QSB Quality System Basics & Q7 tools in practice

QSB Quality System Basics & Q7 tools in pracice

Introduction
QSB is a kit of tools and methods which provide a fast response in the case of claim. It also avoids our customers getting defective parts. 1. Fast reponse 2. Control of nonconforming products 3. Standardized work 4. Standard operator training 5. Risk Reduction (RPN) 6. Error proofing verification 7. Layered Audits 8. C.A.R.E 9. Lessons learned Corrective action

Preventive action

QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

is a system that standardizes reactions to significant internal and external quality failures, a fast reponse meeting shall be held daily to review the significant quality concerns gathered by Quality, is a communications meeting, not a problem solving meeting. It can be a 10 - 20 minute stand up meeting held on the shop floor or in a production conference room, is a manufacturing review meeting owned by manufacturing and supported by Quality, Engineering, Maintenance, etc
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QSB Quality System Basics and Q7 tools in pracice

Introduction
1. Fast reponse

At the Fast Response meeting, leadership shall

Designate a leader (owner) for each concern/issue. Assign owner report out for next meeting

Owners shall be responsible for assuring all problem solving and exit criteria are met in a timely manner. Owner report out shall include updates on the following:
Fast Response Tracking Sheets Standardized Work Instructions Problem Solving Form(s) PFMEA Control Plan Layered Audit Workforce Notification
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QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

Report out to Leadership is scheduled on the Fast Response tracking form as deemed necessary. The Fast Response Tracking form should be part of a visual management system. The format should be displayed as large as is practical in the meeting area.

QSB Quality System Basics & Q7 tools in pracice

Introduction
1. Fast reponse

QSB Quality System Basics & Q7 tools in pracice

Introduction
2. Control of nonconforming products

QSB Quality System Basics & Q7 tools in pracice

Introduction
3. Standardized work

QSB Quality System Basics & Q7 tools in pracice

Introduction
4. Standardized operator training

QSB Quality System Basics & Q7 tools in pracice

Introduction
5. Risk reduction (RPN) operator training

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QSB Quality System Basics & Q7 tools in pracice

Introduction
6. Error proofing verification

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

Extract from DC specific requirements for use with ISO TS 16949

QSB tool # 6 Error proofing verification

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QSB Quality System Basics & Q7 tools in pracice

Introduction
7. Layered audits

Extract from DC specific requirements for use with ISO TS 16949

QSB tool # 2 Control of nonconforming products QSB tool # 1 Fast reponse

QSB tool # 9 Lessons learned

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QSB Quality System Basics & Q7 tools in pracice

Introduction
8. C.A.R.E CUSTOMER ACCEPTANCE REVIEW & EVALUATION

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QSB Quality System Basics & Q7 tools in pracice

Introduction
9. Lessons learned

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

17

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

19

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

20

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Run chart

Inspection chart

Pareto analysis

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

Pareto analysis

Histogram

22

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

25

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

26

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

27

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

28

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

29

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

30

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

31

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

32

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

8-D-Report

33

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

8-D-Report

QSB 1 Fast response (Fast Response is the tool monitoring all other activities)

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QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

35

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

36

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

37

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

38

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

39

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

40

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

41

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

42

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 2 Contr. of NC products

8-D-Report

PFMEA

43

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

PFMEA

44

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

PFMEA

QSB 6 Error proofing Verification

45

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

PFMEA

QSB 6 Error proofing Verification

Controlplan

46

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

PFMEA

QSB 6 Error proofing Verification

Controlplan

47

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

48

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

49

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 5 Risk reduction RPN

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

50

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 8 C.A.R.E.

QSB 5 Risk reduction RPN

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

51

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 8 C.A.R.E.

QSB 5 Risk reduction RPN

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

52

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 8 C.A.R.E.

QSB 5 Risk reduction RPN

QSB 7 Layered audits

PFMEA

QSB 6 Error proofing Verification

Controlplan

QSB 9 Lessons learned

53

QSB Quality System Basics & Q7 tools in pracice

Quality System Basics & Q7 tools in practice

The basic 7 quality tools
Record failures Squeeze & picture failures Find out root cause & solutions Action plan

Control chart

Inspection chart

Pareto analysis

Histogram

Ishikawa diagram

5 why analysis

Action plan

Internal failure or customer complaint

QSB 3 standardized work

QSB 2 Contr. of NC products

8-D-Report

QSB 4 Standard oper. training

QSB 8 C.A.R.E.

QSB 5 Risk reduction RPN

The process state of the green colored boxes is indicated here

PFMEA

QSB 7 Layered audits

QSB 6 Error proofing Verification

Controlplan

QSB 9 Lessons learned

54