Fast Response Governance Drill Deep and Wide

Abel Acuña January 27th 2010

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Fast Response Owner:Fast Response #: Initiation Date: Rev.Date: Review #:

GQTS DMR # Problem Description:

Part Name & Part #: Supplier by:

PPAP Appv. level: PPAP Date: Percent Material Non-conforming:

Did / could defect pass thru to customer Plant?

Problem Definition:-

Containment:-

Time from initial contact until contained material is delivered: Hours

Root Cause: - Process Failure:

- Detection Failure:

- Systemic Failure:

Corrective Action:---

Time from initial contact until Error Proofing / Detection is in place: Days

Improve Process Detection:---

Original PFMEA RPN: Severity Occurrence Detection

Interim PFMEA RPN: Severity Occurrence DetectionRevised PFMEA RPN: Severity Occurrence Detection

Steps to closure: Estimated Date of Closure: New PPAP Status:-

Lessons Learned:-

Contain Corrective Actions Error Proofing Work Instructions Layered Audit SREA / PCN PFMEA / PCP 5 - Why

R R RRR R R R

Define process failure.

Define detection failure.

Define systemic failure.

Detail corrective action activities.List responsibilities.Identify targeted implementation dates.

Detail improvements to the detection process.List responsibilities.Identify targeted implementation dates.

Detail all next steps, responsibility, and target implementation dates to close item.

Detail all lessons learned, so they may be shared plant wide.

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Meeting Structure

● One hour meeting led by appropriate SQD and supplier.

● When● During verification phase● Before final 8D approval/closure

● Meeting participants to include:● Manager – Global Supplier Quality● Fast Response team members● Purchasing representative● Supplier representative● Timken plant QA and Quality Manager

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Meeting Agenda

● 8D Presentation

● Root Cause Identification● Can the issue be turned on and off?

● Corrective Action● Short and long term

● PFMEA● Before and after comparison● Impact to RPN

● Error Proofing● Poke Yoke(s) implemented● Safeguards● Detection methods

● Standard Work● Updates to work instructions/procedures/inspection methodology

● Layered Audit● Implementation● Frequency

● Verification of Effectiveness

● Read Across/Lessons Learned● Similar processes/products identified

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Meeting Documentation

● 8D

● PFMEA (before and after)

● Process Control Plan (before and after)

● Layered Audit Results

● Verification method

● Timing Plan (if implementation is not complete)