Q.R.Q.C Quick Response Quality Control M Davies - Aug 2009

(Quick response Quality Control) NO IMAGINATION, JUST FACTS. WHAT IS QRQC ? (Quick response Quality Control) QRQC is based on "San Gen Shugi". San Gen Shugi is a Japanese expression meaning "the three reals": Gen-ba: the real place  Gen-butsu: the real part  Gen-jitsu: reality Apply QRQC principles in the field each day, and by learning from experience in the field: NO IMAGINATION, JUST FACTS.

Data driven activity based on either Voice of the customer Q.R.Q.C Methodolgy Data driven activity based on either Voice of the customer Voice of the process

HOW DOES QRQC WORK ? Multi Skilled Teams (QA/Eng./Prod./Logistics) Daily Meetings to evaluate Concerns (Data Collection) Top 3 Concerns Targeted Quality Tools used to investigate Root Cause of Concerns Team members Tasked with activities Aggressive task completion times ( TODAY !!!) - CONTAINMENT Feedback on Task progress in Daily meeting Track & Monitor Improvements – Display - Highly Visible to all Update data record sheets to capture Improvements - ratchets Brief whole Team on introduced changes – inc. operators

OBJECTIVE not SUBJECTIVE QRQC in Action The 1st step in QRQC is to agree STANDARDS Standards agreed with customer or set Internally Standards make Quality Control OBJECTIVE not SUBJECTIVE

QRQC in Action The 2nd step in QRQC is to ensure TRACEABILITY Traceability back to Shift, Operator & Time of Production This would highlight any Special Cause events

QRQC in Action Data Driven Decision The 3rd step in QRQC is ‘Monitoring & Data Collection’ Any Root Cause Analysis must use Accurate and current data Utilise 8D Problem Solving Core Tools to be used for Root Cause Analysis Two Failure Types – Process Failure – How defect made Inspection Failure – Why Not Deteceted Data Driven Decision

THE MAN ON THE JOB KNOWS THE PROCESS BEST QRQC in Action The 4th step in QRQC is FEEDBACK Feedback to Operators all Concerns Visual Management THE MAN ON THE JOB KNOWS THE PROCESS BEST

Display Highly Visible for all to see QRQC in Action The 5th step in QRQC is to IMPROVE THE PROCESS Any Improvements introduced have to be highlighted to all and any Process control documentation updated with any new parameters (Ratchet Device to hold gains) E.g Countermeasure Audits Display Highly Visible for all to see

QRQC SUMMARY The QRQC attitude: Quick Response Quality Control How can we make more progress in quality? The future is decided in the field, by being in close touch with day-to-day production. Commitment from everybody is vital. The principle of QRQC as applied by My Company. QRQC is a change of culture, of mindset. QRQC is not a tool or a system. It is a quality culture. Key factors for success: management commitment to the change of culture. The key question: What did you improve yesterday? Why QRQC? QRQC improves responsiveness and efficiency in problem-solving. How? By defining priorities and assigning responsibilities.