Jidoka for Quality Improvement Lean en France, 20 May 2011 Yves Mérel, FCI Group Lean Director

2 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement FCI b ackground and profile Creation in 1988 by Framatome for diversification outside nuclear field 20+ acquisitions and 20+ years later, FCI is one of the largest global connector manufacturers November 3, 2005: FCI is acquired by Bain Capital, a private investment fund With operations in 30 countries and a turnover of 1.3 billion € in 2010, FCI is a leading connector manufacturer Its 14,000 employees are committed to providing their customers with high-quality and innovative products for a wide range of consumer and industrial applications

3 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement A variety of solutions and products Microconnections connectors Motorized Vehicle connectors Electronic connectors

4 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 24 manufacturing sites and 14 R&D centers Europe 7 manufacturing sites 1 Corporate Research Center 6 R&D centers Americas 5 manufacturing sites 2 R&D centers Asia 12 manufacturing sites 6 R&D centers

5 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement FCI Lean Initiatives Every department is monitoring a continuous improvement process contributing to customers satisfaction and costs reduction People Empowerment for Accidents, Absenteeism and Turnover Quality for Customers Complaints and Non Right First Time Supply Chain for Late Deliveries, Inventory and Distribution Lead Time Supplier Development for Receiving Frequency, Complaints, Gap to AVL Process Design for Bottlenecks and Idle equipments Product Development for Time To Market and Design Changes Customer Focus for Time To Quote and Customers Disappointments

6 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Continuous Improvement on Quality

7 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Customers Quality Feedback We discover our actions impact 3 months later

8 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Quality Improvement Tools Complaint 8D and Quality Wall In case of complaint, 8D to make sure this type of problem won’t occur anymore For any Quality risk identified, make sure people are able to check all parts Red Bin Review and Quality Workshop Review daily every red bin, to solve quickly many stupid defects Workshop to test root cause hypotheses on most complex problems Go 1 st Part and 1 st Defect Stop Before starting to produce, check if there is a fair chance to produce good parts While producing, stop at 1 st defect to allow people to investigate the cause

9 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Quarterly 8D audit of shop floor evidences D1: Team Cross-functional including operators D2: Problem Defective parts available and data on “who, when, how many, what, where, how, why” D3: Containment (within 24 hours) Inspect all stocks, implement Quality Wall, 1 st Defect Stop, and Red Bin Review Analyze several non-detection causes from “man, machine, material, method, environment” through 5 Why and test of hypothesis to reproduce non-detection D4: Root causes Quality workshop to analyze several causes from “man, machine, material, method, environment” through 5 Why and test of hypothesis to reproduce defect D5: Corrective actions Robust actions (poka yoke) implemented on time D6: Effectiveness Actions correctly implemented and measurable impact D7: Prevention Risk analysis, Go 1 st Part, Preventive Maintenance, Training check, Mgt routine... Applicable on similar product and process D8: Closing By management based on shop floor evidences

10 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 8D benchmark From 52% to 87% of rigor definitively fixes many problems and develops customers confidence

11 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Quality Wall Visible and Standardized Inspections

12 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 22% DL inspecting with 3% in Quality Walls Overall less inspections (+233 quality wall -441 random) Less people, but better controlled inspection

13 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement The Red Bin is a tool: by looking into it, we see lots of simple and stupid problems easy to fix quickly Red Bin Review and Quality Workshop At the Pareto “head” we have well known problems occurring very often but complex to fix Usually manufacturing is adapted to avoid customer complaints (containment actions, in line inspection, people awareness), but it costs At the Pareto “tail” we have rare and stupid problems, but customers often received such defective products Lots of Internal PPM: Quality Workshop Lots of Complaints: Red Bin Review Typical internal defects Pareto

14 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Go 1 st Part working standard checklist

15 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 1 st Defect Stop with on line detections

16 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement First defect stop and red bin review implementation on Machine 57 PPM before: PPM after: OEE before: 77 % OEE after: 78 % Epernon factory example

17 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Main difficulties: Needs of resources to quickly implement the corrective actions Cannot be done on bottleneck machines since temporarily reducing the output Organization modifications: Dedicate 2 persons to work on 1st Defect Stop implementation: 1 for machine software modification and immediate actions 1 for immediate actions They move from one machine to another after 2 weeks Epernon factory example

18 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Besancon factory example Video on 1st Defect Stop and Red Bin Review

19 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement Immediate feedback from on line detection Process design minimum requirements for Jidoka: 1- Detections exist for every occurring defects On product, on process, manual inspection, sampling (non-random defect) 2- Detections are capable Reliability & Repeatability analysis 3- Detections are done at every process step Before adding more value to the defective part 4- First Defect Stop Immediately before the clues disappear 5- Defective parts removed manually To get a chance to go and see the defect causes

20 Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 150 to 40 complaints/month within 3 years 8D - Quality Wall - Red Bin - Workshop - Go 1 st Part - 1 st Defect Stop