ZERO QUALITY FAILS L6 PROJECT
3. ESTABLISH LONGTERM CI QUESH ON L6
JUNE 2013
PROJECT PLAN
PROJECT OBJECTIVES
• “3. Establish a long-term method to generate + share L6
QUESH learning’s from the past, present + future across all
shifts.”
“OUR ONLY PROTECTION AGAINST HUMAN ERROR IS
TO DESIGN AND MANAGE OUR BUSINESS PROCESSES
SO WE PROTECT OUT MACHINES AND BUISNESSES
FROM OURSELVES”
Smith, Dr David J., “Reliability and Manintainbility and
Risk”, Elsevier, 2005
http://www.lifetime-reliability.com/tutorials/reliabilityengineering/Human_Error_Rate_Table_Insights.html
MEETING OBJECTIVES
• MEETING OBJECTIVES
• 1. AGREE ON L6 PILOT BOARDS
• 2. SHARE BIGGER PICTURE VISION OF THE WIDER CI
PROCESS
1.PROBLEM
• Operators not listened to
• We are setup to deal with 24 Issues – Longerterm
Issues are not easily resolved
• Reactive Vs Proactive
• Communication needs to be easier
• Follow up
2. VISION
• Top Issues Machine Board
- Operator Outlet
- See they are being listed to
- Hub for Zonal Reviews
• Top Issues Line Board
- Shopfloor Hub for Reconnects + Management Reviews
- High level Summary + Detail in ETQ’s / other systems
- Shopfloor Challenge Sheets – “Can you fix it? – No one
else can?”
• 8D Sheet part filled out by support functions
2. VISION
• Top Issues Machine Board
- Operator Outlet
- See they are being listed to
- Hub for Zonal Reviews
• Top Issues Line Board
- Shopfloor Hub for Reconnects + Management Reviews
- High level Summary + Detail in ETQ’s / other systems
- Shopfloor Challenge Sheets – “Can you fix it? – No one else
can?”
• 8D Sheet part filled out by support functions
3. DEFINITION
• NOT
- a problem solving tool
- NOT a Database
• IS
-
Visual Management Tool
Highlights Longerterm Issues
tracks Actions
Drives Continuous Improvement
4. CONTINUOUS IMPROVEMENT LOOP
• Problem Solving is the same process for
Safety, Quality + Production
• Different Format’s of the same
• 4 C’s
• 8D,
• RCA Forms,
• ETQ’s
4. CONTINUOUS IMPROVEMENT LOOP
NON COMPLIANCE PROCESS
IMPROVEMENT
CHECK
PASS
FAIL
WHAT ? WHEN?
1.FLAG
2. CONTAIN
QC / OP
·
·
MISSED CHECK
FAILED CHECK
QC
·
·
VALIDATE RISK
FREEZE
·
·
·
WHY?
MASS LEARNING
3. INVESTIGATE
4. CAUSE
QC
TL
NO. OF CHECKS
TIMES
OPERATORS
·
·
·
1. PROCEDURE
2. PEOPLE
3. MACHINE
• Aim to Impregnate the CI Loop Picture
• in people’s mind’s eye to see end goal
• Eliminates SILO thinking
5.PREVENT
TL
MASS
COMMUNICATION
5. VISION LONGTERM PROCESS
• CI Loop Proceduralised - Support
Functions streamline steps to make the
flow easy
• Teams identify Bottlenecks
• Spreadsheet to track details – linked to
ETQ’s
5. VISION LONGTERM PROCESS
LINE BOARDS
MACHINE BOARDS
NON COMPLIANCE SPREADSHEET
ETQS
QUALITY
SAFETY
6. FIRST STEP MACHINE BOARDS
FUTURE
NOW
6. FIRST STEP LINE BOARDS
FUTURE
NOW
7. DECISIONS
•
•
•
•
1.Boards Made up
2. Next Meet up
3.?
4.?
8. ACTIONS
•
•
•
•
•
•
•
•
•
1. Shopfloor Feedback
2. Boards Made
3. Boards Installed
4. General Non Compliance Procedure
5. Problem solving Sheets
6. Process Flows – Safety
7. Process Flows – Quality
8. Process Flow – Engineering
9. Safety Non Compliance Procedure
GC
GC
GC
GC
Shaun?
