Welcome to San Mauro plant - Settore...
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Welcome to San Mauro plant San Mauro Torinese This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used, duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Transcript of Welcome to San Mauro plant - Settore...
Welcome to San Mauro plant
San Mauro Torinese
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Escape information
We are here
NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY SPA
C2
C1
B1
A1
A2
B2
Meeting Point Medical Room Ambulance
Escape way Index
Safety advices
Plant information
Products
Main Processes
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Emergency Signals
• Keep calm
• Don’t run
• Don’t use elevators
• Go to the external gathering area:
• Wait for emergency coordinators
• Follow those signals:
EXIT
EMERGENCY
HEARING A DOUBLE TONE SIGNAL:
Index
Safety advices
Plant information
Products
Main Processes
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Plant wide. Smoking
allowed only in
dedicated area outside
the plant
Always. Visitors must
dress reflective safety
jackets to be easily
recognized
Always.
Be aware of all vehicles
Always.
Respect all internal
traffic & Safety rules
Index
Safety advices
Plant information
Products
Main Processes
Visitors recommendations
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Index
Safety advices
Plant information
Products
Main Processes
Agenda
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duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
San Mauro plant
Overview
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Fiat Industrial overview
Fiat Industrial, a specialist supplier of agricultural and construction
equipment, commercial vehicles, power train components and
services to industry.
Agricultural and
Construction
Equipment
Commercial Vehicles
and Buses
Power Train
Components for
Industrial applications
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
CNH Overview
Total Revenues: $15.6 Billion* in 2010
2010 Total Revenues by Business 2010 Net Sales of Equipment
by Region
Agricultural Equipment
US $11.5 billion
Construction
Equipment
US $2.9 billion
Financial Services
US $1.2 billion
North America
US $6.0 billion
Latin America
US $2.8billion
Western Europe
US $3.3 billion
Rest-of-World
US $2.4 billion
Note: Does not include Financial Services
*Consolidated Revenue
Note: Financial Services US $1.2B includes Eliminations
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
CNH Overview
Case and New Holland Brands
Two global agricultural brands Two global construction brands
Agricultural tractors in
Western Europe Excavators in North America
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
CNH presence in America
17 Manufacturing Locations
Brazil
Belo Horizonte
Crawler excavators,
tractor loader backhoes,
crawler dozers, wheel
loaders, graders
Curitiba
Tractors, combines
Piracicaba
Sugar cane harvesters,
coffee harvesters,
planters, sprayers
Sorocaba
Combines
Canada
Saskatoon, SK
Planting, seeding
equipment, components
Mexico
**Queretaro
Tractors, components
** Guanajuato
Tractors
United States
Benson, MN
Sprayers, cotton pickers/
packagers, floaters
Burlington, IA
Tractor loader backhoes,
tractor loaders, forklifts
* Calhoun, GA
Crawler excavators,
dozers
Fargo, ND
Tractors, wheel loaders
Goodfield, IL
Soil management
(tillage equipment)
Grand Island, NE
Combines, windrowers
New Holland, PA
Hay and forage
equipment
Racine, WI
Tractor assembly,
transmissions
* Springfield, MO
Parts
Wichita, KS
Skid-steer, track loaders
* Consolidated Joint Venture
**Unconsolidated Joint Venture
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
CNH presence in Europe, Asia
21 Manufacturing Locations Austria
St. Valentin
Tractors
Belgium
Antwerp
Components
Zedelgem
Combine harvesters,
hay and forage
China
Harbin
Tractors
* Shanghai
Tractors, components
France
Coex
Grape harvesters
Croix
Cabs
Tracy-Le-Mont
Hydraulic Cylinders
Germany
Berlin
Graders
India
New Delhi
Tractors
** Pithampur
Tractor loader
backhoes, compactors
Italy
Jesi
Tractors
Lecce
Excavators,
telehandlers, dozers,
wheel loaders
Modena
Components
* San Mauro
Crawler excavators,
Wheeled excavators
Mini Excavators
Pakistan
**Dera Ghazi Khan
Tractors
Poland
Plock
Combines, components
Russia
* Naberezhnye Chelny
Tractors, Combines
Turkey
**Ankara
Tractors
United Kingdom
Basildon
Tractors, components
