Layered Audit Process
Jan 27th,2004
QFS Conference
Elena Donahue
1
What is a Layered Audit?
Is a group of audits performed by the site personnel to verify that operational
standards such as:
Work Instructions
Procedures
Inspections
Tools
Error Proofing Devices
FIFO
Others… are being performed and followed up
in a quality and safe manner.
An audit to assure non-conformances or abnormalities to the quality system are
identified and corrected
Conducted by various levels of plant leadership
Covers the entire manufacturing facility
2
Purpose
Is an avenue for
leadership to coach
and engage all the
employees in the
organization.
Remove
roadblocks to
correcting
unsatisfactory
items
3
Reduce the number of
non-conformances to
existing procedures
and policies
Increase the
frequency at
which various
levels of
management
perform audits
Standardize
types of items
audited /
checked by plant
personnel
Scope & Benefits:
Applicable to all operations that are deemed critical for quality,
reliability, performance etc.
Interaction
& coaching
between the
Leadership
and the
Operator
Consistency
of the
standards
among
departments
Operator
Awareness
People
Enthusiasm
&
Communication
FTQ (First Time Quality)
COST
4
Customer
Satisfaction
through
higher “built
in” quality
To do list:
Determine the assembly process/system to be monitored under
layered audits.
This determination is based on quality data, process capabilities
(including operator sensitive operations), safety or high impact
processes (process that if not followed properly could lead to a
major product deficiency).
Determine the method and frequency of auditing.
Determine the main items to revise / audit.
Define the process for immediate correction, monitoring &
implementation of non-conformance / abnormal conditions.
5
Things to know:
A common checklist of items is developed for each operation.
Audit Frequency is determined for each layer, e.i.:
Leadership
Team Leader / Group Leader
Area Manger / Quality Manager
Plant Manager
Frequency
Daily (3 x shift)
Weekly
Bi-Monthly
The layered audits are performed at pre-determined time by leadership. The
Operator is aware of audit.
This is NOT a surprise audit.
The auditor reviews the checklist and determines if the element is being followed.
Results of the audit are captured on the checklist. When non-conformances or
abnormalities exist; the correction and ownership is also recorded.
6
LAYERED AUDIT CHECKLIST
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Layered Audit
Check List
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Communication
Workplace & Environment
Set-Up
Operator Certification
Standardized Work
Control Plan
First Time Quality
Measurement Systems
Containment/Rework
PM Activities
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
7
816F1 – Rev Date: 12-7-01
Section #1
Communication
 Interview Operators
 Awareness of quality issues (formal and
informal)
 Knowledge of alarm limits
 Use of control plans
LAYERED AUDIT CHECKLIST
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up
 Verify that quality alerts are
posted

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
8
816F1 – Rev Date: 12-7-01
Section #2 Work Place Organization
& Environment
 Check all material
identification
 Incoming
 In-process
 Outgoing
 Re-work
 Scrap
 Containment
 Verify material flow (FIFO)
 Verify that proper containers
are being used
 Observe overall
environmental conditions
 Verify error-proofing is in
place and functioning
9
- Including level error proofing
LAYERED AUDIT CHECKLIST
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
816F1 – Rev Date: 12-7-01
Section #3 Set up
 Confirm that current setup
documentation was used
LAYERED AUDIT CHECKLIST
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment
 Make sure that changeover
instructions were used

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up
 Verify that control plan
requirements are followed
 Error Proofing / Gauging / Masters used
 Visual aids available
 Corrective action for any item found to
be out of control on set-up
 All previous stock purged from cell / line
 All KPC’s/KCC’s charted and abnormal
or out of control conditions addressed..

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
10
816F1 – Rev Date: 12-7-01
Section #4 Operator Certification /
Standardized Work
LAYERED AUDIT CHECKLIST
 Are Operators and Supervisors
following standardized work?
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment
 Are Operators certified on the
job?
 How do you know?

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work
 Are there operators in training?
 Is there a training plan?
 What are the requirements for
certification on a job?

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
11
816F1 – Rev Date: 12-7-01
Section #5 Control Plan
LAYERED AUDIT CHECKLIST
 Verify required control plan
checks
 Frequency
 Sample size
 Fixtures / tooling
 Form
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work
 Confirm that checks are within
specification and normal
operating parameters.

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework
 Make sure that reaction plans
are being followed
12

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
816F1 – Rev Date: 12-7-01
Section #6 FTQ (First Time Quality)
LAYERED AUDIT CHECKLIST
AUDITOR:
 Is FTQ data being
collected at all reject points
in the system?
 Are alarm limits visually
displayed?
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up
 Are alarm limits being
adhered to?
 How would you know?
 Is FTQ data posted?

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems
 Are rejected parts properly
identified?

