Template War Room Set-Up Rev. 0 03-10-06

War Room Set-up Guide

War Room Set-Up

• Once a suitable location is secured. Start building your room using this basic format.

Assessment Summary Commitment Letter Action Plan Action Plan indicators Sustaining Indicators Project Status

Project #:

Supplier: Holset, Charleston, SC USA Dates of Assessment : 7/18-7/27

Critical Prism Focus Customer Problem: Turbo Noise – Cummins

Bent Blades – Holset.

Direct Root Cause: Bent Blade - Manual Process.

Detection Root Cause: Reliance on Variable Sorting Rig (VSR) tester.

Systemic Cause (5- Why Based):

New process did not consider bent blades at assembly station as a possible failure mode during introduction.

Process Control Focus FMEA Adequacy: FMEA is not a living document. No linkage to operation . FMEA did not match

Control Plan. Ranking system not appropriate or consistent. FMEA construction is incorrect.

Control Plan Adequacy:

Control Plan and PFMEA linkage is inconsistent.

Implementation Adequacy:

Some items on plan not evident on floor, particularly Receiving Inspection

Systemic Analysis – Weakness:

PFMEA not used as a tool, not up to date, Lessons Learned seldom incorporated in existing products. Items on FMEA not consistently carried through to Control Plan.

System Focus Systemic Analysis – Weakness: 1

Visual Management- Visual factory, 5-S, and scoreboards not used effectively on plant floor.

Weakness: 2 Material Flow Control- Control of Non-conforming material, Handling practices, part Identification, and Hidden Factories not effective. Note: Inconsistent with documented process flow. The following, are key weakness, noted during the assessment; hidden factories, improper usage and storage of racks, whip/supplied & finished product storage and identification/disposal of non-conforming material.

Weakness: 3 LPA- LPA system is not well defined. LPA is not used to drive improvements. Process is immature.

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Project Dates: Start – Target Finish –

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Concurrence:

Supplier Project Leader:

Name: Date: Signature:

Supplier Sr. Executive Sponsor:


QAAT Director:


Chrysler Group SQ Sr. Mgr:


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Supplier locations for read across:

1.

2. 3. 4.

------------------------------------------------------------------------------------------------------------------------------------------------------------------ Monthly Progress Review Meeting Schedule:

ID #

Metric (where applica

ble)

ChampionStart Date

End Date Status Comment

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QAAT Action Plan

Supplier :

Action ItemID #


ble)

ChampionStart Date


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QAAT Action Plan

Supplier :

Action Item

0

50

100

Identify high risk suppliers for quality spills

Analyze PRISM’s and other indicators for selected high risk suppliers to determine deficient business processes

Establish “improvement need” with supplier at corporate level

Perform assessment of appropriate supplier processes using standard tools

Complete Assessment document and Identify Systemic Deficiencies

Form Project Team, including supplier, QAAT, Assembly SQ, subject experts as required (Supplier leads)

Analyze Assessment document, develop corrective action work plan, and determine project deliverables

Develop and sign statement of work with committed improvement, measures, and timing

Make focused training available to the Project Team

Execute the work plan

Measure project results, monitor work plan adherence, and provide weekly status reports

Confirm Agreement on Identified Systemic Deficiencies

QUALITY ASSURANCE AND AUDIT TEAM

Work Process

Assembly Supplier Quality

QAAT & Assembly SQ

Assembly SQ, Commercial Procurement, QAAT, Supplier Sr. Exec.

QAAT Lead Assessor, Supplier Leader, QAAT Leader

QAAT Lead Assessor, Supplier Leader, QAAT Leader

Supplier Leader, QAAT Leader

Project Team

Project Team & Supplier Sr. Executive

Project Team

Project Team

Project Team

Supplier Sr. Executive, QAAT Leader

Step 1

Step 2

Step 3

Step 5

Step 6

Step 8

Step 9

Step 10

Step 11

Step 12

Step 13

Step 7

Participants

Establish “improvement need” with supplier on-site at manufacturing location

Step 4Assembly SQ, QAAT, Supplier manufacturing location Exec. Mgt.

0

50

100

0

50

100

Cust. Prob: MF0Direct Root Cause: HF0Detection R/C: C0Sys. Cause (5 why based): CC0

Actual 5-Why

FMEA Adequacy: Weakness 1: LP0C/P Adequacy: Weakness 2: OC0Imp. Action Adequacy: Weakness 3: SS0Systemic Analysis Weakness:

OS0SV0M0

WAR BOARD

Issue Focus Detail (SLIDE)

ISSUE FOCUS System Weekness 1

MF0 Action Plan HF0 Action Plan

Supplier Lead Sheet

(Supplier Overview)

QAAT Assessment Phases Issue /

Control / System Focus

Control Focus Detail

(SLIDE)

CONTROL FOCUS SYSTEM FOCUS System Weekness 2

LP0 Action Plan OC0 Action Plan

SV0 Action PlanSystem

Focus Detail (SLIDE)

QAAT ASSESSME

NT TOOL (completed)

System Weekness 3

OS0 Action Plan

*Alternate Arrangement

* Also known as the Jeffcean War board

Print the following slides for your set-up.

Assessment Summary

Commitment Letter

Action Plan

Action Plan Indicators

Sustaining Indicators

Project Status

War Room Set-Up• As each Focus is completed add

Documentation.

Issue Focus Control Focus System Focus

ID #


ble)

ChampionStart Date


1

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1b1ba1bb1bc

2

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QAAT Action Plan

Supplier :

Action Item

ISSUE FOCUSCONTROL FOCUS SYSTEM FOCUS

Systemic Weakness SummaryThe Critical Few

Project Commitment Letter

Improvement Plan

Read Across

System Assessment

QAAT Process Control Focus

FMEA & ControlPlan Effectiveness

FMEA Adequate?

Control PlanAdequate?

Effectively Implemented?

CONTROL FOCUS

System Assessment Analysis of General Process Control:

Purpose:FMEA & Control Plan AdequacyDegree of implementationMethods of Detecting Issues

Method:Review Selective Parts (over period of time)Document linkages (FMEA, Control Plan…)Implementation on the floorRelationship to Real Issues (Scrap, defects,…)Detection Audit

Detection Audit

Dedicated Detection

Audit

Detection Methods

Adequate?

Issue Focus

Control Focus

System Focus

Vijay Example

Template War Room Set-Up Rev. 0 03-10-06

Documents

Transcript of Template War Room Set-Up Rev. 0 03-10-06