WOCO Ipartechnika Kft. - Budapest
THE BASICS
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group2
THE BASICS
Gábor Bárdos [GM]
WOCO Ipartechnika Kft. – Woco Group3
I. BASED ON DATA
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group4
I. BASED ON DATA
 Global databases for the following processes (e.g.)
 Scrap collecting card (part number specific)
 Sc...
I. PROCESS MAP WITH THE SPECIAL
DATABASES
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group6
IM Setup s...
II. STANDARD PROCESSES
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group7
 Goal:
 Maximum support of ...
III. COMMUNICATION
 Goal:
 quick, based on data, transparent, planned and team building communication
(meeting) methods
...
III. COMMUNICATION - INPUTS
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group9
1
2
3
4
4
4
1 – ppm and ...
III. COMMUNICATION – INFO/FOLLOW UP
BOARD
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group10
III. COMMUNICATION – INTERNAL
„NEWSPAPER”
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group11
5 minutes...
IV. FAILURE DETECTION
 Clear failure description, limits
 Based on data
 Clear visualisation
 Compaire the good and th...
IV. FAILURE DETECTION
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group13
 Goal:
 Improve the efficie...
V. PROTECTIVE MEASURE – 24H
 Goal: protect the customer till the analysis and the final solution!
Gábor Bárdos [Managing ...
VI. FACTOR ANALYSIS
 Goal:
 Understand the processes!
 Tools:
 Factors (FT)
 The atoms of the processes …
 5 Why
 A...
VI. FACTOR ANALYSIS
 Factors - definitions
 Those points, phase of the process or product, which are clear isolable, def...
VI. FACTOR ANALYSIS – 5WHY
 5Why
 Systematical method to find the real root cause. The five is not a law. You have to
as...
VI. FACTOR ANALYSIS – FMEA
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group18
Factors
Customer
RPN
Pro...
VI. FACTOR ANALYSIS – FMEA
 Sample
Factor FMEA
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group19
Spr...
VII. ACTIONS
 Goal:
 On the real root cause defined, easy follow up, documented action handlings
 Tools:
 WeWin boards...
VII. ACTIONS – FACTOR SHEET
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group21
1
3
4
2
1 – Failure dat...
VII. ACTIONS – FACTOR ANALYSIS IN THE
ACTIONMAN
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group22
1 –...
VII. ACTIONS – EFFICIENCY
 Status of the actions (automatic PDCA report from the ActionMan
database)
 LLC efficiency che...
VII. ACTIONS – EFFICIENCY : AUDITS
 Type of audits - responsibilities
Gábor Bárdos [Managing Director]
WOCO Ipartechnika ...
VII. ACTIONS – EFFICIENCY : AUDITS
 Goal:
 Regularly self and management check
 Tool:
 Internal audit database program...
VII. ACTIONS – EFFICIENCY : AUDITS
 Layered Layout audit system
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. –...
VII. ACTIONS – EFFICIENCY : AUDITS
 Layered Layout audit system
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. –...
VII. ACTIONS – EFFICIENCY : AUDITS
 Statistic modul (e.g.) of the database
 Weekly results per workstation or production...
Thank you!
Gábor BÁRDOS
Managing director
Woco IPARTECHNIKA Magyarország Kft.
Újhegyi út 25 - 31.
1108 Budapest - Hungary
...
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  1. 1. WOCO Ipartechnika Kft. - Budapest
  2. 2. THE BASICS Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group2
  3. 3. THE BASICS Gábor Bárdos [GM] WOCO Ipartechnika Kft. – Woco Group3
  4. 4. I. BASED ON DATA Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group4
  5. 5. I. BASED ON DATA  Global databases for the following processes (e.g.)  Scrap collecting card (part number specific)  Scrap data collecting + complete analysis in one database  SPC data collecting + analysis  Incomming Material Control Center = Incoming check + results + complaints + evaluation  MSA database  Injection moulding setup parameter database  Maintenance databases  Handling of non conform material database  Customer complaints database  ActionMan = Global project/action database  … Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group5
  6. 6. I. PROCESS MAP WITH THE SPECIAL DATABASES Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group6 IM Setup sheets Scrap collector card Scrap stat CMR | SOFA | Log. complaints Training center Incoming Material Control Center Planned maintenance Interventions Internal audits Customer complaints SPC MSA ActionMan Doc manager PEP Productiv times Score Card Drying follow up Tool exchange
  7. 7. II. STANDARD PROCESSES Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group7  Goal:  Maximum support of the production with standardized, high quality instruction, standard working places, comparable working, quality work and cleanliness  To say HOW, not just WHAT!!  Tools:  Best practice industrialization  OK for economy, safety and quality  easy to understand the process  Unification of the same process points  Regular check Nr1 High level document design
  8. 8. III. COMMUNICATION  Goal:  quick, based on data, transparent, planned and team building communication (meeting) methods  Tool:  Daily WeWin meeting  Daily overview of the results from the day before  Daily analysis of the TOP 3 failure (according to scrap rate and/or scrap cost)  Complete statistical analysis with all relevant data (Scrap database)  Analysis at the failure place (workstation, line, area …)  INFO Board Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group8
  9. 9. III. COMMUNICATION - INPUTS Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group9 1 2 3 4 4 4 1 – ppm and scrap cost per lines 2 – ppm per shift leaders 3 – part number pareto (ppm) 4 – TOP 3 part number failure list Daily report
  10. 10. III. COMMUNICATION – INFO/FOLLOW UP BOARD Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group10
  11. 11. III. COMMUNICATION – INTERNAL „NEWSPAPER” Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group11 5 minutes for the quality: •explaining of one implemented quality tool •Newspaper style to make the understanding easier
  12. 12. IV. FAILURE DETECTION  Clear failure description, limits  Based on data  Clear visualisation  Compaire the good and the bad parts, issues  Based on factor and data  Failure history from database Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group12 Nr1 High level Photo quality
  13. 13. IV. FAILURE DETECTION Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group13  Goal:  Improve the efficiency of the self control and degrease the not added value final control activities  Tools:  Integrated scrap analysis databases with automatic self-control statistic modules.  Regular feedback to the TOP failure types  Improve the visualization of the failure descriptions, catalogues.
