1. Koyo Torrington Seven Step
Abel Acuña
January 21th 2010

2. Top level Seven Step process
Data
Pareto
Prioritize
Scorecard
Closure
Paynter
Solve

3. Development Process Koyo Seven Step
Supplier process “Gain Control”
Seven Step focuses supplier and SQD /SQA resources
Utilize the data effectively Pareto high impact
Establish supplier commitment to “Improve”
The supplier is part of the Value Stream within Koyo’s manufacturing operations
Standardize lessons learned
Develop a close loop
Read across commodity
Eradicate defects
Focus on prevention vs. detection in the process
Sorting alone will not achieve a stable process
Errors can occur and will escape
Integrate into the APQP model
Go back to the PFMEA and control plan and build on known risk factors

4. Development Process- Raise the bar
Summary
Build accountability
It takes leadership at all levels
Protect the supply chain, while your process is being stabilized
Leverage value stream network
SQD focus is to work with other functional areas to balance the “production cell” in the value stream
Treat the supplier as if the Value Stream was within Koyo’s manufacturing plant
We are dependent on our suppliers performance to quality and service

5. Supplier 2010 Performance DMR

6. Supplier – Name Quality Analysis Process Pareto

7. #1 Issue – Defect Pareto Level II

8. Root Cause Verification – Proof
#1 Issue – Defect
Root Cause Analysis -
Issue
Root Cause Verification – Proof
Actions -
Action
Target
Date
Responsibility
Effect
Root Cause Analysis – i.e. Through Six Sigma analysis root cause was verified as rack condition, describe or show data to support that conclusion
Actions – list the top 3 actions addressing the root cause, including timing and responsibility and anticipated EFFECT on PPM

9. #1 Issue – Defect Deployed CS1 Installed Level 2 Poka-yoke
2007 Forecast of C/A Impact
Deployed CS1
Installed Level 2 Poka-yoke
Establish Predictive Tool Maintenance Schedules
The waterfall should PROJECT PPM performance as a result of the specific actions described on the previous slide

10. #2 Issue – Defect

11. Root Cause Verification – Proof
#2 Issue – Defect
Root Cause Analysis -
Issue
Root Cause Verification – Proof
Actions -
Action
Target
Date
Responsibility
Effect
Root Cause Analysis – i.e. Through Six Sigma analysis root cause was verified as rack condition, describe or show data to support that conclusion
Actions – list the top 3 actions addressing the root cause, including timing and responsibility and anticipated EFFECT on PPM

12. #2 Issue – Defect 2007 Forecast of C/A Impact
The waterfall should PROJECT PPM performance as a result of the specific actions described on the previous slide

13. Overall Waterfall CS1 Containment Level 2 Poka-yokes
New lever packaging
The individual actions should be deducted from the baseline (in the month they occur) to achieve the projected overall PPM.

14. 2007 Supplier Effectiveness Paynter Chart
Corrective Action Implemented
Corrective Action Not Effective
Corrective Action Effective