01 Verification Station Master Forms 20070315

document.xlssGMS Revision Record

Printed: 04/17/2023

Date Name Worksheet Name Update Description

01/20/06 Joe Koss Fast Response Sign-in SheetMoved to Fast Response Template file

document.xlsVS_Revision Record

Printed: 04/17/2023

Date Name Worksheet Name Update Description

Verification Station Board - Three Sided LayoutFEET 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5

1.0

0.5 WEEKLY PARETO TOP 5

DEFECTS

DAILY VERIFICA-TION

STATION MEETING

Sign-in

IMMEDIATE RESPONSE

ACTION SHEET / ALARM SHEET

Day/Aft Shift Tally Sheet

Meeting Assignment

Sheet

Verification Station - Alarm

Escalation Procedure

FTQ Trend Chart

Monthly PPSR

Closure Tracking

PROBLEM TRACKING

AND STATUS

Side1 Side

2

Side3

Side2

Side1

Side3

Defect Pareto

Scrap Trend Chart

Monthly Defects Over Time Trend

Chart

PR&R Weekly / Monthly Tracking of the

REPORT Cards

LiasonIssues List

SCRAP Trend Chart over Time

Mtg. Assignmts.

Practical Problem

SOLVING#1

Practical Problem

SOLVING#2

1st Shift Problem Solving

Monthly PPSR

Closure Tracking

Practical Problem

SOLVING#2

Practical Problem

SOLVING#1

2nd Shift Problem Solving

Problem Solving Tracking

Defect Tally Sheet

Immediate Response Action Sheet

Alarm Escalation Proc.

Daily Meeting Sign-in

1st Report Card - Q-Final

2nd Report Card - Liaison (Night Letter)

FINAL Report Card - LGR (GM-Customer)

PR&Rs

Customer Incidents - Trend ChartPR&Rs

PPSRs Completed

OPEN

FTQ Trend Chart over Time

PPSRs Closure Chart

PPSRs Closure ChartPPSRs Completed

PPSRs Completed PPSRs Completed

Liaison Issues

Common Inspection Criteria METHOD

METHOD

1

2 50

3 51

4 52

5 53

6 54

7 55

8

9

10

11 Honda Specific Inspection Criteria METHOD

12 70

13 71

14 72

15

16 METHOD

17 80

18 81

19 82

32 83

84

85

196

86

87

88

89

95

95

General MotorsSpecific Inspection Criteria

Toyota Specific Inspection Criteria

Defect Tally SheetVerification Station:Shift: 1st / 2nd

Date:(circle one) Revised: 5/31/2007

PROCESS SCORE CARDSupervisor-

1 (Customer Disatisfier)

Dept. Approval:Team Leader -

1 2 3

Associate(s) Name: Number of completed boxes / totes (for each part #) =1 2 3 4

DATE Process Name Available Minutes

450

Good Parts CHROME DEFECTS Plater Assembly ASB ASB ASB ASB ASB ASB ASB ASB ASB ASB TOTAL

Plan Act

+/-

BL CB ST DW S1 NS OC PS PT RF SK SH WC FU

SE

R B

UR

NT

TA

BS

TO

RN

TA

PE

HI/L

O

LA

BE

L W

RO

NG

TA

PE

MIS

SIN

G

TA

PE

RE

LE

AS

ING

REWORK

Part # HOUR Cum Cum BL

IST

ER

CH

RO

ME

BU

RN

DE

FO

RM

ED

PA

INT

SC

RA

P

PIT

S

SK

IP P

LA

TE

WH

ITE

WA

SH

Reserved for Early Start (O/T = 1 hr)

Cummlative Totals= A B Total Scrap C D E

Post to COB

Scrap% (C/(B+C))=

Unscheduled Downtime Problems (* = "Other" Defect: Describe)