  14. 14. V. PROTECTIVE MEASURE – 24H  Goal: protect the customer till the analysis and the final solution! Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group14 1 2 3 1. failure description (what, when, how many, who produced…) 2. Clear action plan per process + worker signatures 3. Identification of the good parts
  15. 15. VI. FACTOR ANALYSIS  Goal:  Understand the processes!  Tools:  Factors (FT)  The atoms of the processes …  5 Why  Ask as the children …  FMEA  Failure Method and Effect Analysis Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group15
  16. 16. VI. FACTOR ANALYSIS  Factors - definitions  Those points, phase of the process or product, which are clear isolable, definable and measurable  The factors are the atoms of the process, which can be defined with parameters, and to cut to smaller units is not possible, or hasn’t got sense.  The factors are the blocks of the flowchart.  The factors are the setup parameters of a machine  In all cases the attributes of the factors have to be defined with parameters (Yes/No can be also parameter).  The factors has to be splitted – especially in case of non conformity – into the 2 following groups:  Occurrence  Not detection Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group16
  17. 17. VI. FACTOR ANALYSIS – 5WHY  5Why  Systematical method to find the real root cause. The five is not a law. You have to ask so many times, till you find the real root cause.  Example:  Surface damage on the Washington monument.  Why? – Hard, aggressive liquid onto the surface. Why? – Clean the pigeon guano. Why (lot of guano)? – They eat from the lot of spiders. Why (lot of spider)? – They eat from the lot of mosquito Why (lot of mosquito)? – They comes onto the light at nightfall.  Solution: switch on the lights just after dark! www.isixsigma.com Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group17
  18. 18. VI. FACTOR ANALYSIS – FMEA Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group18 Factors Customer RPN Process RPN Product RPN Factor failure Effect on the process Effect on the product Effect on the customer Function Process
  19. 19. VI. FACTOR ANALYSIS – FMEA  Sample Factor FMEA Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group19 Spray head Spray head damage Viscosity Viscosity too high Temperature Pressure Temp. too high Press. too high Temp. too low Viscosity too low Press. too low
  20. 20. VII. ACTIONS  Goal:  On the real root cause defined, easy follow up, documented action handlings  Tools:  WeWin boards and forms + ActionMan database Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group20
  21. 21. VII. ACTIONS – FACTOR SHEET Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group21 1 3 4 2 1 – Failure data 2 – immediate actions (Protective measure) 3 – Factor analysis 4 – Actions 5 - Validation 5
  22. 22. VII. ACTIONS – FACTOR ANALYSIS IN THE ACTIONMAN Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group22 1 – Failure (issue) data 2 – Factor analysis 3 – Actions 1 2 3
  23. 23. VII. ACTIONS – EFFICIENCY  Status of the actions (automatic PDCA report from the ActionMan database)  LLC efficiency check diagram from scrap database – daily overview Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group23
  24. 24. VII. ACTIONS – EFFICIENCY : AUDITS  Type of audits - responsibilities Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group24 Type Description Area manag/ Prod QS Manag System audit Complete system audit Process audit Production and stock processes Product audit Complete audit on 5 parts Quick audit LAYOUT Work station audit Complaint close audit Actions and factor audit WeWin audit Complete mindset audit Supplier audit Start of prod and complaint audit Layered
  25. 25. VII. ACTIONS – EFFICIENCY : AUDITS  Goal:  Regularly self and management check  Tool:  Internal audit database program  All questioners in one platform  All results in one database  Complete statistic module Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group25
  26. 26. VII. ACTIONS – EFFICIENCY : AUDITS  Layered Layout audit system Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group26 Clear visualisation of the workstation The Basics (questionary) Results
  27. 27. VII. ACTIONS – EFFICIENCY : AUDITS  Layered Layout audit system Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group27 Daily self audit Well done audit Not well done audit Weekly QS audit Monthly PM audit
  28. 28. VII. ACTIONS – EFFICIENCY : AUDITS  Statistic modul (e.g.) of the database  Weekly results per workstation or production line  Visualisated reports from the Layout audit results Gábor Bárdos [Managing Director] WOCO Ipartechnika Kft. – Woco Group28
  29. 29. Thank you! Gábor BÁRDOS Managing director Woco IPARTECHNIKA Magyarország Kft. Újhegyi út 25 - 31. 1108 Budapest - Hungary 47°28'03.26"N - 19°10'11.62" E Center: +36 1 431 0580 | Tel.: +36 1 434 2734 | Fax.: +36 1 431 0598 | Mobil: +36 20 826 0992 Mailto: gbardos@hu.wocogroup.com | Internet: www.wocogroup.com

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