Uzbekistan
* Tashkent
Tractors, planters
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
San Mauro Torinese Plant area & figures
Index
Safety advices
Plant information
Products
Main Processes
Area total 202.000 sqm
covered 56.000 sqm (including new warehouse)
Staff 480 people
Product lines: Chex
Mhex
Whex
Midi Whex
Cylinders for local production, sister Plants (Calhoun, Belo H. & Lecce)
Key Data
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
1986 Start-up CHEX-WHEX production
1993 ISO 9001 Quality system Certification
(1° C.E. Plant in Europe)
1997-99 Range renewal (TIER 1) - 13 models
1999 ISO 14001 Enviromental Certification
2001 ISO 9001 VISION 2000 Certification
2002 KOBELCO global alliance
2003 Range renewal (TIER 2) - 13 models
2004 Production of excavator number 40.000°
2005 New Holland brand launch
2006 Launch new Product line (WHEX)
2007 Full range renewal (TIER 3) – CHEX and WHEX
2008 Kick-off WCM program, Production of excavator
number 50.000°,
2009 New painting system
2010 Safety Management System (OHSAS 18001) Certification
2011 New Mini Excavator line and New automatic warehouse
Plant history
Index
Safety advices
Plant information
Products
Main Processes
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Product portfolio
Crawler
Excavator
Midi
Wheel
Excavator
Heavy
Wheel
Excavator
Index
Safety advices
Plant information
Products
Main Processes
Mini
Excavator
Range
13t-48t
9t-12t
12t-21t
1.6t-5t
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
CUTTING
ASSY LINE
CHEX
MHEX
WHEX
MWHEX
FA
BR
ICA
TIO
N
LO
WE
R F
RA
ME
FA
BR
ICA
TIO
N
UP
PE
R F
RA
ME
PAINTING
Lower /upper frame BUFFER STOCK
FINISHING
FUNCTIONAL
TEST
SHIPPING
AREA
BUFFER
STOCK
FABRICATION
ARM
FABRICATION ARM
CYLINDERS
FABRICATION
AND
ASSEMBLY
PAINTING
CYLINDERS
PA
INT
ING
AR
M
RAW
MATERIALS
FINISHED
GOODS
Building 1
Building 2
Frames
Boom & Arms
Cylinders
Process flow
Index
Safety advices
Plant information
Products
Main Processes
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Around 300 live suppliers
• 50% Italy
• 28% Japan
• Around 18,000 live parts
• Logistic flow
• Bulky parts
• Direct feeding to the assembly lines
• Class A and B parts
• Automatic warehouse: 5,250 storage locations, 3 loading bays, 3 unloading bays
• 3 kitting areas
• Class C parts
• Supermarket: 2,100 storage locations
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
49%
28%
10%
9%2% 2%
Jan-May 2011
Italy
Japan
Europe
Intercompany
China + Rest of Asia
Other
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Output:
• blanks for internal production
• Main Equipment:
• 3 Cutting machines
• 2 Deburring machines
• 2 Chamferring robots
• 2 Presses
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Output:
• CHEX lower frame
• WHEX lower frame
• CHEX upper frame
• WHEX upper frame
• Main Equipment:
• 10 Welding robots
• 5 Machining centers
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Output:
• CHEX booms and arms
• WHEX booms and arms
• TLB booms (CNH Lecce)
• Main Equipment:
• 14 Welding robots
• 2 Machining centers
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Output
• Hydraulic cylinders
• CHEX, WHEX San Mauro
• CHEX (CNH Calhoun)
• CHEX (CNH Belo Horizonte)
• DOZ (CNH Lecce)
• Main Equipment:
• 2 Friction welding machines
• 9 Lathes
• 4 Welding Robots
• Skiving/Burnishing machines
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• Equipment
• 1 Robotized painting line (frames)
• 1 Painting line (booms)
• 1 Painting line (cylinders)
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Process flow
• CHEX assembly line
• 25 stations
• Max output: 10 units/shift
• MHEX assembly line
• 9 stations
• Max output: 10 units/shift
• WHEX assembly line
• 3 stations
• Max output: 1 unit/shift
• MWHEX assembly line
• 2 stations:
• Max output: 1 unit/shift
Suppliers Cutting Frame Booms Arms
Cylinders Painting Assembly
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Quality Plant process overview
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
San Mauro plant certifications
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
WORLD CLASS MANUFACTURING (WCM)
WCM
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
WORLD CLASS MANUFACTURING (WCM)
World Class Manufacturing is a Change Program designed to reach world class
performances in Operations, cutting out Wastes and Losses, enhancing Standards
& Methods, Involving All Employees in Continuous Improvement.
