LIFE SYSTEM

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version

QRQC

Date
Contacts

QRQC Monitoring and

Coaching

LIFE System Problem Solving QRQC

Monitoring & Coaching
V0
Dec. 2015
Julie Fontana

Manage Topics
LIFE
System

Problem Solving

V0

QRQC Monitoring & Coaching

QRQC

1)
Objectives

2)

Key Points
2

To guide the team on the proper use of the methodology to be able to identify root
causes and eliminate defects
To develop the culture of QRQC at all levels of the organization with appropriate
support and tools

The Process Engineer (PE) role:

The PE has a key role to play in the monitoring of all opened QRQCs his/her scope by the
implementation of a daily QRQC review in the workshop with the leaders.

The PE should provide technical support to the leader in the analysis to identify the root
cause.

The PE also should help the leader to improve existing standards when deviations are
recurrent and create new standards when missing.

He/she is the one to set the alert levels (based on historical datas or targets) depending on
the amount of QRQC the team can manage.
The Supervisor role:

The supervisor should be the guide and facilitator for the teams in the problem solving.

The review of the workshop QRQC board is part of his/her daily routines.

He/she is in charge of escalating the QRQC and liaise with other resources out of his
department.

CONFIDENTIAL ESSILOR 2014 Internal use only - All rights reserved Do not disclose, copy or distribute

Manage Topics
LIFE
System

Problem Solving

V0

QRQC Monitoring & Coaching

QRQC

1)
Objectives

2)

To guide the team on the proper use of the methodology to be able to identify root
causes and eliminate defects
To develop the culture of QRQC at all levels of the organization with appropriate
support and tools

The Production Manager role:

He/she is the referent in the problem solving approach on the shop floor.

He/she should have a global vision of all QRQCs ongoing (during the daily production
meeting) and report on it during the plant meeting.

He/she validates with the QA Manager the alert levels set by the area Process Engineers,
depending on the amount of QRQC the teams can reasonably manage at each level.

His/her main roles are:

To set the right priorities and arbitrate resources for all QRQCs.

To challenge the teams on the use of the methodology.

The CI Manager role:

He/she is the support to the Production Manager on the methodology and the escalation
process.

The QA Manager role:

He/she takes the lead on escalated QRQCs when an 8D is needed.

He/she validates with the Production Manager the alert levels set by the Process
Engineers, depending on the risks level for the customers.

Key Points

CONFIDENTIAL ESSILOR 2014 Internal use only - All rights reserved Do not disclose, copy or distribute

Manage Topics
LIFE
System

Problem Solving

V0

QRQC Monitoring & Coaching

4

QRQC
Leader

Filter of
standards
(Alert to
Step 2)

Opens QRQC, collects defective parts

and completes Problem Description
(Step 1) with concerned operator(s)
within 30 min from alert.
Checks for deviations to any relevant
standards , adjusts and fills in QRQC
form (Step 2) within 2 hours from alert
Monitor Actions for Step 2: Come back
to Standards until end of Shift.
Posts the QRQC form on the board
and informs Process Engineer

Structured
Problem
Solving
(Step 3 to
7)

If deviation to standard is found,

adjusts and call QRQC Meeting for
Root cause Analysis and Corrective
actions.
Informs next shift leader and monitor
Actions Until Step 7 within 2 days.
If no deviation to standards,
requests support from Process
Engineer to do the analysis (Step 3 &
4)
Creates OPL with leader and CI
manager based on lessons learned
(summary) of closed QRQCs

Process Engineer (PE)

Supervisor

For any new QRQC (within the shift):

Checks step 1: looks for proper
description and sketch of defect.
Analyzes the defective lens in case of
doubt.

Computes the alert levels per defect

based on past 2 weeks performance to
ensure the number of QRQC will be
manageable by the team ( 1 day)

Checks step 2: if recurring deviation to

standard, challenges the standard and
updates it. If new standard is needed,
supports the leader to create it.

Daily checks the QRQC board in the

area before Production meeting and
reports numbers during the meeting.

Supports the leader in the identification

of the possible causes / root cause
based on experience and previous
problem solving lessons learned.
Supports the leader to define and
prioritize the corrective actions.
Creates OPL with leader and CI
manager based on lessons learned
(summary) of closed QRQCs

Daily checks analysis method (proper

use of Ishikawa, 5 Why) and relevance
of actions vs causes.
Challenges the team if results are not
effective.

Participates into an analysis with

leader and PE at least once/week on
ongoing QRQC (6 days).
Requests for escalation on aging
QRQCs (>6 days)

CONFIDENTIAL ESSILOR 2014 Internal use only - All rights reserved Do not disclose, copy or distribute

Manage Topics
LIFE
System

Problem Solving

V0

QRQC Monitoring & Coaching

5

QRQC
Production Manager

Filter of
standards
(Alert to
Step 2)

Validates, with the QA manager, the

alert levels computed by the
supervisors (based on past 2 weeks
perf) to make sure the number of
QRQCs will be manageable.
Asks his/her supervisors for daily
reporting of the number of QRQCs
within their scope.
Challenges the team on the number of
QRQCs opened (1/day), the number
of standards created/updated
For ongoing QRQC (6 days) checks
for resource needs and prioritizes
QRQCs across areas.

Structured
Problem
Solving
(Step 3 to
7)

Challenges the supervisors on the

efficiency of the QRQCs (% solved
within 2 days, % aging, recurring
QRQCs)
Once per week, takes 2 aging QRQC
(based on priorities) and
challenges/guides the teams on the
analysis methodology and actions
verification.
Requests for escalation to 8D on aging
QRQCs

CI Manager

QA Manager

Provide initial training and refresher on

QRQC to all
leaders/PE/supervisors/Production
manager

Validates, with the production

manager, the alert levels computed by
the supervisors (based on past 2
weeks perf) to make sure the number
of QRQCs will be manageable

Ensures the QRQC boards are in place

in each area and followed (include in
Kamishibai)
Helps on the use of the QRQC
template and improves the template if
needed.

Supports the process engineers and

supervisors to compute the efficiency
of the QRQC
Supports the production manager in
his/her weekly coaching on QRQC
(stay focused on the proper use of
methodology and not discuss technical
causes/actions)

Ensures that updates to standards or

new standards do not create risk for
customers . And specifically for PCP
ensures that the information is given
back to GE.

Can support the production manager in

the weekly QRQC coaching on
methodology use.
Takes the lead on 8D for escalated
aging QRQCs.

Can create OPL with process engineer

and leaders based on lessons learned
(summary) of closed QRQCs

CONFIDENTIAL ESSILOR 2014 Internal use only - All rights reserved Do not disclose, copy or distribute