QRQC Problem Solving Techniques [PDF]

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QRQC for non manufacturing processes 5W2H

1 Start Date:

[1.1]

GOOD AND BAD PART PROCESS VISUALIZATION

2

[3.8]

ADDITIONAL INFORMATION

Describe the process by using Flow Charts, Process Maps, Sketches etc.

Was the process performed according the standards (no rework or deviations from procedure)? [3.1]

Part / Process Name: [1.3]

Function

[1.4]

UNDERSTAND THE PROCESS BY VISUALIZATION

3

GOOD PROCESS / GOOD PART

[1.2] QRQC Id:

[1.5]

Category Where was the part produced / process performed? [3.2]

QRQC-Team:

[1.6]QRQC-Leader:

5W2H [1.7]

WHAT has happened?

[3.3]

When was the part produced / process performed?

[1.8]

WHY is it a problem?

[3.4]

[1.9]

WHEN was is detected? SINCE WHEN we have this problem?

Do we detect the problem with our own equipment?

Which WABCO processes / people are involved or might be affected? [3.5]

BAD PROCESS / BAD PART

[1.10]

WHERE was it detected?

[3.6]

[1.11]

WHO detected it?

[3.7]

[1.12]

HOW was it detected?

[1.13]

HOW many parts are affected?

In case of recurrence: What was the countermeasure / corrective action?

[2.1]

[1.14]

Escalation Level: (if necessary)

Team Leader:

Name:

Date:

Regional/Functional Leader:

Name:

Date:

CONTAINMENT ACTIONS

4 [4.1]

Containment Actions

[4.2]

Who

What is the difference between a good and a bad part / process?

FACTOR TREE ANALYSIS (FTA): Why did the problem occur?

5a 5 [4.3]

Plan date

[4.4]

Status

[5.1]

4M

[5.2]

Factors

Standard

[5.3]

[5.4]

Good part / process

[5.5]

Bad part / process

Describe what have you done to reproduce the failure:

Results:

In case you were not able to reproduce please escalate to next level and give reasons:

No Yes

No

No Yes No

MAN

Yes

No

No

Yes

Yes No

MACHINE

Yes

No

No

Yes

Yes

No Yes

No

OTHERS

Yes

No

No

Yes

Yes

5WHY ANALYSIS FOR OCCURENCE

5WHY ANALYSIS FOR NON-DETECTION

6b 9

Why did it happen?

[7.3]

Why 1 :

Why 1 :

Evidence 1 :

Evidence 1 :

Why 2 :

Why 2 :

Evidence 2 :

Evidence 2 :

Why 3 :

Why 3 :

Evidence 3 :

Evidence 3 :

Why 4 :

Why 4 :

Evidence 4 :

Evidence 4 :

Why 5 :

Why 5 :

Evidence 5 :

Evidence 5 :

Real Root Cause for occurence

COUNTER MEASURES

No Yes

METHOD

[7.2]

8

Difference

Yes

No

[7.1]

Bad part / process

No

Yes

6b 6a

Good part / process

Yes

No

Reproduce the failure based on the significant factors found on FTA. If you could reproduce the failure, it means that the Factor has a direct link with the problem.

Standard

MATERIAL

Yes

OTHERS

Factors

No

No

MACHINE

REPRODUCE THE FAILURE

4M

Yes

Yes

MAN

FACTOR TREE ANALYSIS (FTA). Why didn't we detect the problem ?

5b 7

Difference

Yes

METHOD

6a 7

[5.6]

No

MATERIAL

[6.1]

Did the problem occur before (recurrence)?

[7.4]

Why didn't we detect?

Real Root Cause for non-detection

Verification of Counter Measures and Sign Off

9

What is the amount of the deviation before and after the QRQC [8.1]

Permanent Corrective Actions

[8.2]

Who

[8.3]

Plan date

[8.4]

Status [9.1]

Insert Graph Titel

Insert Graph Titel Here

11 10

Quantity

9 8 7 6 5 4 3 2 1 Date

0 [8.5]

Update documents: Actions Implemented

Documented Procedure Work Instructions

[9.2]

P/D-FMEA

TControl Plan H JED ILessons Learned Card N TOthers (specify): K H Process Owner Name: I Sign-off: u N n K t iu ln lt [8.6]

[9.3]

Date + 1

Date + 2

Date + 3

Date + 4

Date + 5

Date + 6

Date + 7

Date

Quantity

*See instructions for detailed information [9.4]

Comments:

[9.5] QRQC closed!

Sign-off:

QRQC Leader Sign-off:

Name:

Sign-off:

QRQC closed! Team Leader Sign-off:

Name:

Sign-off:

Date: