Jidoka for Quality Improvement   Lean en France, 20 May 2011Yves Mérel, FCI Group Lean Director
FCI background and profile      Creation in 1988 by Framatome for diversification outside      nuclear field      20+ acqu...
A variety of solutions and products                                  Electronic connectors                                ...
24 manufacturing sites and 14 R&D centers                                                                                 ...
FCI Lean InitiativesEvery department is monitoring a continuous improvement process  contributing to customers satisfactio...
Continuous Improvement on QualityYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement   6
Customers Quality Feedback                  We discover our actions impact 3 months laterYves Mérel, FCI Group Lean Direct...
Quality Improvement Tools       Complaint 8D                            and       Quality Wall              In case of com...
Quarterly 8D audit of shop floor evidences      D1: Team             Cross-functional including operators      D2: Problem...
8D benchmark                                       100                                        90                          ...
Quality Wall                               Visible and Standardized InspectionsYves Mérel, FCI Group Lean Director, 20 May...
22% DL inspecting with 3% in Quality Walls 55% 50% 45% 40% 35% 30% 25% 20% 15% 10%   5%   0%                      L       ...
Red Bin Review and Quality Workshop      The Red Bin is a tool: by looking into it, we see lots of simple and stupid      ...
Go 1st Part working standard checklist                                                 GO FIRST PART        Date :        ...
Number of detections                                                                                                      ...
Epernon factory example                                                                             OEE follow up         ...
Epernon factory example      Main difficulties:        Needs of resources to quickly implement the corrective actions     ...
Besancon factory example                                                              Video on                            ...
Immediate feedback from on line detectionProcess design minimum requirements for Jidoka:1- Detections exist for every occu...
150 to 40 complaints/month within 3 years                        200                        190                        180...
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Lean Jidoka for Quality lecture at Lean en France - Yves Merel on 20 may 2011

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A lecture done by Yves Merel in Paris on May 20th 2011,

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Lean Jidoka for Quality lecture at Lean en France - Yves Merel on 20 may 2011