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Project focus & targets
People involvement, value creation, customer satisfaction Values
Co
st
Dep
loym
en
t
Workplace
Organization Quality Maintenance Logistic
Focus Productivity Quality
Improvement
Technical
Efficiency
Service
Level
Method
& std.
Total Industrial
Engineering
Total Quality
Control
Total Productive
Maintenance Just in Time
Target zero
waste
zero
defects
zero
breakdowns
minimal
inventory
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
WCM pillars
L
og
istics / C
usto
me
r S
erv
ice
S
afe
ty /
Hygie
ne
& W
ork
ing
En
vir
on
me
nt
C
ost
De
plo
ym
en
t
E
nvir
on
me
nt
E
arl
y P
rod
uct /
Eq
uip
me
nt M
an
ag
em
en
t
P
eo
ple
Deve
lop
me
nt
F
ocu
se
d Im
pro
ve
me
nt
Q
ua
lity
Co
ntr
ol
A
uto
no
mo
us A
ctivity / W
ork
pla
ce O
rg.
P
rofe
ssio
na
l Ma
inte
na
nce
Commitment, Involvement, Communication, Understanding, Measurement, Deployment,
Implementation, Evaluation, Standardization with Visibility, Documentation
World Class Manufacturing
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duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Audit System
Progress is measured through formalized Audits, which score:
10 Pillars, rated from 0 to 5, based on roadmaps with 7 steps
10 Management Criteria, rated from 0 to 5 each one
Min: 0 - Max: 100
Bronze >= 50 Silver >= 65 Gold >= 80
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Management of Quality Problems: QA MATRIX
WCM
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QA-MATRIX inputs
MES
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QA-MATRIX format
QA – Matrix is our input of defects for the q-gate list and the resulting checklist.
It priortizes the defects (man, method, machine and material) depending on:
- the frequency (how often they occured),
- the cost (labour & material cost for repair) and
- the detection point, depending on how late in the process the defect was found
(end of line check = low score vs. customer = high score).
Models: WHEX CHEX MHEX MIDI TLB .. ..
Total volume: 77 252 375 40 692 .. ..
Models: WHEX CHEX MHEX MIDI TLB .. ..
CQA volume: 9 26 55 1 200 .. ..
Referring period:
Q2_Q3 - 2011
Help A Help A A Help B B Help C C
n. % R=1:5 € R=1:5 min R=1:5 1 2 3 4 4 5 7 8 30
CH
EC
K
Plan Do Check ActBefore
5Q0D
After
5Q0D
ReclamoTLB Bracci TLB con verniciatura NOK (segn. Lecce)
45 6,5 3 300 3 120 3 30 540 45 45 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Bracci
Reclamo Mhex Rotture braccio mono Mhex5 1,3 2 800 5 240 4 30 540 5 5 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Rottura braccio mono tra mozzo e fiancata (modello E245B) 6 2,4 2 3.000 5 360 4 30 540 6 6 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura braccio 3 in prossimità del mozzo (modello E385B) 3 1,2 2 3.000 5 360 4 30 540 3 3 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
ReclamoTLB Bracci TLB non a disegno (lavorazioni meccaniche)
18 2,6 2 150 3 120 3 30 360 18 18 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Progetto SPC
Reclamo TLB Bracci TLB non a disegno (saldature NOK) 10 1,4 2 150 3 120 3 30 360 10 10 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x SOP & OPL
Reclamo Chex Vernice sfogliata (cilindri chex segn. ODB)4 1,6 2
2503 120 3 30 360 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Cilindri
Reclamo Chex Verniciatura ralla-ripari inferiori sfumata (segn. UK) 3 1,2 2 150 3 120 3 30 360 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
ReclamoChex Perdita da tubo flex 87664902 (Raccordo mot. traslaz. e giunto centrale)
3 1,2 2 60 2 80 3 30 300 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore+ kaizen
Reclamo Chex Rottura braccio in prossimità del mozzo (modello E215B) 1 0,4 1 3.000 5 360 4 30 270 1 1 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura saldatura fondello cilindro benna (11E-0218)1 0,4 1 1.500 5 180 4 30 270 1 1 0% 0% 0% 0% 0% 0% 0% 0% 100% 0% x Kazien saldat, cilndri
Reclamo Chex Verniciatura zavorra con RAL non corrispondente a RAL sportelli (segn. ODB) 1 0,4 1 1000 5 180 4 30 270 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Ruggine su valvola martello (serie C)4 1,6 2
1002 60 2 30 240 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% Azione su fornitori
Reclamo Chex Ruggine su braccio boom causa pallini di granigliatura3 1,2 2 40 2 60 2 30 240 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
5Q0DActivities progress
Processes - % of cases
WH
EX
Ase
mb
ly
CA
RP
EN
TE
RIA
BR
AC
CI
CA
RP
EN
TE
RIA
TO
RR
ET
TE
CA
RP
EN
TE
RIA
TE
LA
I
CIL
IND
RI
VE
RN
ICIA
TU
RA
CH
EX
Asse
mb
ly
MID
I A
sse
mb
ly
TA
GL
IO
MH
EX
Asse
mb
ly
So
urc
e
Lab.