TA

BS

M

ISA

LIG

NE

D

* OT

HE

R

GA

TE

NO

T

TR

IMM

ED

RA

CK

TA

B N

OT

IN

SP

EC

CH

RO

ME

S

TA

IN

LIN

E /

SC

RA

TC

H

NIC

KE

L

S

HO

W

OF

F

CO

LO

R

RO

UG

H

SU

RF

AC

E

WH

ITE

/ SH

INY

S

PO

TS TOTAL

SCRAP Plated

TOTAL SCRAP

Assy

TOTAL REWORK

07:00-08:00 AM

08:00-09:00 AM

09:00-10:00 AM

10:00-11:00 AM

11:00-12:00 PM

12:00-01:00 PM

01:00-02:00 PM

02:00-03:00 PM

03:00-03:30 PM

DEFECT CUMMLATIVE TOTALS

Direct Run % ((B-D)/(B+C))=

TRIGGER 1 ALARM1 PC TRIGGERTRIGGER 3 ALARM PLATER AND/OR MODLING DEFECTS ONLY

TRIGGER 2 ALARM (WIP)3 PC TRIGGER

TRIGGER 1 ALARM

TRIGGER 2 (WIP) ALARM

TRIGGER 3 ALARM CONFIRM & PLACE INTO UP-STREAM DEFECT BOX

FOR ALARM TRIGGERS GREATER THAN ONE:IDENTIFY EACH ALARM TRIGGER PULLED BY CIRCLING THE HASH MARKS THAT SET OFF THE ALARM (CALL FOR HELP)

IMMEDIATE RESPONSE ACTION SHEET / ALARM SHEET

VERIFICATION STATION: Y / N = Yes /No (circle one for each question, #2 - #5) *S=Supplier, A=Assembly/Build issue

# Serial# Defect Description / Number Time Time

1 6:

2 6:

3 6:

4 6:

5 6:

6 6:

7 6:

8 6:

9 6:

1

0 6:

1

1 6:

1

2 6:

VERIFICATION STATIONS RESPOND(Completed by the Verification Operator)

PRODUCTION RESPONDS(Completed by the responder)

Date/Shift

Product Line

Who Was Called

Escalation Level 1-5

Immediate FixWhat was done with the defective Part?

Corrective Action:1-Identify Point of Cause Station # ?2-Standardized work followed?3-Correct Tools / Fixtures / Error Proofing?4-Correct Parts?5-Parts in spec?6-What did you do to STOP a REPEAT defect from occurring?

*S A

Who Answered

BreakpointCSN #

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N

IMMEDIATE RESPONSE ACTION SHEET / ALARM SHEETVerification Station:

# Product Defect Description / Number Time Time

DM

1 A IC

DM

2 A IC

DM

3 A IC

DM

4 A IC

VERIFICATION STATIONS RESPOND(Completed by the Verification Operator)

PRODUCTION RESPONDERS(Completed by the responder)

Date/Shift

Who Was Called

Escalation

Level1-5

Intermediate Action(Containment)

What did you do to contain the defective Part?

Corrective Action:1. Define (What is the problem?)2. Measure (How Many Defects for this Occurrence)3. Analyze (Why did this problem occur?)4. Improve (What are you going to do to fix it?)5. Control (Is the part back into Spec?)

Point of Cause

SupplierMoldPlateAssembly/Build Issue

Who Answered

Breakpoint

When did defect free

material flow begin again

"Lesson Learned"WHAT DID YOU DO TO PREVENT A REPEAT DEFECT FROM OCCURRING




DM

5 A IC

DM

6 A IC

DM

7 A IC

"Leason Learned"WHAT DID YOU DO TO PREVENT A REPEAT DEFECT FROM OCCURRING



Verification Station - Alarm Escalation Procedure

Alarm Trigger Immediate Action Types of Response

Level 1

One (1) defect Inspector alerts Production Team Leader

Team Leader responds; Determines Point of Cause

Inspector enters type of defect, time, name of person contactedName: ____________ 1st ShiftPhone:Name:_____________ 2nd ShiftPhone: Name:Name: Name:

Responder institutes containment/corrective action and fills out right side of Immediate Response Action Sheet (and Containment Form, if applicable) Institutes a Buddy check if necessary to make sure the Verification Station doesn't see this defect again this shift.