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
13
816F1 – Rev Date: 12-7-01
Section #7 Measurement Systems
LAYERED AUDIT CHECKLIST
AUDITOR:
 Are error proofing verification
checks complete?
 Are measurement devices being
used properly?
DEPT:
SHIFT:
Process Element
Y N

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Is in-process & outgoing material properly ID’d?
Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?
 Error proofing devices

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
 Error detection devices
 Gages

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
 Available at the workstation
 Numbered
 Calibrated
Date
Corrected
Workplace Organization & Environment

 Are measurement devices:
Comments
Communication

 Fixtures
DATE:
LINE/MACHINE/CELL:
Set-Up
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
14
816F1 – Rev Date: 12-7-01
Section #8 Containment & Rework
 Verify that containment
information is recorded
 Confirm that in-plant rework /
teardown is completed per
instructions
 Verify that everything is labeled
correctly
 Make sure that proper containers
are used
LAYERED AUDIT CHECKLIST
AUDITOR:
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
15
816F1 – Rev Date: 12-7-01
Section #9 Preventive Maintenance
LAYERED AUDIT CHECKLIST
AUDITOR:
 Are PM activities verified as
complete?
 Determine which PM activities
have occurred
 If PM is not on schedule,
determine why
DEPT:
DATE:
LINE/MACHINE/CELL:
SHIFT:
Process Element
Y N
Comments
Date
Corrected
Communication

Are employees aware of any recent PRR’s / quality issues? Is a
Quality alert posted for any recent WFCC’s/quality issues?

Any observations from operator interviews or other input
communicated?
Workplace Organization & Environment

Is in-process & outgoing material properly ID’d?

Any mixed or wrong material found in process?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a
designated area?

Are proper containers used?

Is material in containment properly identified & segregated?

Are working and environmental conditions suitable?
Set-Up

Are Masters being run if required by the Control Plan?

Are Visual Aids (required by the Control Plan) available?

Is Set-up current per routing?

Are Change Over instructions followed?
Operator Certification/Standardized Work
 How was the product verified
after PM activities were
complete?

Are Operators following standardized work?

Are Operators certified on the job?
Control Plan

Are control plan checks made at the proper frequency, with the
correct sample size and on the correct form?

Are product/process checks within specification? If not, are
reaction plans being followed?
First Time Quality

Are alarm limits being adhered to?
Measurement Systems

Are Error Proofing verification checks complete?

Are Error Proofing devices, gages and fixtures used properly?

Are all gages (required by the Control Plan) available at the
workstation? Are the gages numbered, calibrated and match the
Control Plan? Are significant process events recorded?
Containment/Rework

Is containment information documented when the product is
nonconforming?

Is in-plant rework/teardowns completed per instructions with
proper identification?

Are out-of-spec conditions recorded and corrective actions
documented?
P.M. Activities