Cost.
Fre
quency %
N.
of
cases -
(during t
he
refe
rrin
g p
eriod)
Fre
qu
en
cy
CQ
A S
co
re -
IF
ap
plica
ble
Ma
teri
al C
os
t
Mat.
Cost.
La
bo
ur
Co
st.
Detection
DE
LIB
ER
A
Pro
du
ct
Problem Description
LIN
EA
OK
OL
FU
NZ
ION
AL
E
DE
AL
ER
CL
IEN
TE
/SIC
UR
EZ
ZA
QA MATRIX - PLANT Referring period: Q2_Q3 - 2011
CA
RP
EN
TE
RIA
TO
RR
ET
TE
CA
RP
EN
TE
RIA
TE
LA
I
Processes - n. of cases
VE
RN
ICIA
TU
RA
A*(B+C)*
(∑Di)
Responsible
Priority
Index
Di
CA
RP
EN
TE
RIA
FIN
IZIO
NE
CQ
A
MID
I A
sse
mb
ly
TA
GL
IO
WH
EX
Ase
mb
ly
CH
EX
Asse
mb
ly
MH
EX
Asse
mb
ly
CA
RP
EN
TE
RIA
BR
AC
CI
CIL
IND
RI
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
0
1000
2000
3000
4000
5000
6000 56275033
2149 2078 2047
453 398 303 114 106
Pri
ori
ty In
dex
Processes
MATERIAL
QUALITY
LOSSES
METHOD
13% 55%
MAN
32% 0%
MACHINE
Referring period:
2Q / 3Q - 2011
Help A Help A A Help B B Help C C
n. % R=1:5 € R=1:5 min R=1:5 1 2 3 4 4 5 7 8 30
Reclamo Mhex Rotture braccio mono Mhex 12 3,2 3 800 4 240 4 30 720 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 12 720 100% 0 0 0
Reclamo Mhex Cingoli in gomma danneggiati 3 0,8 1 2.400 5 120 3 30 240 3 240 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita olio dall’ o-ring 72283052. Segnalazione dealer modello E39B 5 1,3 2 70 2 60 2 30 240 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 240 100% 0 0 0 0 0 0
Reclamo Mhex Radiatore sostituito perchè ammaccato / rovinato 1 0,3 1 1.000 2 120 3 30 210 0 0 0 0 0 0 0 0 0 0 0 0 0 1 210 25% 50% 25% 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita refrigerante da radiatore: componente sostituito 1 0,3 1 1.000 4 80 3 30 210 0 0 0 0 0 0 0 0 0 0 0 0 0 1 210 100% 0 0 0 0 0 0 0 0 0
Reclamo Mhex Motore non si avvia: motorino in corto. 1 0,3 1 1.100 5 60 2 30 210 0 0 0 0 0 0 0 1 210 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Cavo danneggiato su impianto elettrico: la macchina improvvisamente si blocca 1 0,3 1 250 3 120 3 30 180 0 0 0 0 0 1 180 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Macchina consegnata in con mancante configurazione carichi sospesi 1 0,3 1 700 4 60 2 30 180 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 180 20% 80% 0
Reclamo Mhex Rottura cinghia pompa acqua puleggia ventola dovuto a mancato serraggio viti ventola 1 0,3 1 550 4 60 2 30 180 0 0 0 0 0 0 0 1 180 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Flex scoppiato su valvola anticaduta (flex invertiti) 2 0,5 1 1 1 180 4 30 150 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 150 100% 0
Reclamo Mhex Sostituita elettrovalvola/pressostato su distributore 1 0,3 1 500 3 60 2 30 150 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 150 100% 0 0 0 0 0 0 0 0
Reclamo Mhex A/C non funziona causa elettrovalvola non alimenta elettroventola non alimentata per cablaggi NC 1 0,3 1 200 2 60 2 30 120 0 0 0 0 1 120 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Ripristino verniciatura 2 0,5 1 200 2 60 2 30 120 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Cingolo dx non si tende 1 0,3 1 150 2 60 2 30 120 1 120 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Motore non si accelera: diagnosi impianto 1 0,3 1 150 2 60 2 30 120 0 0 0 0 0 0 0 0 0 0 0 0 1 120 100% 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita connessione idraulica braccio (O-RING ZD12P01400 sostituito) 1 0,3 1 100 2 60 2 30 120 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 120 100% 0 0 0
Reclamo Mhex Corrosione su cabina 1 0,3 1 120 2 60 2 30 120 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita olio da serbatoio gasolio ( o'ring da sostituire) 2 0,5 1 100 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 90 100% 0 0 0 0 0 0