Level 2

No response to Alarm within 10 minutes

Second (2 Total) defect - Exactly the same defect as in Step#1

Quality CoordinatorName: ______________ 1st ShiftPhone:Name: ______________ 2nd ShiftPhone: Name:Phone:

Same as above plus investigates cause of slow response

Document corrective actions for defect and slow response on Immediate Response Action Shhet

Level 3


Third (3 Total) defect - Exactly the same defect as in Step#1

Contact Area SupervisorName:_____________1st ShiftPhone:Name: ____________ 2nd ShiftPhone:


Level 4


Foufth (4 Total) defect - Exactly the same defect as in Step#1

Contact Operations ManagerName: _____________1st ShiftPhone: Name:_____________ 2nd ShiftPhone:


Level 5


Fifth (5 Total) defect - Exactly the same defect as in Step#1

Same as above plus investigates cause of slow response, and potentially Stop Production

Contact Plant managerName:______________Phone:

Verification Station - Alarm Escalation Procedure

Alarm Trigger Immediate Action Types of ResponseLevel 1

Level 2

Level 3

Level 4

Level 5

Verification Station Visual Signals to Call for Help

Team Member alerts Assembly BSM Team Leader

Team Leader responds; Determines Point of Cause within the assembly process.

Inspector enters type of defect, time, name of person contactedName: Jenny W. 1st ShiftPhone:Name: April S. 2nd ShiftPhone: Name:Phone:

Responder institutes: Containment/corrective action and fills out right side of Immediate Response Action Sheet (and Containment Form, if applicable) Institutes a Buddy check if necessary to make sure the Verification Station doesn't see this defect again

RESPONSE TIME: (10 minutes)Team Leader is Unable to Contain or Resolve the issue at the Point of Cause within 10 minutes.

REPEAT DEFECT CONDITION: 2nd Occurenence: Exact Same defect as in Alarm Trigger 1, or 2nd Group collected for Alarm Triggers 2

Assembly BSM Team Leader plusQuality Coord.Name: Debbie K. 1st ShiftPhone: Name: Shelly Yokam 2nd ShiftPhone:


Document corrective actions for defect and slow response on Immediate Response Action Sheet

RESPONSE TIME: (20 minutes)No corrective action to Alarm within 20 minutes

REPEAT DEFECT CONDITION: 3rd Occurrence: Exact Same defect as in Alarm Trigger 1, or another Group collected for Alarm Triggers 2 or 3.

Asb. T/Ldr, Quality Coord plus Assembly SupervisorName:Amy W. 1st ShiftPhone:Name:Edvin B. 2nd ShiftPhone:


RESPONSE TIME:(30 minutes)No corrective action to Alarm within 30 minutes

REPEAT DEFECT CONDITION:

4th Occurrence: Exact Same defect as in Alarm Trigger 1, or another Group collected for Alarm Triggers 2 or 3.

Asb. T/Ldr, Quality Coord, Assembly Supr plus Assembly ManagerName: Roy I. 1st ShiftPhone: Name:James N. 2nd ShiftPhone: Name: Hillary Bradley 3rd Shift


RESPONSE TIME: (40 minutes)No corrective action to Alarm within 40 minutes

REPEAT DEFECT CONDITION:

5th Occurrence: Exact Same defect as in Alarm Trigger 1, or another Group collected for Alarm Triggers 2 or 3.

Same as above plus investigates cause of slow response, and potentially Stop Production

Plant ManagerJohn B ext 5555

Alarm Trigger One: (Customer Disatisfier)1 Part - Assembly Defect(RED Shaded Defect Description Area on PSC Sheet)

Re

ject

Pa

rts

C

oll

ect

ion

Bin

1 2 3

1 2

Alarm Trigger Two:(Higher Frequency-Easy to Detect)3 Parts - Assembly Defect(Gray Shaded Defect Description Area on PSC Sheet)

Alarm Trigger Three: (Upstream process Escapes)

4 Parts - Total Any Type of Plating and/or Molding Defects

(Non-Shaded Defect Description Area on PSC Sheet)

Verification Station Review for week of: Shift:

InitialsTitle MON TUE WED THU FRI SAT SUN

Plant Manager

Quality Manager

Engineering Manager

Maintenance Manager

Area Supervisor

Other Daily Leadership Review-VS Operator Report Out

1. Review the First Time Quality and Scrap Charts Is it getting worse, better or staying the same?

2. Review Alarms from Previous Shift(s) What are the problem(s)? Was the Immediate Action Response Sheet utilized? Was the response timely? Was Point of Cause and Root Cause identified? Did the defect re-occur and was the escalation process used?

