated child seat


Our Customers - All Major Vehicle Manufacturers


Zero Defects – Corporate Policy Deployment

Design robust

products Buy flawless

components Manufacture

flawless products Verify conformity of

products

Product & Process

Development

Production System Supplier

Management

After Delivery


Why Zero Defects?


What is a Defect?

Zero Defects is defined as meeting all the

criteria listed below:

No Customer nonconformance

No Supplier nonconformance

No Scrap

No Dropped parts on floor (Scrap)

No Lot Acceptance testing nonconformance

No Rework, Retest, Reprocessing


There is one thing more important than Zero Defects – JIDOKA! • It is critical to recognize and praise someone that

stops production when they find a problem or

potential problem.

The goal is NOT to report Zero Defects,

The goal IS to find and fix root cause of Defects to

achieve Zero.

JIDOKA

While inspecting housings for the 5C, Brad noticed the dog bone was abnormal. Brad notified his AMT who contacted the PQE. The housings were from totes of material that were on sort but had not been picked

up from the cell’s material rollers.

GREAT CATCH BRAD!

Containment action documented in Dispatch

Dispatch #: _____814416_

Root cause: Man / Machine / Method / Measurement / Material

Quality Manager Signature______________ ___________________

Brad Weir 5C / Swings

Date found: [2/4/16]

Jidoka Example – Recognition for Stopping


Purpose of Zero Defects Activities

Employee development

Improve team work across multiple sections of the company

Break the “PPM” thinking and achieve “EVENT” thinking

Eliminate complacency of current condition

Make quality personal for everybody

Pursue real root cause elimination for each defect

Get rid of mindset of “having a few defects is normal”

Change from inspection mindset to prevention mindset

Deliver perfect parts to the customers (external / internal)

Eliminate the blame game. Move from “their problem” to “our

problem”, we need to work through it either way.

Develop a Team that believes Zero Defects is possible.


Zero Defects

“Land of Uncomfortable”.

The Zero Defects Journey On our zero defects journey,

we will be tempted to turn around and go back.

What message do

we send if we turn

around?

How many will

follow us the next

time we do

something new?

We MUST be

committed to

drive towards

True North, learn

from our actions

and continue to

improve!


Many Organizations have “Islands” of

Quality Improvement Activity

Poka Yokes

– Design

Process &

Supplier

MPS

Compliance

SAPQP

Design for

Robustness

& Reliability

Red Bin

Processes

Variation

Reduction

Projects

Master FMEA

Development

Line/Design

Workshops

Regional

Problem

Matrix

PFMEA

Go,See&Fix

Standardized

Work

QE

Development

Process

Design

Reviews Problem

Solving Skills

AS 51 Supplier

Performance

Improvement

Change

Point

Control

Jidoka -

Proactive

and

Reactive

NQC

Reduction

Global

Yokoten

Meetings


The “Aligned” Road to

Zero Defects

DESIGN ACTIVITIES/TOOLS

Design

Reviews

Master

DFMEA

Development

Design for

Robustness

& Reliability

Design Poka

Yokes

PROCESS ACTIVITIES/TOOLS SUPPLIER

ACTIVITIES/TOOLS

MPS

Compliance Jidoka -

Proactive

and

Reactive

PFMEA

Go,See&Fix

Zero Defect

Workshops

WORMPIC

Reduction

Red Bin

Process

Master

PFMEA

Development

Standardized

Work

Process

Poka

Yokes

SAPQP

Supplier

PFMEA

Go,See&Fix

Supplier

Design

Reviews

AS 51

Supplier

Performance

Improvement

Supplier

Poka

Yokes

Foundation “ROADBED” elements

Change Point Control Divisional Read Across Global Yokoten Reviews

Line/Design Workshops Practical Problem Solving Skills MPS Disciplines, Std Work,

Six Sigma (Variation Reduction) Tool Set QE Development Process-QE101/201/301 Certification