Reclamo Mhex Perdite olio da pompa idraulica 1 0,3 1 125 2 10 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 1 90 100% 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdite olio dal giunto modelli 15/16/18 2 0,5 1 150 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 2 90 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Macchina con decal sbiadita 1 0,3 1 120 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita olio da raccordi distributore 2 0,5 1 80 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 90 80% 20% 0 0 0 0 0 0 0 0
Reclamo Mhex Corrosione su lama 1 0,3 1 60 1 40 2 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Macchina con serratura interna porta cabina danneggiata 1 0,3 1 80 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita olio da flex 87635608 1 0,3 1 150 2 30 1 30 90 0 0 0 0 0 0 0 0 0 0 0 0 0 1 90 100% 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita da filtro di aspirazione 2 0,5 1 50 1 60 2 30 90 0 0 0 0 0 0 0 0 0 0 0 0 2 90 100% 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Scrostatura vernice torretta 375 100,0 5 25 1 45 2 5 75 0 0 0 0 0 0 0 0 0 375 75 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Scrostatura vernice telaio 375 100,0 5 25 1 45 2 5 75 0 0 375 75 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
CQA Mhex Difetti estetici saldatura cabina 6 20 36,4 5 1 1 10 1 7 70 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Danneggiamenti di verniciatura 7 1,9 2 1 1 90 3 8 64 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7 64 50% 50% 0 0 0
Reclamo Mhex Perdita olio da manipolatore causa flex lento 1 0,3 1 50 1 15 1 30 60 0 0 0 0 0 0 0 0 0 0 0 0 0 1 60 100% 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perdita olio su blocchetto 72271359, causa raccordi lenti 1 0,3 1 40 1 15 1 30 60 0 0 0 0 0 0 0 0 0 0 0 0 0 1 60 100% 0 0 0 0 0 0 0 0 0
Reclamo Mhex Livello indicatore combustibile non funziona 2 0,5 1 20 1 25 1 30 60 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 60 100% 0 0
Reclamo Mhex Parte superiore porta cabina con ruggine 3 0,8 1 10 1 15 1 30 60 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
CQA Mhex Difetto fusione zavorra 6 9 16,4 4 10 1 30 1 7 56 0 0 0 0 0 0 0 0 9 56 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0
CQA Mhex Difetti di finitura vernice componenti lama e cilindri 6 10 18,2 4 15 1 30 1 7 56 0 0 5 28 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 28 100% 0 0 0
Reclamo Mhex Livello olio idraulico NOK 5 1,3 2 50 2 15 1 8 48 0 0 0 0 0 0 0 0 0 5 48 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0
Ass.y line Mhex Staffe NOK (problemi su saldature e dimensioni) 10 2,7 2 300 3 300 4 3 42 0 0 10 42 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Scrostatura vernice braccio e lama 56 14,9 4 15 1 30 1 5 40 0 0 0 0 0 0 0 0 0 56 40 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Livello olio idraulico NOK 96 25,6 5 15 1 15 1 4 40 0 0 0 0 0 0 0 0 0 96 40 100% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Livello parafluè NOK 158 42,1 5 5 1 15 1 4 40 0 0 0 0 0 0 0 0 0 158 40 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Flex traslazione invertiti (P2-P3) 4 1,1 2 1 1 180 4 4 40 0 4 40 80% 20% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Bloccaggio perno fermo rotazione NOK 5 1,3 2 60 2 50 2 4 32 0 0 5 32 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Atterezzo da ingrassare 50 13,3 4 15 1 30 1 4 32 0 0 0 0 0 0 0 0 0 50 32 100% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Radiatore ammaccato / rovinato 70 18,7 4 5 1 30 1 4 32 0 0 0 0 0 0 0 0 0 0 0 0 0 70 32 25% 50% 25% 0 0 0 0 0 0 0 0 0