3. Review Feedback from Downstream Customers: Were there any issues for the past 24 hours? Were the details of the issue communicated to the team members? Has a Quality Alert Been Posted? Is the issue being checked for at the Verification Station?

Weekly Problem Solving-Team Report Out4. Review the Control Charts of Top Defects What are the Top Defects and What is the next issue to be worked on?

5. Problem Solving Team Report Out and Review Team member reports out to current problem solving step. Are there any road blocks that need to be removed? Are there any other resources that need to be assigned? Is the Tracking Report up to date and statused appropriately? Do any Problem Solving Assignments need to be escalated?(i.e. Shainin, 6-Sigma)

PROBLEM REPORT OUT DAY

DAILY VERIFICATION STATION MEETING

Verification Station:

Required Attendance: All attendees are listed below and must sign in when attending a meeting

Attendee or designate Monday Tuesday Wednesday Thursday Friday

DATE

TIME 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM

Plant Manager

Operations Manager

Quality Manager

Engineering Manager

Materials Manager

HR Manager

Production Manager

Area Supervisor

Team Leader

Quality Engineer

Verification Station Operator

Other

Other

Other

Other

Other

Other

Other

Other

Other

Other

Other

Instructions: The purpose of this meeting is to review customer satisfaction data, daily VS data, and, where applicable, alarm sheet response actions. Make assignments as required and review Assignment Action Sheet for any updates

Wee

kly

Pro

ble

m S

olv

ing

Mee

tin

g

Wee

kly

Pro

ble

m S

olv

ing

Mee

tin

g

(circle one)

Other

Shift Assign to Task Name Start Date

Assignment Action Sheet (from daily and /or weekly review)

Expected Completion

Date

Actual Completion

Date

MONTH: TOTAL:

DEFECT Desc. / QTY 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62

WEEK 1

WEEK 2

WEEK 3

WEEK 4

WEEK 5

Defect Tracking Bar Chart

This chart is generated on Mondays from data entered for the prior week.

This chart is to be used in conjunction with the weekly problem solving meeting.

VERIFICATION STATION:

DEFECTS OVER TIME

JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY

300290280270260250240230220210200190180170160150140130120110100

908070605040302010

0

QU

AN

TIT

Y D

EF

EC

TIV

E

WEEKLY COLOR

KEY

Wk # 3

Wk # 4

Wk # 1

Wk # 2

Wk # 5

TAR

GE

T

WEEKLY and MONTHLY

300290280270260250240230220210200190180170160150140130120110100

908070605040302010

0

VERIFICATION STATION

DEFECTS OVER TIME


WEEKLY and MONTHLY

300290280270260250240230220210200190180170160150140130120110100

908070605040302010

0

QU

AN

TIT

Y D

EF

EC

TIV

E

WEEKLY COLOR

KEY

Wk # 3

Wk # 4

Wk # 1

Wk # 2

Wk # 5

PROBLEM TRACKING AND STATUS

Shift Start Date Description of Problem Assigned To SolutionProblem Number

Date Solved

Date Validated

Status R-Y-G


Practical Problem Solving - Number Closed


WEEKLY and MONTHLY

2019181716151413121110

9876543210

QU

AN

TIT

Y

WEEKLY COLOR

KEY

Wk # 3

Wk # 4

Wk # 1

Wk # 2

Wk # 5

Supplier NameMonth Year

June 20236

Dock Audit Performance

No PR&R type defects

Found a PR&R type defect

Failure Report

Date of Failure No. of Units Rejected Failure Description

31

2928 30

2122

2324

2526

27

1213

1415

1617

1819

20

23

45

67

89

10111

Green

Red

Select Month at Right ->

Supplier name - Liaison IssuesMonth Year

June 2023

Located at the GM-Customer Plant

No PR&R type defects

Found a PR&R type defect

Failure Report

Date of Failure No. of Units Rejected Failure Description

31

2928 30

2122

2324

2526

27

1213

1415

1617

1819

20

23

45

67

89

10111

Green

Red

GM-Customer PR&RMonth Year

June 2023

LEGEND:

