War Room Set-up

Guide

War Room Set-Up

Once a suitable location is secured. Start
building your room using this basic format.
Assessment Summary

Commitment Letter

Action Plan

Action Plan indicators

Sustaining Indicators

Project Status

P ro je ct #:
S up p lie Hr: ol se t, C h arl es to n , S C U S A

D a tes of A s s es s m en
7 /1t :-87/ 2 7

C r it ic al P r is m F o cu s
C us to m e r Pr ob le m T: ur bo N oiseC u m m in s
B en t B la desH ol set.
D i re ct R o o t C a us e:B en t B la -d M
e a n ua l P ro ce s s.
D e te ct io n R o o t C aRusele:ia nc e o nriaV ba le S o rt in g R i g (V S R ) te s te r.

N a :m e

D a: t e

S i g n :a t u r e

- -S- - u- -p - -p - l- i- e- n-r - s-l -o-f c-o -ar--t r-i -oe --a 1- d- .- - - - - - - - - - - - - - - - - -- - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - -Q-- -A- - -A- - T- - - -A- - c- -t- i- -o- n- - - -P l a n
- -a- -c - r- o- - s- - s- -: - - - - - - 2.
S u p p l ie r :
P r o j e c t D a t e s :S t a r3t .
T a r g e t F i n i s h
M e t r ic
4.

- - - - - - - - - - - - - - - - - - - -- - - - -- - - - -- - - - - - -- - - -- -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -I D
- -- - - -- - - -- - - - --

A c t io n I t e m

(w h e r e
S t a r tE n d
C h a m p io n
S tatu s
a p p lic a
D a t eD a t e
b le )

S ys te m ic C a u se
(5- W h y B a s ed ):

N ew p r o ce s s d id no t c o n s id e r b e nt bl ad es at ass e m bl y s ta ti on as a p os s ib le fai lu re
m o de d u ri n g i nt ro du c ti on .

P r o ce ss C on t ro l F o cu s
F M E A A d eq u ac y: F M E A i s n o t a l iv in g d o c u m en t . to
N oo pe
l inrak ag
tioen . FM E A d i d n o t m at ch
C o nt ro l P lan . R an k i n g sy st em n o t ap p r o pr ia te o r c o n sis te n t. F M E A co n st ru c tio n
is in co r re ct .
C on tr ol P l an
C o nt ro l P lan an d PF M E A li nk a ge is i nc ons is te n t.
A d e q u ac y :
Im p lem e n ta ti on
A d e q u ac y :

S u p p lie r P r o je c t L e a d e r :

1a

C h r y so l peu r S GQ r S r . M g r :

N o t e:In co n si st en t w it h d o cu m en te d p ro c es s f lo w . T h e f ol lo w in g , a r e k e y
w ea k n e ss , no te d d u ri ng th e a ss es s m en t; hi d d e n f a cto rie s , i m pr op er u sa ge an d
st o rag e o f r ac ks , w h ip /s u pp li ed & f in is h ed p ro d u ct s to ra g e an d
id en ti fic a tio n /d al
is po
o f s n -co
on nf or m in g m a te ri al .
L P A- L P A s ys te m is no t w e ll de fin e d. L PA i s n ot us ed to dr iv e
im p ro ve m e nt s. P roc e ss is im m a tu re.

1a

P a r t ic ip a n t s

C om m ent

1a a
1a b
1a c

100

2a

2a
2a a
2a b
2a c

- - - - - - - - - - - - - - - - - - - -- - - -- - - - - - - - - - - - - - - - - - - - -- - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - --2 b- - - - - - - - - - - - - - - - - - - - - 2b a
- - -- - - -- - - -- - - - -- - 2b b
2b c

- - - - - - - - - - - - - - - - - - - -- - - -- - - - - - - - - - - - - - - - - - - - -- - - - -- - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - -- - - -- - - -- - - - -- - M o n t h l y P r o g r e s s R e: v ie w M e e t i n g S c h e d u l e