Funzionale Mhex Interferenza flex su deviatore (lay out NOK) 64 17,1 4 1 1 30 1 4 32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 64 32 100% 0 0 0 0 0 0 0 0
Funzionale Mhex Interferenza flex su attrezzo-braccio (lay out NOK) 58 15,5 4 1 1 30 1 4 32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 58 32 100% 0 0 0
Funzionale Mhex Cavo acceleratore da registrare 53 14,1 4 1 1 30 1 4 32 0 0 0 0 0 0 0 53 32 80% 20% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Operator manual errato o non pervenuto 6 1,6 2 1 1 5 1 8 32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
CQA Mhex Disallineamento cover con zavorra 6 8 14,5 4 1 1 20 1 4 32 0 0 0 0 0 0 0 0 8 32 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Cofanature da registrare 38 10,1 4 1 1 30 1 4 32 0 0 0 0 0 0 0 0 38 32 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Lama storta 9 2,4 2 1 1 60 2 4 24 0 0 9 24 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita da flex su attrezzo 16 4,3 3 1 1 30 1 4 24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 16 24 100% 0 0 0
Funzionale Mhex Livello olio motore NOK 20 5,3 3 15 1 15 1 4 24 0 0 0 0 0 0 0 0 0 0 0 0 20 24 100% 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Manca grasso su poli batteria 15 4,0 3 1 1 15 1 4 24 0 0 0 0 0 0 0 15 24 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita parafluè da radiatore sfondato (spessore rondella errata) 2 0,5 1 80 2 180 4 4 24 0 0 0 2 24 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Riparo radiatore cabina da allineare 27 7,2 3 1 1 15 1 4 24 0 0 0 0 0 27 24 80% 20% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ass.y line Mhex Ossidazione su fori incernieramento colonna snodo 200 53,3 5 10 1 30 1 2 20 0 0 200 20 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Stampigliatura s/n macchina, su torretta, NOK 1 0,3 1 5 1 15 1 8 16 0 0 1 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Valvola martello montata al contrario 9 2,4 2 1 1 30 1 4 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 9 16 100% 0 0 0
Funzionale Mhex Perdita da flex su deviatore 4 1,1 2 1 1 30 1 4 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 16 100% 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita da flex serbatoio olio 4 1,1 2 1 1 30 1 4 16 0 0 0 0 4 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Cavo brandeggio da registrare 4 1,1 2 1 1 30 1 4 16 0 0 0 0 0 0 0 0 4 16 80% 20% 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex CE smarrito 3 0,8 1 5 1 20 1 8 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Reclamo Mhex Perno incernieramento benna di diametro errato 1 0,3 1 1 1 15 1 8 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Cavi su batteria non fissati 6 1,6 2 1 1 15 1 4 16 0 0 0 0 0 0 0 6 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Avvisatore acustico: connessioni scollegate 7 1,9 2 1 1 15 1 4 16 0 0 0 0 0 0 0 7 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Sensore temperatura scollegato 5 1,3 2 1 1 15 1 4 16 0 0 0 0 0 0 0 5 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Eccessivo grasso su attrezzo 4 1,1 2 1 1 15 1 4 16 0 0 0 0 0 0 0 0 0 4 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Contaore non fissato correttamente 5 1,3 2 1 1 15 1 4 16 0 0 0 0 0 0 0 5 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Cavo acceleratore da fascettare 4 1,1 2 1 1 15 1 4 16 0 0 0 0 0 0 0 4 16 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita olio da flex (crimpatura) CVB3- CVB5 1 0,3 1 10 1 60 2 4 12 0 0 0 0 1 12 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Assemblati cingoli in gomma anziché in ferro 3 0,8 1 1 1 60 2 4 12 3 12 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita di paraflue da sensore temperatura su motore termico 3 0,8 1 1 1 60 2 4 12 0 0 0 0 0 0 0 0 0 0 0 0 3 12 100% 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Flex su deviatore piegato: sostituito 1 0,3 1 1 1 60 2 4 12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 12 100% 0 0 0 0 0 0 0 0