Zero Defect Workshop Methodology

Establish team and workshop plan / structure

Ensure robustness of

previous corrective actions

Solve current problems

Anticipate potential problems

– PFMEA Go & See & Fix

Active Yokoten

<LEVEL 1>Design

Pokayoke

<LEVEL 2> Mechanical Pokayoke

<LEVEL 3>Mechanical Inspection in Process

<LEVEL 4>Manual

Inspection in Process

<LEVEL 5>Mechanical Inspection

in Line

<LEVEL 6>Manual

Inspection in Line

<LEVEL 7>Sampling

Inspection

Stronger Weaker


Autoliv Zero Defects Workshop

Ma

na

ge

me

nt R

evie

w

Validation of

Completed Actions

Review of Open

Action Items

Celebrate Zero

Defects as Cell

Achieves Zero

Defects at 15

Working Days

Continue to Find

Actions to Improve

Pre-Analysis

• Objective of

Workshop

• Collection and

Review of

Past Data

• Review of

Current Data

• PFMEA

Review

• Jidoka

Review

• Scrap Review

• Audit Reviews

Kic

ko

ff/D

isco

ve

ry

Se

t O

bje

ctive

/Actio

ns

Ma

na

ge

me

nt R

evie

w

Workshop

• Discovery

Day 1

• Set Objective

• Brainstorm

• Create Actions

Day 2

• Complete

Actions

Day 3

• Training

• Validation of

Actions

• Yokoten

Follow-Up

AOA Zero Defects Workshop

Formation of Teams

Design Team

John Spader

Naoki Morita

Falon Welch

Marcus Barney

Kodey Kunz

KC Atkinson

Process Team

Larry Hunsaker

Ryan Bradley

Harley Erickson

Layne Layton

Keith Bingham

Craig Standing

Maritza Weaver

Equipment Team

Don Fenton

Jann Albio

Derek Farr

Adam Montoya

Colby Sycamore

Standard Team

Josh Barneck

Connie Hammon

Carla Lopez

Sandra Aparicio

Ryan Zampedri

Kevin Figuerora

Tyson Smith

Antonio Espinoza

Cross-functional Teams:

• Manager

• Safety Engineer

• Quality Engineer

• Supplier Quality Engineer

• Design Engineer

• Industrial Engineer

• Customer Representative

Team Members from ALL shifts:

• Production Associates

• Production Cell Team Leaders

• Maintenance

Workshop Groups


Day 1 Brainstorming – Focus Ideas

Review of Quality Issues Customer concerns, Lot Acceptance tests, Scrap, Historical Corrective Actions and

Jidoka.

Review of Design Issues Design – DFMEA, Customer concerns

Prototype – Limit Testing issues, Scrap

Review of Process/Production Issues Jidokas w/Corrective Action, First Time Quality, Yokotens, 8Ds

Review of Equipment Issues Drawings, PFMEA, JBS/Control Plan, SC/CC/CIP

Equipment downtime, Work orders, Machine Mod Sheets

Review of Standard Work/Motion Workshops Review of past workshops – what needs updated


5S Cell information: Living Pareto


Scrap Collection for Review



Go and See Activities Design and Process Teams PFMEA Go and See Document Review

Review of each machine in the cell

Supplier Issues Potential Drawing updates

Interface between Customer and Autoliv drawing

Equipment Team Review of each sensor on each process

Review of automation/programing on each process

Standard Work/Motion Team Review past improvements – Is the improvement still effective?

Focus on standard motion to eliminate current scrap

Review video of standard motion



E – Easy

W – Workshop

L – Long-Term


Days 2 & 3 Drive Actions to Success

The Goal is to accomplish as many action during the workshop as possible. Easy Actions

Day 1

41 Submitted, 41 Complete - 100%

Day 2

17 Completed

Workshop Actions

25 Actions – 60% complete

Set Priority

10 became long-term actions

Long Term Actions

Day 1 – 40 actions

Day 2 – total 50 actions

Plan to accomplish Weekly follow-up until actions complete


Post Workshop Follow Up

All Defects are treated as a Crime

Scene.

Team Lead and Maintenance are

notified of Defect to be investigated.

The Team also performs a weekly

review of open actions to achieve

Zero Defects Date: 12/9/2014 Facilitator Location: Cell 65

Status

Assigned Target Completed

1L. Hunsaker / A. Montoya Shave down the B-Pillar tooling on hardware.

12/09/14 12/09/14 12/09/14Shave tooling.

4

2M. Barney Take unused bolt out of tape scanner on bag fold.

12/09/14 12/09/14 12/09/14Remove unused bolt.

4

3M. Barney Install bolts and locknuts on tape dispensers on

bag fold. 12/09/14 12/09/14 12/09/14Added bolts and locknuts.

4

4

Naoki Why is the Pillar ramp / Loom flap there?

12/09/14 12/09/14 12/09/14

So the cushion rolls down the loom flap

during deployment instead of the bracket. 4

5J. Spader Move stamp position on cushion.

12/09/14 1/5/2015Supplier to keep stamp out of throat area

minimum of 50 mm. 2

6Naoki Part # 620711800H/01H - Add SC to tox process

12/10/2014 1/7/2015 1

7

Naoki Due some pressure testing in order to remove SC

on C- fold- Drawing part # 6256572 12/10/2014 1/15/2015 1

8L. Hunsaker / A. Montoya Cushion mounting brackets not meeting sensors.

12/09/14 01/30/15Submit a work order to redesign tooling.

1

9Naoki Evaluate brackets drawings for burrs called out

and add sharp edges not acceptable. 12/10/2014 1/30/2015 1

10

Naoki Part# 617064700A - change to 628960900B-

Caution needs to be place at current position. Do

not change.

12/10/2014 1/30/2015 1

11

Naoki Part #626079700B- Increase length on tape to

help holding the cushion roll, since this tape is

going over the bracket and the cushion and this

area is the thicker area.

12/10/2014 TBD

This needs be evaluate and be agreed by

Nissan

1

12Naoki Pillar ramp / Loom flap to hard to fold over at

hardware & Tape keeps coming apart. 12/09/14Use longer tyvek tape.

1

Comments/Updates Closure Criteria

(Who, What and How)

Keith B.

Action

Number

Person responsible for

item completion

Method

(Description of Action required)

Dates

Action 50% Completed22

New Action Assigned0

Action in Process1

Action 75% Completed3

Action 100%Completed4 Action Verified5


Weekly Management Review

Achieved Goal of 15 consecutive

days of Zero Defects

Current number of days at Zero

Best continuous run of Zero

Total cumulative days of Zero


Design Team

Benefit:

Reduced chance of label peeling during

transportation from vendor, Torque and

Cushion Fold.

Before

Zero Defects Design Improvements

Autoliv Proprietary Zero Defects Workshop – Presentation

After

Improvement:

Cushion Barcode has poor adhesion, and is

prone to damage, ie. Tearing, rolling,

folding, etc.

1. Move location of cushion label

2. Add second stitch

1. Proposal to move cushion label 7 mm away

from housing initiated.

2. Rotate printing 90 degrees and add second

stitch to secure cushion label

Benefit:

Reduced chance of broken bridges during

folding operation

Before



After

Improvement:

Cushion wrap bridges break during folding

operation.

1. Work with vendor to control cutting process

2. Increase bridge width from 2.5 mm +1.5/-1

3. Standardized knacks at torque and folding

operations across all associates to reduce

tension on bridges via JBS

1. Negotiations/understanding of vendor

constraints initiated.

2. Proposal to revise bridge specifications initiated.

3. Complete.

Drawing changes in

process

1 2 3 4 5 6


X61A – Holes tearing •Scrap is being created because of forcing / stretching wrappers to engage stud holes circled below.

•It was also discussed to reinforce the thickness of the material around the wholes

X61A – Proposed Change

•We are proposing that test and move hole

locations

2-5mm

Approx. 5mm

• Making this change will reduce scrap

from hole tear through and tearing

bridge seams



Process Team


Stop, Call & Wait

Opportunity identified:

Reprocessing of part on tooling


Tools Used

5 Why Root Cause Analysis

Have to periodically reprocess part

Why? – Failing for cushion presence

Why? – Cushion isn’t being detected

Why? – Sensor doesn’t always see cushion

Why? – Sensor beam being partially blocked

Why? – Slot for sensor beam is blocking

Solution? – Widen slot for sensor beam


Results

Widened slot over sensor

Eliminated reprocessing defect


Dropped

Parts Opportunity identified:

Bands catching on each other, dropping to floor


Results

Cell team member created magnetized lid

- Catches loose bands as they’re coming out

- Also used as retrieval point for operator

Photo(s) before

and remarks

Benefit: Reduce/eliminate mini-wrap scrap

Before

Process Zero Defects

• On going SPC to stabilize process

Zero Defects Workshop – Presentation

After

Improvement: Stabilize Cushion Roll

Process through SPC

9181716151413121111

110

105

100

95

90

Observation

In

div

idu

al

Va

lue

_X=99.25

UC L=106.99

LC L=91.52

9181716151413121111

16

12

8

4

0

Observation

Mo

vin

g R

an

ge

__MR=2.91

UC L=9.50

LC L=0

1

111

1

1

1

1

1

1

1

I-MR Running Chart of Push Pin 11/3/14-

Benefit:

Before



After

Improvement:

Cushion fold – Added guide to

bagfolder to keep cushion flap from

being caught in blade

Eliminate torn cushion wraps


Equipment Team CHUCK EDDY TECHNICAL SUPPORT LEAD

CHRIS JENSEN MACHINE BUILD SUPERVISOR

ELDEN SEVY MAINTENANCE TECH AUTOMATION

JEFF ORN AUTOMATION ENGINEER

GREG MCGHEE CELL ASSOCIATE

RICK GONZALES CELL ASSOCIATE

DENNIS THOMPSON PAB PROJECT MANAGER

Photo(s) before

and remarks

Benefit: Easier to identify proper pressure

settings for various air supply locations

Before

Photo(s) after

and remarks


After

Improvement: Installed Standard air gauges

on multiple regulators

Equipment Zero Defects

Before


After

Wire damage from exposed wiring. Modified

tooling and re-routed wires to prevent

damage.


Benefit: We can see problems before they

happen and correct them before causing

defects.

Before


After

Improvement: No Preventative Maintenance

specific to load cell and shunt valve

There is no PM for checking load

cell and shunt value

Detailed PM for load cell and

shunt value



Standards Team

Benefit:

Multiple sensors allows operators to pull

tape from any location without wasting any.

If the tape shifts when replace roll won’t be

affected.

Before



After

Improvement:

Added multiple sensors on tape machines

to eliminate wasting unused tape.

Operators have to pull from right to left

otherwise machine feeds next row of

tape wasting the unused portion

Additional sensors allow operators

to pull tape in any combination

Before


After

Continued from last page:



Safety Alert!

Opportunity identified:

Ergonomic strain from

water spider lifting

cushions into bin

Water spider position

designated as one of

the most difficult jobs by

plant physical therapist


Tools Used

5 Why Root Cause Analysis

Water spider getting hurt

Why? – Experiencing shoulder pain

Why? – Must lift cushions up and into bin

Why? – Bin walls are tall

Solution? – Cut out portion of rear wall to enable easier

access

Also standardized motion of

spider placing cushions into

bin


Results

Cut out rear

wall of

cushion bin

Ergonomic

strain

alleviated


Yokoten

Magnetic bandit lids – AOA Yokoten database

Visual aids for water spider – Yokoten to 6 other cells

Water spider safety issue – Yokoten to 6 other cells


Zero Defect Cells

Cell/Process Days 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Total

65 26 181

75 9 95

7C 6 75

Mld 29227 6 70

N4 3 7

44 2 10

Paint No AdPro 13 46

X1 7 62

7L 8 46

Mld 29222 4 33

NQ 6 90

NT 13 91

Mld RF 31 180

Mld R6 36 175

Mld R2 22 175

X5 7 40

NU 10 73

5S 4 27

Mld RG 14 84

Mld R7 31 125

Paint Dropped 8 19

56 3 6

5J 2 9

59 1 1

62 1 1

Total Days without Defects 1720

AOA Zero Defect Lines

1720 days

w/ zero

defects-

54% avg.

scrap

reduction


Creating a Zero Defect Culture where

“We Believe”

zero defect culture - lean network defects - brian hyde...zero defect culture brian hyde, plant...

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