THE NEW FLOW

2

SQP FLOWS – 8D VERSUS KAIZEN

Containment

Action (by 36h)

Containment

Action accepted

Corrective

Action (8D Filled)

Corrective

Action accepted

Bill Closure

8D

KA

IZE

N

CNHI

2

3

4

5

6

Cluster creation

Bill Closure

Containment

Action (by 36h)

Transversalization

(FMEA,Control Plan)

Action plan proposal

8 stage proposal

PLAN

5W1H 4M ISHIK 5WHY

DO

ACT

Bill Opening and

Issue Description

with 5W1H

Robustness/Effectiveness

Evaluation

CHECK

PDCA REPORT

CNHI SUPPLIER

1

2

4

5

7

9

8

Action Plan

Validation

Cluster creation 0

SUPPLIER

0

ACT

8

CHECK 6

Bill Opening and

Issue Description

1

Containment

Action accepted

3

Final approval on

improved parts

3

CLUSTER CREATION

4

SQP FLOW – WHAT IS A CLUSTER ?

CLUSTER BILL

BILL

Weight

20

BILL

Weight

50

BILL

Weight

40

5

Cluster is a “folder”created previously to the bill

It contains the main information about Supplier and part number

Only after the Cluster opening, a bill will be created and linked to it

SQP FLOW – 0) CLUSTER CREATION

Cluster is a “folder”created previously to the bill

It contains the main information about Supplier and part number

Only after the Cluster opening, a bill will be created and linked to it

NOTE : Customer plant can choose the problem resolution process considered more suitable to the issue under investigation,

selecti g 8D or KAIZEN ode

6

BILL OPENING

7

SQP FLOW – 1) BILL OPENING

Bills having the same characteristics (same supplier, same part number or same

supplier production batch) must be linked to the same cluster.

This is valid for a period of 15 days from the cluster opening.

The Cluster Weight will be the highest weight assigned to the linked bills

A pop-up will help Customer Plant for a proper bill attribution redirecting to the right cluster.

CLUSTER BILL

BILL

Weight

20

BILL

Weight

50

BILL

Weight

40

CLUSTER BILL

WEIGHT 50

8

SQP FLOW – 1) BILL OPENING

After the cluster is opened, a bill can be created.

Clusters and bills will maintain a link, and the bill number will be constituted by

the cluster number + progressive number.

For example, if the cluster number is 2017000052724, the bill that will added will

have 2017000052724/0001.

9

SQP FLOW – 1) BILL OPENING AND ISSUE DESCRIPTION

In case of Kaizen mode is selected, Customer Plant has to insert the

mandatory 5W1H and, in addition, some specific attachments as photos

or other documents to support the analysis:

10

CONTAINMENT

ACTION

11

SQP FLOW – 2) CONTAINMENT ACTION

Supplier has provide a containment action by 36h for the Quality Bill and 24h

for the Logistics Bills.

Note: At the expiration of the allowed time, missing this communication, SQP will

issue an automatic Collaboration Bill - Item 19C.

12

SQP FLOW – 3) CONTAINMENT ACTION ACCEPTANCE

Customer will accept or reject the Containment action provided by Supplier.

In case no answer (acceptance or rejection of containment actions) is given by

Customer within 36 hours from the sending of the communication of containment

actions, the latter will be accepted implicitly and their acceptance will be

highlighted automatically in the SQP information system.

13

CORRECTIVE ACTION

(KAIZEN)

14

SQP FLOW – 4) KAIZEN PLAN - 5W1H

Supplier has to propose the 5W1H incident description from his side, in order

to clear up the factors influencing the non conformity.

15

SQP FLOW – 4) KAIZEN PLAN - 4M+5WHY’S

Once 5W1H study is completed, supplier must develop a 4M analisys

(including the application of 5 Why’s tool) through the usage of an SQP

integrated system, identifying primary and secondary causes.

16

Man

Method

Material

Machine

Op.std

compliance

Welding

Training

Mixing of

parts

Operation.

Sequence

Correct

labeling

Inadequate

labels

Conformity

to specs.

Torque

control Machine

Why 3 Why 4 Why 5

Man

Method

Material

Why 3 Why 4 Why 5

Identified root causes will fill

automatically an ISHIKAWA model

17

SQP FLOW – 4) KAIZEN PLAN - 4M+5WHY’S

SQP FLOW – 5) KAIZEN DO

The identified root causes (type and description) will be automatically

replicated into the first section of DO template. For each root cause the

supplier has to define a % weight and insert corrective action description and

break point in the second section of the DO template.

Supplier has to declare at which WCM stage he will go to set his process.

18

SQP FLOW – 6) KAIZEN CHECK (Customer)

Customer Plant CHECKS the proposed DO table filled by Supplier and :

accept or reject the action plan and the stage proposed by the supplier.

decides whether to request the ACT step

Note : when SQE validation is required, the SQE has the role to verify the

consistency of the implemented solution at supplier site 19

SQP FLOW – 7) KAIZEN CHECK (Supplier)

Once the solution is implemented (break point date reached), supplier shall

declare (third section of the template):

Effectiveness (Y/N) and Robustness (based on 5Qx0D analysis, to be

applied and attached)

20

SQP FLOW – 8) KAIZEN ACT (Customer)

If required by Plant (during the check phase), the workflow moves to the status

ACT. The system reproduces the fields already filled in by the supplier before. The

arrival date is related to the last break point filled in by supplier in the «DO» step.