1b a
1b b
1b c

100
50
2a a
2a b
2a c

2b
2b a
2b b
2b c

I d e n t if y h i g h r is k s u p p li e r s f o r q u a li t y s p i ll s

A s s e m b l y S u p p li e r Q u a lit y

50

1b
1b a
1b b
1b c

S u ipe pr l S r . E x e c u t i v e S p o n s o r :

S y s te mF o c u s
S ys te m ic A n aly si s
W e ak ne s s:
1

W e ak ne s s:
3

A c t io n I t e m

ID #

1a a
1a b
1a c

Q A A T D: i r e c t o r

M a ter ia l F l ow C o- nC tro
o ntlro l o f N-c o nnf orm in g m a te ria l, H an d li n g
p r ac ti ce s, p ar t Id e n tif ica t io n, a nd Hriide de
s nnotF eff
a ctec
o ti v e .

W o rk P ro c e s s
S te p 1

1b

S ys te m ic A n aly si sP FM E A n ot us e d a s a t o ol ,on da
o t te,u Le
p tss o n s L e arn ed s el do m in co rp o ra ted
W e ak ne s s:
in ex i sti n g pr od uc ts . It em s o n F M E A n o t c on sis te n tl y ca r r ie d t hro u gh to C o n t ro l
P la n.

W e ak ne s s:
2

C om m ent

M e t r ic
(w h e r e
S t a r tE n d
C h a m p io n
S tatu s
a p p lic a
D a t eD a t e
b le )

S te p 2

A n a lyPz Re I S Ma n sd o t h e r i n d ic a t o r s f o r s e leQ cA teA Td &h i gA hs s e m b l y S Q

r is k s u p p l ie r s t o d e t e rm i n e d e f ic i e n t b u s in e s s p r o c e s s e s

S te p 3

E s t a b lis h i m p ro v e m e n t n e e d w i t h s u Ap ps sli ee mr ba tl y c So Qr p, oCr ao mt e m e r c ia l

P r o c u re m e n t, Q A A T ,
leve l

C o n c u rr e n c e :

S om e ite m s o n pl an n o t oe vi
n fdlen
oo r , p ar t ic ul a rly R e ce iv in g I n sp ec ti on

V is u al M a n a ge -mVen
is tu al f ac to r-Sy,, a5 nd s co r e bo a rd s n ot us ed
ef fe ct iv el y o n p la n t f lo o r .

QU A L ITAYS S U R A NA CN EDAU D ITT E A M

100

Q A A T A c tio n P la n
S u p p l ie r :

50

S u p p li e r S r . E x e c .

A ss e m b ly S Q , Q A A T ,

S te p 4

E s t a b l is h im p r o v e m e n t n e e -sd i t ew ita ht s u p p l i e r o n
S u p p li e r m a n u f a c t u r in g
m a n u f a c t u ri n g l o c a t i o n
lo c a t io n E x e c . M g t .

S te p 5

P e r f o r m a s s e s s m e n t o f a p p r o p r ia t e s uS pu pp lip eli re rp Lr oe ca de es sr , eQs A A T

u s in g s t a n d a r d t o o l s
L e ad e r

Q A A T L e ad A s se s so r,

Q A A T L e ad A s se s so r,

S te p 6

C o m p l e t e A s s e s s m e n t d o c u m e n t a n d SI du pe pn lit ife ry LSeyasd tee rm, Qi c A A T

L e ad e r
D e f i c i e n c ie s

S te p 7

C o n f irm A g r e e m e n t o n Id e n t i f ie d S y s t e m ic D e f ic i e n c i e s

S te p 8

F o r m P r o je c t T e a m , in c lu d in g s u p p lie r , Q SA uA pTp, liAe sr sLeema db ely r ,S QQ A, A T

s u b je c t e x p e r t s a s r e q u ir e d ( S u p p lie Lr elea ad de sr )

S te p 9

S te p 1 0

S te p 1 1

S te p 1 2

S te p 1 3

S u p p li e r S r . E x e c u t iv e ,
Q A A T L e ad er

A n a ly z e A s s e s s m e n t d o c u m e n t , d e v e l o p c o r r e c tiv e
a c ti o n w o r k p l a n , a n d d e t e rm in e p r o j eP cr ot jed ec tlivT e ar amb le s
D e v e lo p a n d s ig n s t a t e m e n t o f w o r k w Pit hr ocjeo cmt mT eit taemd & S u p p lie r
im p r o v e m e n t , m e a s u r e s , a n d t im inS gr . E x e c u t iv e

