Defect Escalation Model

Early Warning & Information system For Quality Problems

Simple Rapid Permanent

7/22/2011

1 Sameer Kadam

AIM: - Early detection of the quality problems - Permanent solution in a short period after the detection
Escalation Level Responsible

Defect Escalation Model

0
BCE

Important note: Defined time frames are maximum times. If it is sure that the defined period will be exceeded Escalation is made without waiting.

1
Max. 1 Production Supervisor

2
Coordinator

3
Max. 90
Manufacturing Engineer

4
Max. 120
Section Manager

5
Mxx Deparment manager QMM Department manager

Max Time

Max. 45

1.Defective part
2. Recorded into the tally chart

6. Start simple problem solving activity (Operator+Supervisor)

Yes

Is a deviation from the production plan expected?

No 16. Inspect the reached point and provide detailed expert input to he problem solving Process.

No

Is the red area reached?

Yes

Yes
3. Stop the machine

Can the problem solved? (Max 45 min.) Can be waited for effectivity if very sure of solution max 1 shift.

Is a serious deviation expected in the production plan? Is there risk to stop the customer? Yes 18. Inform the one upper level manager

20. Organising the resource need, Communication with customer side, informing PT if necessary

No

12. Informing the necessary sides (LOG, Assembly)

15. Follow the problem closely If necessary contact machine manufacturer and TEF1

7. Record the measure to the problem tracking form

8 Info to Coordinator (+ TEF1 if neccessary)

13. Relevant section manager informed.

19. Provide organisational support to the problem solving process

4. Give info to Supervisor. (Pull the cord)

9. Keep on production

10. In case of unavailability block all charges and 100% control.

14. Relevant QMM section manager is informed.

17. Inform Cordinator of the situation and give a approximate solution time

5. Keep on production

11. Take the subject to the Go to Genba

7/22/2011

Training should be given to all levels about their duties

Sameer Kadam

Defect Escalation Model

Sample Tally Chart (Step 2 In Flow)

Form Is Used Daily & Designed For Each Machine

7/22/2011

3 Sameer Kadam

Defect Escalation Model

Problem Tracking Form (Step 7 In The Flow)
Defe ctive part amo unt Machine/ Equipment Possible cause Immediate measure Results of immediate action (Sorting etc.) Due date Responsibl e Defect type Date Root cause Permanent measure

7/22/2011

Can Be Used During Daily Meeting On A Review Board

4 Sameer Kadam

Defect Escalation Model

Simple Problem Solving Form (Process 6 In The Flow)

Possible effects which could be changed

Changes on the

Machine
What
(part, type)

Changes on the

Changes on the

Changes on the

Changes on the

Material

Method, Procdures

Measurement system

Human factor

Others

Where
( which machine, place in the machine)

When
(time information)

How much
(quantitiy info)

7/22/2011

Please Fill All Possible Areas

5 Sameer Kadam