Quick Response Quality

Control
QRQC
 WHY QRQC? HI DOCTOR!
MANY ISSUES ARE OPEN FOR TOO
LONG!
I HAD A FEVER 10 DAYS AGO AND
WAS NOT FEELING WELL.
I AM AFRAID IT WILL COME BACK.
WHAT CAN I DO TO AVOID IT?
LETS COLLECT DATA TO BE
REVIEWED AT END OF MONTH
FROM HIS DESCRIPTION IT
LETS APPOINT A PROBLEM COULD BE HUNDRED OF
DISEASES.
SOLVING GROUP... WHY DIDNT HE COME WHEN HE
HAD THE PROBLEM?
BUT PROBLEM IS GONE BUT IF I WANT TO KEEP HIM AS A
PATIENT, I WILL HAVE TO GUESS
WE CANNOT OBSERVE THE
CONDITION OF THE LINE
OPERATORS NO LONGER
REMEMBER
2017. 11. 03. THE DETAILS. 07/09/2001 2
WHY QRQC?
SITE PAQ
IMPROVE QUALITY
THESE
SYSTEM
ACTIONS ARE
GOOD, BUT
MODIFY QUALITY MANUAL FOR
ISO TS CERTIFICATION

SQA
MONTHLY REVIEW WITH WORST
SUPPLIERS
PERFORMANCE REPORT SENT
WHAT IS THE RELATIONSHIP?
AUTOMATICALLY

IMPROVE PDCA
TRAIN PSG TEAMS
2017. 11. 03. 07/09/2001
IMPLEMENT LOTUS PDCA 3
DATABASE
 WHY QRQC?
CAN YOU SHOW ME CAN YOU SHOW ME
HOW YOU ARE HOW YOU IMPROVED
IMPROVING QUALITY? QUALITY YESTERDAY
ON THIS PRODUCTION
LINE?
OH, YES! I WILL SHOW
YOU THE RESULTS OF
UH UH WHERE IS
THE PSG THAT THE QUALITY
WORKED 3 MONTHS ENGINEER?
AGO ON
MANAGEMENT DOES NOT KNOW WHAT
HAPPENED YESTERDAY
A FEW EXAMPLES IN SOME AREAS OF THE
AND OFTEN NOTHING HAPPENED!
PLANT
2017. 11. 03. 07/09/2001 4
 WHY QRQC?
5 MEETING AT PLANT LETS NECESSARY
SOMETIMES THEY ARE

LEVEL MODIFY PRODUCT

BUT
BUY BETTER
IN 5W
CONFERENCE
2H? ROOM,
GIVE ME BAD
PART AND PROCESS
SOMETIMES
APU MGR TALKSGOODABOUT
PART EQUIPMENT
HOT ISSUES: EASY ANSWER
AVOIDS
CHANGE SUPPLIER
WHAT IS HAVING TO DO
ROOT WHAT IS ANYTHING TODAY
WE VE
CAUSE? GOT MANY PROBLEM?
THOSE ACTIONS
WHY ARE YOU SURE
CHANGE
PROBLEMS SINCE A
COUNTERMEASURE WAS
WILL WORK?
WHILE WITH PART MAKES US FEEL
UNDERWAY FOR ANOTHER
REASON AND MIGHT
XXXXXX PROUD OF OURTOUSE
NOT BE RELEVANT
ITS AGAIN A DESIGN (OR
2017. 11. 03.
OF PDCA
07/09/2001
METHOD:
PROBLEM
5

SUPPLIER) PROBLEM! THIS IS REAL

 WHY QRQC?
5 MEETING AT PLANT NO SANGENSHUGI!
LEVEL WITHOUT HAVING REVIEWED
REAL DATA!
IN 5W
CONFERENCE
2H? ROOM,
GIVE ME BAD
PART AND GENJITSU Reality
APU MGR TALKSGOODABOUT
PART NOT HAVING BEEN ON THE
HOT ISSUES: SHOP FLOOR AND WITHOUT
WHAT IS TALKING TO OPERATORS!
ROOT WHAT IS GEMBA - Real Place
WE VE
CAUSE? GOT MANY PROBLEM?
WHY ARE YOU SURE NOT HAVING COMPARED
PROBLEMS SINCE A
COUNTERMEASURE
WILL WORK? GOOD AND BAD PARTS!
WHILE WITH PART GEMBUTSU - Real Thing
XXXXXX
ITS AGAIN A DESIGN (OR WILL YOU SIGN THAT PROBLEM
2017. 11. 03. 07/09/2001
WILL NOT HAPPEN TO- 6

SUPPLIER) PROBLEM! MORROW?

