Optimizing Quality Management in an Unprepared Environment (Lean + Agile)
Starting point
- High amount of NCI/NCE
- NCE/NCI information on paper
- Complexity of controlling the cost of non-quality
- Absence of Quality “Doors”
- Increased waste and therefore costs
- Lack of quality KPIs
- Impossible to make the right decisions
- Integration of business processes
- NCE/NCI Management Flow
- Total control of quality KPIs
- Smart Reporting of Losses
- Cost reduction of poor quality
- Introduction to Quality Checklist
Total Quality: Staff formation
Summary of Training Activities
Implementation of Problem-Solving Techniques for Middle Managers
Implementation of Group Problem-Solving Techniques
- PREPARATION FOR ANALYSIS
- INTRODUCTION & PSYCHOLOGICAL PREPARATION OF THE TEAM
- IDENTIFICATION & QUANTIFICATION
- APPROXIMATE SOLUTION TO THE PROBLEM
- CONTAINING THE PROBLEM
- ERRORIZATION OF THE PROBLEM THROUGH EXCELLENT PROCESSES
- ERROR/DICATION OF THE PROBLEM THROUGH BETTER TECHNIQUES
- CLOSING OF THE FISCAL YEAR
Methodology template
Total Quality: 5S implementations:
5S Implementations: Agora Zone
5S Implementations: Tool Panels
5S Implementations: Kanban Systems + Layout
Total Quality: Standard Processes for Machine Start-up, Control and Cleaning
STANDARD PROCESSES FOR ELIMINATING VARIABILITY
Creation of standard processes to eliminate variability between operators + Conducting training on the machine.
Standard processes C9 and M6
- INK VISCOSITY CHECKING PROCESS
- MACHINE CALIBRATION PROCESS AT START-UP
- ORDER VERIFICATION
- BLADE REPLACEMENT
- BLADE HOLDER CLEANING PROCESS
- BLADE STATUS CONTROL
- BASIC MACHINE MAINTENANCE (Autonomous Maintenance)
- STARTUP PROCESS / PARAMETERS AFTER A CHANGE
- ORDER VERIFICATION
- MANUAL COLA PREPARATION
- CYLINDER CHANGE – (WEIGHT / ADHESIVE TYPE)
- FOOTPRINT ASSEMBLY PROCESS
- TAKE SAMPLE “0
- SELF-CONTROL
Creation of a custom Reporting Tool
Total Quality Agile Quality Process Management Workflow
Workflow for NCE / NCI management
Implementation of workflows for each type of NCE/NCI from detection to resolution by the responsible section, including the different approval steps.
Definition of the Claims Management Process
Workflow: Before and After
Complete NCE management flow with Lean technique integration
Step 1: NCE Opening by the Salesperson
Step 2-3: Approval & Investigation Flow to the Causing Section
(A3 + Ishikawa + PDCA)
Results of Methodology A3 with Managers: TOTAL NCIs
Evolution of the number of NCIs
2017
Evolution of NCIs (kg)
2017