The plant, checking the parts, inserts the ACT acceptance or rejection

21

22

5W1H Description of the phenomenon

WHAT Some wrong dimensions on the hub

WHEN Problem appears to occur in the

continuous running

WHO Problem affects all the shifts

WHERE Problem is found in the hub assembly

operation

WHICH No particular trend in the appereance of

the phenomena

HOW Equipment does not show any particular

deviation

Root Causes identified

Inadeguate labels

Mixing of parts

Description of the solution

Type Root Cause Weight Break point Corrective Action

Method1 Inadequate

labels

30% 03/07/2017 Visual management:

coloured labels and

versioning code

Men1 Mixing of parts 70% 29/06/2017 Dedicated welding

gigs for every lever

version

Target Stage 7

VERIFY RESULTS COMMENTS

Action Plan

Rejection Description Y

SQE Validation Request

Act Requested

Stage Validation Y

Rejection Description

COMMENTS

FMEA Reviewd Y

Control Plan reviewd Y

Action Transversalized Y

Pieces arrived Y

ACT acceptance Y

Reject reasons

Project leader Starting Date: Implementation team: Completion Date: Costs: Benefits Results: Benefit/Cost Verification:

STANDARD KAIZEN / PDCA

REVISION REQUEST

23

REVISION REQUEST

Foreword (08018 norm – Chapter 5.5)

Supplier assuming not to be responsible for the non-conformity can ask for :

- the Bill Cancelation through specific template available in the SQP system

- Non Conforming Quantity Review, proposing a different value in the

specific template available in the SQP system (for example, after sorting

activity at supplier site)

Warning - Lexical change !

Bill total cross out Bill cancelation

Bill partial cross out Quantity Review

!

24

Bill cancelation can be asked by supplier trough specific SQP template going

through

Then the «cancelation» mode has to be flagged.

Plant Manager Accepts or Refuses the proposal

– –

REVISION REQUEST – BILL CANCELATION

25

QUANTITY REVIEW REQUEST FROM SUPPLIER SIDE

• Supplier proposes the quantities to decrease from the total on the Cluster (with

impact on the PIQ).

• Plant Manager handles the revision request at bill level:

• Plant Manager Accepts or Refuses the proposal

REVISION REQUEST – QUANTITY MANAGEMENT REVIEW

26

QUANTITY REVIEW REQUEST FROM SUPPLIER SIDE

• Plant Manager, in case of acceptance, can modify the supplier proposal

• Accepted quantities feed the «Manage Quantity» template with specific

item, with specific item in order to remark that they are consequence of a

review

• In «NC QTY REVIEW» mode the bill flow proceeds normally (status is not

CANCELED and – if the bill is the heaviest in the cluster – can have

impact on the PIQ)

REVISION REQUEST – QUANTITY MANAGEMENT REVIEW

27

Quantity management template follows an ascending time line going from

the oldest (down) to the latest event (up).

REVISION REQUEST – QUANTITY MANAGEMENT

28

Special features:

• Additional or decreasing quantities can be inserted from plant at any time;

• It is not possible to decrease quantities bigger than the last NC showed on the

top left of the template

• It is mandatory to insert one item for every line. In case of quantity

adjustement accepted by plant, the item description appears automatically.

• The list of the items is shown here:

01. Initial NC quantity

02. Plant adjustment after sorting

03. Bill related to new defect

04. Cross out requested by supplier

05. Bill cancellation request by supplier

06. Batch quantity reviewed

REVISION REQUEST – QUANTITY MANAGEMENT

29

Time line: from the latest event

(up) to the oldest (down)

NC for PPM

In qty insertion the item is

mandatory

Additional or decreasing quantities can be inserted;

it is not possible to decrease quantities bigger than

the last NC showed on the top left of the template. Compulsory notes

REVISION REQUEST – QUANTITY MANAGEMENT

30

REVISION REQUEST – QUANTITY MANAGEMENT

Quantities shown in the CLUSTER are :

• Nc (for PPM)

• Accepted reviewed qty

• Returned qty

as in the first line of the «Manage

Quantity» template

31

SQP Revision – automatic checks

• NC Quantities are inserted only from Quantity Management module in SQP

• CANCELED Quantities, once accepted by Plant, come automatically from the

Revision Request form into the Quantity Management module and are not editable

• RETURNED Quantites are inserted into the Quantity Management module

AUTOMATIC CHECKS INTO THE QUANTITY MANAGEMENTS MODULE

1. Quantity review si referred to the Cluster

2. Supplier proposed quantities can never exceed the quantities in the cluster at

that moment

3. Plant accepted quantities can be different from what proposed by Supplier

REVISION REQUEST – QUANTITY MANAGEMENT

32

REVISION REQUEST FORM (ex Cross-Out)

33