QRQC: BASED ON MANAGEMENT
INVOLVEMENT
MANAGEMENT SPEND 20-40 EVERYDAY TO REVIEW HOW THE
ORGANIZATION RESPOND TO QUALITY ISSUES

KNOWING WHAT GOES ON REALLY AT ACTOR LEVEL BY LOOKING AT

REAL DAILY ISSUES RATHER THAN AT PERIODIC REPORTS PREPARED BY
SPECIALISTS
HOW EMPLOYEES WORK EVERYDAY?
HOW DOES THE ORGANIZATION REACT WHEN A PROBLEM OCCUR?
EDUCATING BY CHALLENGING INTERMEDIATE MANAGEMENT
LISTEN: SANGENSHUGI
CHALLENGE AND VERIFY: SANGENSHUGI
IN CASE OF INSUFFICIENT RESPONSE, REQUEST BETTER PROBLEM
HANDLING FOR NEXT DAY
APPLAUD WHEN TEAMS HAVE SUCCESS: SANGENSHUGI

2017. 11. 03. 07/09/2001 7

 QRQC: QUICK RESPONSE
ORGANIZATION IS QUICKLY RESPONDING TO ISSUES
LESS ISSUES OPEN AT SAME TIME
PRIORITY ON CUSTOMER ISSUES AND A HANDFUL OF INTERNAL
ISSUES IN EACH APU VALIDATED BY MANAGEMENT
DAILY PROGRESS
24HR FOR CONTAINMENT, 3 DAYS MAX FOR CORRECTIVE ACTION
IMPLEMENTATION
ROOT CAUSE ANALYSIS BASED ON REALITY
IMAGINATION IS FORBIDDEN!
BETTER TO 100% ERADICATE THE MAIN ROOT CAUSE TO-DAY
RATHER THAN WAITING FOR 30 DAYS TO HAVE PRODUCT CHANGE,
NEW PROCESS EQUIPMENT OR SUPPLIER CHANGE TO SOLVE ALL
POTENTIAL ROOT CAUSES

2017. 11. 03. 07/09/2001 8

APU QRQC
QUICK ASSIGNMENT
AND ACTION TO STOP
PROBLEM

2017. 11. 03. 07/09/2001 9

APU QRQC EXAMPLE 1
IN MOST CASES, PB
CAN BE SOLVED
WITH SIMPLE
APPROACH

2017. 11. 03. 07/09/2001 10

APU QRQC EXAMPLE 2

QUICK
ASSIGNMENT
TO SOLVE
THE ISSUE

PROBLEM IS
MORE COMPLEX
THAN INITIALLY
THOUGHT

2017. 11. 03. 07/09/2001 11

APU QRQC EXAMPLE 2

2017. 11. 03. 07/09/2001 12

WHY QRQC MEETING?
QRQC CORRECTIVE EDUCATE
ACTION EDUCATE
IMPLEMENTATION EDUCATE
CHECK
THIS IS DAILY
ON JOB TRAINING!
(OJT)
Detection

QRQC
Verification MEETIN Communication
G

APPLAUDE
OR Analysis
REQUEST MORE LISTEN AND
DATA
UNDERSTAND
APPROVE
COACH USING
SHANGENSHUGI!
QRQC ASSIGNMENT
SHEET

2017. 11. 03. 07/09/2001 13

 ONE GOOD WAY TO START
QRQC
EACH APU HAS DAILY QRQC MEETING CHAIRED BY APU MGR TO REVIEW
CUSTOMER ISSUES
RESPONSE TO TOP 3 DEFECTS OF YESTERDAY
PSG PROGRESS
PLANT MGR AND QUALITY MANAGER TOUR APU QRQC ATTENDING ONE EVERYDAY
ON FRIDAY, PLANT LEVEL QRQC TO
REVIEW ALL CUSTOMER ISSUES AND FILL-UP WEEKLY REPORT
SHARE EXPERIENCE BETWEEN APUs
REVIEW TRANSVERSE PSG PROGRESS

DOING THIS WILL MAKE YOU REACH

LEVEL GREEN ON APU QRQC RODMAP
LEVEL YELLOW ON PLANT QRQC ROADMAP

2017. 11. 03. 07/09/2001 14

 WHO IS ATTENDING QRQC MEETING?
APU QRQC MEETING
WITH PLANT MGR CONTROL
PLANT QRQC MEETING
APU MGR (CHAIRMAN) WITH DIV MGR CONTROL
PLANT MANAGER AND QUALITY MANAGER
(ROTATING IN ONE APU QRQC PER DAY)
APU QUALITY

SUPERVISORS
PLANT MGR (CHAIRMAN)
METHOD DIVISION MANAGER AND
MAINTENANCE DIVISION QUALITY MANAGER,
OTHERS AS REQUIRED (SQA, PROJECT
TEAM, )
(WHEN ON SITE)
PLANT QUALITY MANAGER
APU MGRS
LOGISTICS
OTHERS AS REQUIRED (SQA,
PROJECT TEAM, )
BRANCH MGR AND BRANCH
2017. 11. 03.
QUALITY MGR, WHEN ON SITE15
07/09/2001
QRQC MEETING RESPONSE TO WORDS

I BELIEVE THAT MANY

WHAT IS REALITY? HOW MUCH?
I THINK THAT

WHAT IS REALITY?
SOMEBODY DID THEY
PROBABLY
DID
WHAT IS REALITY? WHO DID?
ROOT CAUSE IS IT SHOULD
WHY DO YOU SAY SO? SHOW ME WHAT IS EVIDENCE THAT
DATA! IT WILL?
I DO NOT KNOW
WHY DONT YOU KNOW?
WHEN WILL YOU KNOW?

CHALLENGE TO GET PRECISE INFORMATION

BUT DO NOT TRY TO CORNER PEOPLE

2017. 11. 03. 07/09/2001 16

QRQC at VIDEOTON

2017. 11. 03. 07/09/2001 17