No PR&Rs

Customer Quality Disruption(eg. PRR, Pull, Spill)

31

2928 30

2122

2324

2526

27

1213

1415

1617

1819

20

23

45

67

89

10111

Green

Red

CURRENT MONTH

No Customer Complaint

s

VERIFICATION STATIONCUSTOMER INCIDENTS - # DAYS RED


MONTHLY

31302928272625242322212019181716151413121110

9876543210

QU

AN

TIT

Y D

AY

S R

ED

(circle one)CUSTOMER COLORKEY

Dock AuditGP-12

Customer

LIAISON

VS-Asy

CUSTOMER INCIDENTS - # DAYS RED

VERIFICATION STATION: Model Line/Vision Area

31302928272625242322212019181716151413121110

9876543210

QU

AN

TIT

Y D

AY

S R

ED

CUSTOMER COLOR

KEY

Dock Audit

GP-12

Customer

LIAISON

(circle one)


MONTHLY

31302928272625242322212019181716151413121110

9876543210

Model Line/Vision Area

MAY

MONTHLY

Side #2Instrument Panel

Verification Station

TEAM PROBLEM SOLVING

Q-1 Instrument Panel

Verification StationProblem Solving

Side #2

Q-1 Instrument Panel

Verification StationDefects LEAVING the Verification Station

Side #3

Defect Tally Sheet

Alarm Escalation Procedure

Immediate Response Action Sheet

Daily Meeting Sign-in

Weekly Problem Solving Meeting Sign-in

Meeting Assignment Log/Tracking

Weekly & Monthly: Defects Over Time

Weekly Pareto-Top 5 Defects

1st Shift Problem Solving

2nd Shift Problem Solving

1st Report Card - Q-Final

2nd Report Card - Liaison (Night Letter)

Problem Solving Tracking

FTQ (First Time Quality) Trend Charts (over time)

FINAL Report Card - LGR (GM-Customer) PR&Rs

Scrap Trend Chart (over time)

Current PR&R LIAISON REPORT

Current PR&R LIAISON REPORT

PPSR's Closure Chart

PPSR's Closure Chart

Customer Incidents - Trend Chart

Customer Incidents - Trend Chart

PPSR's Completed

PPSR's Completed

PPSR's Completed

PPSR's Completed

1st Report Card - Q-2

3rd Report Card - Liaison Report

2nd Report Card - Q-FINAL

- CHART MARKERS -

GREEN

YELLOW

RED

BLUE

PURPLE

LIAISON REPORT

FAST RESPONSE ATTENDANCE

SIGN-IN SHEET

Blank Forms Drawer Labels


- BLANK FORMS -

Defect Tally Sheet Immediate Resp./Action

Daily VS Sign-In Meeting AssignmentSheet

Practical Problem Solving Report

Weekly VS Meeting Sign-In

Problem Tracking &Status

PPSR Closure Chart

MONTHLY REPORTCARDS

CUSTOMER INCIDENTSTREND CHART

COMPLETED FORMS LABELS


COMPLETED FORMS

Defect Tally Sheet- 1st Shift -

Immediate Resp./Action- 1st Shift -

Defect Tally Sheet- 2nd Shift -

Immediate Resp./Action- 2nd Shift -

Daily VS Meeting Sign-in Daily Meeting AssignmentSheet

Weekly Pareto TOP 5 Defects Charts

Defects Over TimeMonthly Trend Charts

Practical Problem Solving Reports

- 1st Shift -

Practical Problem Solving Reports

- 2nd Shift -

MONTHLY REPORTCARDS


MONTHLY REPORTCARDS


Documents

01 Verification Station Master Forms 20070315