M a k e f o c u s e d t r a i n i n g a v a i l a b l e t o t h Pe r oP jer oc jet Tc et aTme a m

E x e c u t e t h e w o r k p la n

P r o je c t T e a m

M e a s u r e p r o j e c t r e s u lt s , m o n i t o r w o r kP pr olajenc ta Td eh aemr e n c e ,
a n d p r o v i d e w e e k ly s ta tu s r e p o rt s

*Alternate Arrangement

WAR B OA RD

Supplier
Lead Sheet
(Supplier
Overview)

QA A T
A ssessment
Phases Issue /
Control /
System Focus

Issue Focus
Detail
(SLIDE)

C ontrol
Focus Detail
(SLIDE)

System
Focus Detail
(SLIDE)

ISSUE FOC US
C ust. Prob:
Direct R oot C ause:
Detection R / C :
Sys. C ause (5 why based):
Actual 5-Why

C ONTROL FOC US
FM EA A dequacy:
C / P A dequacy:
Imp. A ction A dequacy:
Systemic A nalysis Weakness:

System Weekness 1
M F0
M F0 Action Plan HF0 Action Plan
HF0
C0
CC0

SY STEM
Weakness
Weakness
Weakness

FOC US
1:
2:
3:

QAAT
A SSESSM E
NT TOOL
(completed)

* Also known as the Jeffcean War board

System Weekness 2
LP0
LP0 Action Plan OC0 Action Plan
OC0
SS0

System Weekness 3
OS0
OS0 Action Plan SV0 Action Plan
SV0
M0

Print the following

slides for your set-up.

Assessment Summary

Commitment Letter

Action Plan

Action Plan Indicators

Sustaining Indicators

Project Status

War Room Set-Up

As each Focus is completed add
Documentation.
Issue Focus

QAAT
P ro c e s s
S y s te m A s s e s s m e n t

Control Focus

C o n tr o l F o c u s
S ys te m A ss es s m e n t

System Focus

Q A A T A c tio n P la n
S u p p l ie r :

A c t io n I t e m

ID #
1

IS S U E F O C U S
CO NTRO L FO CU S
SYSTEM FO CU S

C O N TROL FO C US
F M E A & C o n t ro l D e t e c t io n
P la n E f f e c t iv e n e s s A u d it

S y s te m ic W e a k n e s s S u m m a r y
T h e C r it ic a l F e w
P r o je c t C o m m itm e n t L e tt e r
Im p r o v e m e n t P la n
R e a d A c ro s s

F M E A A d e q u a t e ? D e t e c t io n
M e th o d s
A d e q u a te ?
C o n t ro l P l a n
A d e q u a te ?
E f f e c t iv e ly
Im p le m e n t e d ?

D e d i c a te d
D e t e c t io n
A u d it

A n a ly s i s o f G e n e r a l P ro c e s s
C o n t ro l :
P u rpo s e:
F M E A & C o n tr o l P l a n A d e q u a c y
D e g r e e o f im p l em e n ta tio n
M e t h o d s o f D e te c tin g Is s u e s

M e th o d :
R e v i e w S e le c tiv e P a rts (o v e r p e rio d
o f tim e )
D o c u m e n t lin k a g e s (F M E A , C o n tro l
P la n )
Im p le m e n ta tio n o n th e flo o r
R e l a tio n s h ip to R e a l Is s u e s (S c ra p ,
d e fe c ts , )
D e te c tio n A u d it

1a
1a a
1a b
1a c
1b
1b a
1b b
1b c
2

2a
2a a
2a b
2a c
2b
2b a
2b b
2b c

M e t r ic
(w h e r e
S t a r tE n d
C h a m p io n
S tatu s
a p p lic a
D a t eD a t e
b le )

C om m ent

Issue Focus

Control Focus

System Focus

Vijay Example