  1. 1. Jidoka for Quality Improvement Lean en France, 20 May 2011Yves Mérel, FCI Group Lean Director
  2. 2. FCI background and profile Creation in 1988 by Framatome for diversification outside nuclear field 20+ acquisitions and 20+ years later, FCI is one of the largest global connector manufacturers November 3, 2005: FCI is acquired by Bain Capital, a private investment fund With operations in 30 countries and a turnover of 1.3 billion € in 2010, FCI is a leading connector manufacturer Its 14,000 employees are committed to providing their customers with high-quality and innovative products for a wide range of consumer and industrial applicationsYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 2
  3. 3. A variety of solutions and products Electronic connectors Microconnections connectors Motorized Vehicle connectorsYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 3
  4. 4. 24 manufacturing sites and 14 R&D centers Europe 7 manufacturing sites 1 Corporate Research Center 6 R&D centers Asia 12 manufacturing sites 6 R&D centers Americas5 manufacturing sites 2 R&D centersYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 4
  5. 5. FCI Lean InitiativesEvery department is monitoring a continuous improvement process contributing to customers satisfaction and costs reduction People Empowerment for Accidents, Absenteeism and Turnover Quality for Customers Complaints and Non Right First Time Supply Chain for Late Deliveries, Inventory and Distribution Lead Time Supplier Development for Receiving Frequency, Complaints, Gap to AVL Process Design for Bottlenecks and Idle equipments Product Development for Time To Market and Design Changes Customer Focus for Time To Quote and Customers DisappointmentsYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 5
  6. 6. Continuous Improvement on QualityYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 6
  7. 7. Customers Quality Feedback We discover our actions impact 3 months laterYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 7
  8. 8. Quality Improvement Tools Complaint 8D and Quality Wall In case of complaint, 8D to make sure this type of problem won’t occur anymore For any Quality risk identified, make sure people are able to check all parts Red Bin Review and Quality Workshop Review daily every red bin, to solve quickly many stupid defects Workshop to test root cause hypotheses on most complex problems Go 1st Part and 1st Defect Stop Before starting to produce, check if there is a fair chance to produce good parts While producing, stop at 1st defect to allow people to investigate the causeYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 8
  9. 9. Quarterly 8D audit of shop floor evidences D1: Team Cross-functional including operators D2: Problem Defective parts available and data on “who, when, how many, what, where, how, why” D3: Containment (within 24 hours) Inspect all stocks, implement Quality Wall, 1st Defect Stop, and Red Bin Review Analyze several non-detection causes from “man, machine, material, method, environment” through 5 Why and test of hypothesis to reproduce non-detection D4: Root causes Quality workshop to analyze several causes from “man, machine, material, method, environment” through 5 Why and test of hypothesis to reproduce defect D5: Corrective actions Robust actions (poka yoke) implemented on time D6: Effectiveness Actions correctly implemented and measurable impact D7: Prevention Risk analysis, Go 1st Part, Preventive Maintenance, Training check, Mgt routine... Applicable on similar product and process D8: Closing By management based on shop floor evidencesYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 9
  10. 10. 8D benchmark 100 90 80 Conformity to 8D expectations (%) 70 60 50 40 30 20 10 0 n la n L rg X ng ya an L n ng on a X es re lo o gi i Ma ena do fe MV MV no iok EL Su rin EL be n P Pau an alo an ya nt gu ro nc ho ing er To g- rn Ish Ma in- Ch g- Ju S in- tab ro m sa ng ng ttig Ep on Nu on o nt Na ed ch ch Be Do Ba Sa Ta Hu nt nt Co Co Na Na Sa First audit Last audit From 52% to 87% of rigor definitively fixes many problems and develops customers confidenceYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 10
  11. 11. Quality Wall Visible and Standardized InspectionsYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 11
  12. 12. 22% DL inspecting with 3% in Quality Walls 55% 50% 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% L a em n ro n LX am rg an ya g VL an ig n LX re hi lo ng n un con ng g hi ka s on ino To i i V ul ur do I ng ed fe ao a Ta yan a FC B nte to no to on be u lo M n S en E S M gu M oc io E P ho C Pa ha r g ba an ga an ur an r C Ish a tin N pe S n g n M C N J ta es S att E N oc D B H N 2009 Inspection / Direct 2010 Inspection / Direct Overall less inspections (+233 quality wall -441 random) Less people, but better controlled inspectionYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 12
  13. 13. Red Bin Review and Quality Workshop The Red Bin is a tool: by looking into it, we see lots of simple and stupid problems easy to fix quickly Typical internal defects Pareto At the Pareto “head” we have well known problems occurring very often but complex to fix Lots of Internal PPM: Quality Workshop Usually manufacturing is adapted to avoid customer complaints (containment actions, in line inspection, people awareness), but it costs Lots of Complaints: Red Bin Review At the Pareto “tail” we have rare and stupid problems, but customers often received such defective productsYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 13
  14. 14. Go 1st Part working standard checklist GO FIRST PART Date : Time : Reference : Operator To check at each batch and each shift start Workstation is clean and everything is located as defined Listed Poka Yoke and Safety devices are checked Equipment settings are within tolerances and cycle time is at standard Maintenance has been done as scheduled Operator is qualified to the job First part is conformYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 14
  15. 15. Number of detections N ur 0 100 200 300 400 500 600 700 nb e To rg Ta ri ta no ba ny Se a N Ep nai an er t o no n M g- n at E L t H igh X un o tin fen gd M on a Sa Do nte n ng s Pe gu d r an o First Defect Stop N Su N am la anYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement t o yan ng g -M Ju V L ro C ng B han e C s an g i 1st Defect Stop with on line detections oc c h o Non First Defect Stop C in- n oc M hi VL n Sa -EL o X B Pau an ga l o lo re15
  16. 16. Epernon factory example OEE follow up 100 80OEE before: 77 % 60 40OEE after: 78 % 20 0 Week 39 Week 40 Week 41 Week 42 Week 43 Week 44 Week 45 Week 46 First defect stop OEE follow up and red bin review implementation on Machine 57 PPM follow up 16000 14000 12000 10000PPM before: 14 800 8000 6000PPM after: 7 100 4000 2000 0 Week 39 Week 40 Week 41 Week 42 Week 43 Week 44 Week 45 Week 46 PPM follow up Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 16
  17. 17. Epernon factory example Main difficulties: Needs of resources to quickly implement the corrective actions Cannot be done on bottleneck machines since temporarily reducing the output Organization modifications: Dedicate 2 persons to work on 1st Defect Stop implementation: 1 for machine software modification and immediate actions 1 for immediate actions They move from one machine to another after 2 weeksYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 17
  18. 18. Besancon factory example Video on 1st Defect Stop and Red Bin ReviewYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 18
  19. 19. Immediate feedback from on line detectionProcess design minimum requirements for Jidoka:1- Detections exist for every occurring defects On product, on process, manual inspection, sampling (non-random defect)2- Detections are capable Reliability & Repeatability analysis3- Detections are done at every process step Before adding more value to the defective part4- First Defect Stop Immediately before the clues disappear5- Defective parts removed manually To get a chance to go and see the defect causesYves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 19
  20. 20. 150 to 40 complaints/month within 3 years 200 190 180 170 160Number of Complaints 150 140 130 120 10 1 100 90 80 70 60 50 40 30 20 10 0 8 9 0 Se 8 Se 9 Se 0 M 9 M 0 M 1 M 8 N 8 Ja 8 M 9 N 9 Ja 9 M 0 N 0 Ja 0 1 -0 -0 -1 l-0 l-0 l-1 -0 0 -0 -0 0 -0 -1 1 -1 -1 0 1 1 p- p- p- n- n- n- ov ov ov ay ay ay ar ar ar ar Ju Ju Ju M Group 6MRA Group actual 8D - Quality Wall - Red Bin - Workshop - Go 1st Part - 1st Defect Stop Yves Mérel, FCI Group Lean Director, 20 May 2011, Jidoka for Quality Improvement 20

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