GC
GC
Shaun?
WHAT AM I WORKING ON?
• REDUCING THE RISK OF QUALITY FAILS ON LINE 6
-
PEOPLE + TOOLS
PROCEDURES
MACHINES
MATERIALS
• WHICH ONE IS THE MOST IMPORTANT?
- YOU!!
• SUCCESSFUL TOOLS CAN BE ROLLED OUT TO
OTHER LINES LATER
WHY LINE 6?
• Production are not following robust Quality
Procedures on L6 and there are not adequate
failsafes against Quality Issues.
HOW MANY QUALITY FAILS IN LAST 4 YRS?
• 101 CONSUMER COMPLAINTS
• 81 INTERNAL COMPLAINTS
• Any further complaints will damage the brand,
site reputation and Job Security
HOW MANY DIFFERENT TYPES OF FAIL ON L6?
POTENTIAL FAULTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20
21
22
23
24
25
26
27
28
WRONG GLASS
DAMAGED / OUT OF SPEC GLASS
DIRTY GLASS (CORRODED PRODUCT)
WRONG CLOSURE
DAMAGED / RUSTY CLOSURE
MISSING BOTTLE BBE
WRONG NECK BBE
UNDERFILLED
LEAKING / NOT SEALED
WRONG FLAVOUR (right closure + bottle)
STRANGE TASTE / APPEARANCE
MICRO
WRONG CARBONATION
WRONG PROPORTIONING
FOREIGN MATTER - FOOD SAFETY
FOREIGN MATTER - SAFE
INCORRECT SLEEVE
WRONG NO. OF BOTTLES IN A PACK
INCORRECT FILM (PRICEMARKED?)
BAGGY PACK
BULLSEYE TOO BIG
DAMAGED PACKS
INCORRECT PACK CODES (BBE)
INCORRECT TRAY (marked with wrong product)
TRAY DAMAGED / OUT OF SPEC
UNSTABLE PALLET
WRONG NO OF PACKS ON PALLET (& WRONG FORMATION)
WRONG PALLET BAP / DBW
WRONG LOCATOR
TOP 4 RISK ON L6?
LINE 6 FAULT RISK LOG
POTENTIAL FAULTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1. WRONG GLASS
DAMAGED / OUT OF SPEC GLASS
2. DIRTY GLASS (CORRODED PRODUCT)
WRONG CLOSURE
DAMAGED / RUSTY CLOSURE
3. MISSING BOTTLE BBE
WRONG NECK BBE
UNDERFILLED
LEAKING / NOT SEALED
WRONG FLAVOUR (right closure + bottle)
4. STRANGE TASTE / APPEARANCE
MICRO
WRONG CARBONATION
WRONG PROPORTIONING
FOREIGN MATTER - FOOD SAFETY
FOREIGN MATTER - SAFE
INCORRECT SLEEVE
WRONG NO. OF BOTTLES IN A PACK
NO OF COMPLAINTS IN
RISK = SEVERITY X LIKLIHOOD
LAST 4 YEARS
CONSUMER
8
7
92
2
INTERNAL
(FST )
RISK
SEVERITY
LIKLIHOOD
OF
CONSUMER
5
HH
H
H
M
M
M
H
M
H
M
H
L
M
M
L
H
H
M
M
H
L
M
H
L
L
M
L
M
H
L
H
H
M
L
M
L
L
M
L
L
M
L
M
H
L
L
M
L
L
M
L
L
M
L
3
5
11
1
3
1
9
33
1
1
1
3
CONTINUOUS IMPROVEMENT
•
•
•
•
COMMUNICATION TOOLS (FOR OPERATOR)
SIMPLE QUALITY AUDIT TOOLS (FOR TL)
NON COMPLIANCE SYSTEM REVIEW
MACHINE FAILSAFES
“OUR ONLY PROTECTION AGAINST HUMAN ERROR IS TO
DESIGN AND MANAGE OUR BUSINESS PROCESSES SO WE
PROTECT OUT MACHINES AND BUISNESSES FROM
OURSELVES”
Smith, Dr David J., “Reliability and Manintainbility and Risk”, Elsevier, 2005
http://www.lifetime-reliability.com/tutorials/reliability-engineering/Human_Error_Rate_Table_Insights.html