Are QNPM/TPM activities verified as complete?
Delphi Energy & Chassis Systems
16
816F1 – Rev Date: 12-7-01
Layered Audited Chart (accessible to all)
Dept: 30-16
Area: Cell 1
Date/Shift: 11/14/01/ - 1st
Auditor: J Peters
Completed
Dept: 30-16
Area: Cell 2
Date/Shift: 11/12/01 – 2nd
Auditor: T. Fairbanks
Completed
Dept: 30-16
Area: Cell 3
Date/Shift: 11/12/01 – 32nd
Auditor: J. Stone
Completed
17
Dept: 20-18
Area: K Line
Date/Shift: 11/13/01 – 1st
Auditor: F. Cannon
Completed
Dept: 20-15
Area: Line 2
Date/Shift: 11/13/01 – 2nd
Auditor: J. Keeley
Completed
Dept: 20-15
Area: P Line
Date/Shift: 11/13/01 – 32nd
Auditor: D. Lee
Completed
Dept: 50-01
Area: Press Area
st
Date/Shift: 11/13/01 – 1
Auditor: E. Lopez
Completed
Dept: 50-02
Area: Line 1
Date/Shift: 11/13/01 – 2nd
Auditor: R. Smith
Completed
Dept: 50-02
Area: Line 2
Date/Shift: 11/13/01 – 32nd
Auditor: D. Mitchell
Completed
Layered Audit for Support Areas
(Example)
Problem Description
Problem Case Issued
Plant Quality
Classification
Plant PC&L
Quantity
Problem Case Response
5 Why (3 Legged)
Root Cause
Suppliers
Corrective Action
Problem Case Closure
Validation
Plant Quality
Closure Problem Description
Plant PC&L
 Classification
Plant Audit Teams
Quantity
Plant Quality, Plant PC&L
Supplier Quality Supervisors
5 Why
Validation
Divisional Audit Teams
Customer Satisfaction
Plant Audit Team Results
Supplier Quality
Executive Audit
Customer Satisfaction
Supplier Quality
18
Divisional Audit
Team Results
Layered Audit for Support Areas
(Example)
ProblemDescription Classification
Quantity
5 Why
Corrective Action
PROBLEMCASE NUMBER L1
L2
L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
20030605-190013718
20030722-163717933
20030623-163649456
20030612-192453429
20030116-214711738
20030825-171720160
19
Q&A
20
Quality
PPM
TIME
Cost
First Time Quality
Jan 27th,2004
QFS Conference
Elena Donahue
21
What is FTQ?
First
*Immediate Action
*Containtment
*Alarm
*“Protect the
Customer”
Time Quality is a
measure of the number
of pieces rejected in a
manufacturing process
versus the total number
of pieces attempted.
REJEC
TS
22
*Continual
Improvement
*Reduce Qty. of
rejected parts
*Reduce Operational
Cost
Why?
Because
if we don’t make good parts the
first time, we have to inspect in quality
know inspection is at
best 85% effective
defects
We
inspection
Therefore,
anytime FTQ is
greater than 0, we are
dependent on inspection to
protect the customer
To
reduce manufacturing costs and defects
through continuous improvement (Gate chart)
To
problems
Cost
Customer Satisfaction
monitor process stability and react quickly to potential issues (Alarm
limits and process monitoring sheets)
23
Why to measure FTQ?
»
It is the first signal that a process is out of control
»
It allows us to respond to problems internally before they
reach our customers
»
It measures improvement from corrective actions implemented
If we don’t fix our quality problems internally,
we will never be able to fix our external
customer issues
24
FTQ process:
Problems
Analyze Data
Understand Defects and
Decide the Order of Priority:
4
1
2
3
3
2
2
2
1
1
1
1
A B C D
Assign problems to
Cross-Functional Group:
Select and
Plan the Improvement:
2
25
1
1
1 Right Information
DEFECT
1. ---------------------2. ---------------------3. ----------------------
Fix the Biggest Problems First:
2
2 Right Cause
Responsible
Team Works
Problems
3 Right Timing
Hour
Glass
How to calculate FTQ?
FTQ is reported in parts per million (PPM) defective
It can be measured at any step in the manufacturing process
where parts are rejected especially where the defect is originated.
It is calculated by counting the number of pieces rejected versus
the total number of pieces attempted
The total number of pieces attempted includes all good pieces
produced plus all pieces rejected
Pieces rejected are all parts scrapped or reworked prior to usage
by subsequent processes. The actual calculation looks like this:
Number of Pcs. Rejected
Total Number of Pcs. Attempted
26
X 1,000,000 = FTQ PPM
What to do with the FTQ ppm?
•After FTQ problems have been identified through data analysis,
improvement plans must be developed.
•Track Implementation and actions status.
•Implement Improvement
•Evaluate
•Institutionalize lessons learned
Quality Tools
6 Sigma
Shainin
27
Lean Tools
 Value Stream Mapping
 Workplace Organization (5S)
 Error Proofing
FTQ Gate Chart
X X X F asten ers
T re n d R e p o rt -
T o p H itte r s : L a s t 3 m o n th s
35 0
M o n th y P P M
M o v in g A v e r a g e P P M
30 0
25 0
PPM
20 0
W a rp /B e n t P a r ts
15 0
( 1 0 : 1 R a ti o )
1
W r o n g L a b e l o n C a r to n
1
M a n u f a c tu r in g
1
F o r e i g n M a te ri a l
1
10 0
P ro b l e m A re a / D e fe c t
N o v-0 1
O c t- 0 1
S e p -0 1
A u g -0 1
J u l -0 1
J u n -0 1
M a y-0 1
A p r-0 1
M a r- 0 1
F e b -0 1
D e c-0 0
0
J a n -0 1
5 0
H a n d li n g D a m a g e
0
0 .5
1
1 .5
N o . o f P R /R ' s
C o r r e c t iv e A c t i o n
C u s to m e r
R esp on si b i l i ty
PR O C E SS
F o r e ig n M a te r ia l
H a n d li n g D a m a g e
M a n u f a c tu r in g
In c r e a s e d a u d i ts b y P A L a b
D e lp h i
CW
A u d it o f S u p p l ie r f a c i li ti e s a n d a c t io n s
D e lp h i
CW
In t e r n a l A u d i ts o f m a t e r ia l h a n d li n g te c h n i q u e s
D e lp h i
JK
In c r e a s e d a u d i ts b y P A L a b
D e lp h i
CW
A u d it o f S u p p l ie r f a c i li ti e s a n d a c t io n s
D e lp h i
CW
In t e r n a l A u d i ts o f m a t e r ia l h a n d li n g te c h n i q u e s
D e lp h i
JK
P a r t S p e c i f ic C o r r e c t iv e A c ti o n s
D e lp h i
PM
In c r e a s e d a u d i t s b y M N P
D e lp h i
CW
Im p l e m e n t s in g l e l s o u r c e la b e l r e s p o n s ib il it y p e r s h if t
D e lp h i
VL
L A B E L IN G
28
W ro n g L a b e l o n C a rto n
Date
FTQ Improvement Process
Analyze Data
Record Data
Select and Plan Improvement
Implement Improvement
Evaluate
Institutionalize Lessons Learned
29
Q&A
30