Supplier Lessons Learnt Cards [PDF]

Zitiervorschau

Lessons Learnt Cards in Incident Management System

April 2006 1

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Lessons Learnt Cards in SRM What is a Lesson Learnt Card (LLC)? It is the capitalization of experience: what have we learnt from an incident? It is a synthesis of acquired experience classified by root cause

Why LLC? To capitalize experience on C1, recurrent incidents, Warranty Returns… To help Suppliers to structure their experience

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LLC process overview PROCESS WITHOUT LLC Check Act < 10 Days

Plan Do < 5 Days

Supplier submits Analysis Plan Do

Supplier submits Analysis Check Act

OK/ NOK

Close

OK/ NOK

Close

PROCESS WITH LLC Plan Do < 5 Days

Supplier submits Analysis Plan Do

OK/ NOK

Close

Check Act < 10 Days

Supplier submits Analysis Check Act

LLC At “Check Act” screen, the Supplier has to complete the LLC

OK/ NOK

Close

New data 3

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When is LLC requested? LLC requested at “Plan Do” LLC mandatory in case of: –C1 incident –Recurrent incident –Warranty Return

Valeo can also request a LLC for a specific incident

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Property of Valeo – Duplication prohibited April 2006

New “Check Act” screen when LLC requested At “Check Act” screen, supplier completes the LLC 1. Fill in the 5W2H in English 2. Select main root cause(s) 3. Enter data regarding the main root cause

LLC must be completed in ENGLISH 5

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Selection of main root cause(s) (1/2) By default, the “Occurrence” screen is displayed To switch from one root cause to another, just click on the corresponding root cause

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Selection of main root cause(s) (2/2) Supplier has to select at least 1 root cause type When a root cause is selected…

… All data related to the corresponding root cause becomes mandatory and must be filled by the supplier

It is possible to select several root causes 7

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Upload of attachments For a selected root cause Attach photos/schemas for “Bad part” and “Good part”

Attach photos/schemas for ”Process before” and “Process after”

Once LLC is completed, click on “Submit Analysis Check Act” to submit to Valeo 8

Property of Valeo – Duplication prohibited April 2006

Examples of Lesson Learnt Card To display the LLC when completed, click on “Lessons Learnt Card”

It will display a LLC file in PDF format

The LLC is a way to Have a global view of the incident Capitalize experience

Check the following slides to see examples of LLC

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Property of Valeo – Duplication prohibited April 2006

Example of LLC on Occurrence WHAT WAS THE PROBLEM? (5W + 2H)

What happened? Fork lift damaged bulk package Why is it a problem? Products damaged When did it happen ? 17 March 2006 Who has detected it ? Cars International Where has been detected? Overseas shipping area How has it been detected? Visual inspection at reception How many ? 3 pallets out of 7

WHAT IS THE CAUSE? PROCESS\Packing

To be able to read label, pallet was oriented in a way that could potentially cause damage to parts during fork lift maneuvers

BEFORE

AFTER

Physical pallet issues No standard to define location of label on the pallet. If the pallet 2 is aligned along the wrong side, the fork lift taking pallet 1 damages the packaging and parts of pallet 2 Bad Part

Label is systematically put on package length so that fork lift can take packages on side A

Process Before

Good Part

Process After

(broken)

ITEM (Control Factor) Label position

WHAT WE LEARNED METHOD Visual check by Logistic operator

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CRITERIA Label put systematically on side A Property of Valeo – Duplication prohibited April 2006

Example of LLC on Non-detection WHAT WAS THE PROBLEM? (5W + 2H) What happened? Wrong part assembly (cap of wiper arm) Why is it a problem? Part not corresponding to the right vehicle When did it happen ? 19 March 2006 Who has detected it ? Autocars, inc. Where has been detected? Customer line How has it been detected? Not possible to mount part on vehicle How many ? 29

WHAT IS THE CAUSE? PROCESS\Test and measurement equipments Visual check of parts, not physical. Part reference on package not checked at start of shift

BEFORE Mix of part numbers

AFTER Gauge added to check if cap is the appropriate

Part checked visually Bad Part

ITEM (Control Factor) Diameter of cap

Process Before

Good Part

WHAT WE LEARNED METHOD Place cap in gauge

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Process After

CRITERIA Cap fits to gauge Property of Valeo – Duplication prohibited April 2006

Example of LLC on Management WHAT WAS THE PROBLEM? (5W + 2H) What happened? Delivery of mixed parts (T5 found in container of B5) Why is it a problem? T5 do not have the same specifications as B5 When did it happen ? 22 April 2006 Who has detected it ? EuropAuto GMBH Where has been detected? End of line How has it been detected? Abnormal noise How many ? 36

WHAT IS THE CAUSE? STRUCTURE Mix of references during sorting operations (due to internal issue)

BEFORE Mix of references

AFTER

Two references processed in the same area, as One reference sorted at a time and in the same allowed by work instructions. Non-standard area. Barcode check to verify product, packaging process not managed like standard process and label (same as standard process) Bad Part

Process Before

Good Part

(mixed references)

ITEM (Control Factor) Number of references simulteneously packed in the same area

Process After

(single reference)

WHAT WE LEARNED METHOD 1 reference sorting at a time and barcode check

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CRITERIA Adequation between part, packaging, label Property of Valeo – Duplication prohibited April 2006

APPENDIX – Detail of available root causes 1st Level

DESIGN

PROCESS

COMPONENT

OCCURENCE 2nd Level Part /components Process / tools design Software Hardware Specifications QAPp Late modification Insufficient QAP process Disrespect of process parameters/instructions Maintenance / Tool breakdown Not capable process Men Rework / downgraded process Organization Flow organization Start of production / batch exchange Worn out tools Unauthorized process modifications Raw material / component use Packing Design Manufacturing Validation Counterfeit Identification

1st Level

DESIGN

PROCESS

COMPONENT

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NON-DETECTION 2nd Level

MANAGEMENT 1st Level 2nd Level

Non-respect of validation phases Test coverage QAPp not-sufficient

Non-respect of Control Plan Lack of self control Training of operators Test and measurement equipments 5S not applied

Incoming inspection Tier 2 QAPp not sufficient

SYSTEM

(none)

STRUCTURE

(none)

SKILL

(none)

STRATEGY

(none)

Property of Valeo – Duplication prohibited April 2006