APSS 011 1.2 - 0 Defect.docx

APS Standards Autoliv ChinaName APSS 011APS Standard Autoliv CHINAZero DefectAPSS 011Distribution to: Autoliv China APS Managers, Autoliv China Plant ManagersAuthor:Carl HuXXApproved by:Frederic BurguezVersion:1.2Release date: 29-06-2014Pages: 5APSS 011 version 1.2 / 21-08-2012 Page 8 of 8Table of Contents APSS 011INTRODUCTION31PURPOSE32SCOPE33RESPONSIBILITY34PROCEDURE35REFERENCES86APPENDICES86.1Appendix A Visual Board86.2Appendix B Defect Record86.3Appendix C Defect Calendar86.4Appendix D Action Register87MODIFICATION INDEX8Introduction1 PurposeThe purpose of this standard is to describe Autoliv Chinas zero defect activity.This activity is created to give opportunity to re-set quality mindset of all employees in autoliv plant.2 ScopeAll plants within Autoliv China3 ResponsibilityIt is the responsibility of the site APS leader and PQM to plan, implement and execute this standard4 Procedure4.1 The zero defect activity is the teamwork in genba.Participant should be Plant Manager, Manufacturing Manager, AMC Manager, PQM, PQ, PE, SQE, IE, CQ, COP, APS etc.4.2 What is defect?4.2.1 NCE/NCM4.2.2 Customer PPM4.2.3 Components defect Components defect that is assembled to the product Components defect that is found before assemble to the product and after incoming4.2.4 Dropped down parts4.2.5 Defect on a change overSetting piece is defined in the standard during change over, such like die casting process, webbing process etc.4.2.6 DPMUIt includes all defects recorded throughout the process steps that cause units and parts to be rejected, reworked, re-run or scrapped. Defects are recorded independent from the root cause: sub supplier, tooling, maintenance or handling all parts or units which are not passing first time through the line4.2.6.1 DPMU TableIn the table below some issues are explained, how they shall be counted or not counted in the formula for DPMU:4.2.6.2 Re-RunRepeating a process step with the same part (e.g. repeating of testing operations orfolding a bag a 2nd time)4.2.6.3 ReworkAll corrected/repaired defects in or out of the process flow and which is not a standard operation (e.g. cover with scratch replacement; misaligned nut on bolt replacement)4.2.6.4 RejectPart separated from the process flow and put into the reject box (e.g. wrong assembled part or part with bad riveting). 4.2.6.5 ScrapRejected parts that can never be used again (e.g. inflator without barcode, split line open of wrap).4.3 Defect matrix in zero defect activity4.4 Workshop openFollow strictly the workshop process, why this WS, Action Register, intensive days, success story, Yokoten etc.4.5 Daily review AMCs review the actual situation in a daily meeting Inform a trend (Going worse / better) New type of defect happening Problem for action progress Plant management team review the zero defect status in daily plant status review4.6 Weekly review PQM and APS managers review the zero defect status in the genba with the workshop leaders Inform a trend (Going worse / better) New type of defect happening Problem for action progress4.7 Monthly review Plant management team review the zero defect status in the genba every month (Minimum) Trend of defect happening Root cause analysis of Top items in AMC/G Deep dive and coach the team as OJT Progress of actions Support needed4.8 Others AMC/G team goes to Genba when the top item happens in order to catch the root cause Follow the CPC process for any actual changes by Kaizen When change or create the SWI, it shall be made by team include operator then tried by team member by themselves APS and related managers support education and training of required items4.9 Standard of visual board4.10 Zero defect status board The Golden Flower: Keeping zero defects more than 26 days. The Silver Flower: Keeping zero defect more than 15 days and less than 26 days The Copper Flower: keeping zero defect more than 7 days and less than 15 days4.11 The defect market:5 ReferencesALA APS S 001 Visualization of Zero Defect Activity6 Appendices6.1 Appendix A Visual Board6.2 Appendix B Defect Record 6.3 Appendix C Defect Calend