Funzionale Mhex Manovra posizionatore invertita, causa inversione flex mandata 1 0,3 1 1 1 45 2 4 12 0 0 0 0 0 0 0 0 0 0 0 0 0 1 12 100% 0 0 0 0 0 0 0 0 0
Funzionale Mhex Connessioni invertite martello cesoia 2 0,5 1 1 1 30 1 4 8 0 0 0 0 0 0 0 0 0 0 0 0 0 2 8 50% 50% 0 0 0 0 0 0 0 0 0
Funzionale Mhex Olio idraulico in eccesso 2 0,5 1 1 1 30 1 4 8 0 0 0 0 0 0 0 2 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita da flex su giunto rotante 1 0,3 1 1 1 30 1 4 8 0 0 1 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita da tubi rigidi su giunto rotante 1 0,3 1 1 1 30 1 4 8 0 0 1 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Staffa sostegno valvola servocomandi montata al contrario 2 0,5 1 1 1 30 1 4 8 0 0 0 0 0 0 0 0 0 0 0 0 0 2 8 100% 0 0 0 0 0 0 0 0 0
Funzionale Mhex Viti perni lente su attrezzo 2 0,5 1 1 1 30 1 4 8 0 0 0 0 0 0 0 0 0 2 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Filtro olio motore bollato 1 0,3 1 5 1 15 1 4 8 0 0 0 0 0 0 0 0 0 0 0 0 1 8 100% 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Perdita da flex motore traslazione 1 0,3 1 5 1 15 1 4 8 0 1 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Or rotto/pizzicato su flangia serbatoio olio 2 0,5 1 1 1 15 1 4 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 8 100% 0 0 0 0 0 0 0
Funzionale Mhex Interruttore ventola riscaldamento, invertito con interrutore tergicristallo 2 0,5 1 1 1 20 1 4 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 8 100% 0 0
Funzionale Mhex Radiatore riscaldamento ammaccato/rovinato 2 0,5 1 1 1 20 1 4 8 0 0 0 0 0 0 0 0 2 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Minimo automatico non funziona: connessioni scollegate 3 0,8 1 1 1 15 1 4 8 0 0 0 0 0 0 0 3 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Interferenza cavi elettrici sotto pedana (lay out NOK) 2 0,5 1 1 1 15 1 4 8 0 0 0 0 0 0 2 8 50% 50% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Cingoli in gomma lenti 1 0,3 1 1 1 15 1 4 8 1 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Funzionale Mhex Interferenza cavo batteria con marmitta (lay out NOK) 3 0,8 1 1 1 15 1 4 8 0 0 0 0 0 0 3 8 100% 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
P18 P22 R23R16 R17 P14 R24 R25 P16 P17 P20 P21LM8 R15LM5
M2
- M
AC
HIN
E
GR.RADIATORI +
GR.SUPP.POSTO GUIDA
DX/RADIATORE+GR.VALVO
LA
SERVOCOMANDI+GR.VALV
OLA DI
RITORNO+GR.VALVOLA
AUX+GR.VALVOLA
GR.DISTRIBUTORE
GR.SERBATOIO OLIO HYD
16/18 + SERBATOIO
GASOLIO T.T.
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
Cablaggio, kit decal,
collegamenti , batteria
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
Antigelo, gasolio, cilindro soll.,
braccio boom, ingrassaggio
M4
- M
AT
ER
IAL
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
Pio
rity
IN
DE
X
PREMONTAGGIO RALLA SU
TORRETTA
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
GR.MOTORE DIESEL +
GR.POMPA IDRAULICA
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
GR. CILINDRO SCAVO
+GR.CILINDRO BENNA+GR.
CILINDRO DI
SOLLEVAMENTO
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
GR.SERBATOIO OLIO HYD
PNB
FR
EQ
UE
NC
Y
FR
EQ
UE
NC
Y
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
M4
- M
AT
ER
IAL
M2
- M
AC
HIN
E
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
Ruspa, cilindro ruspa,
accoppiamento telaio torretta,
cilindro brandeggio PNB,
stampigliatura
FR
EQ
UE
NC
Y
Gruppo serbatoio olio, valvola
servo, motore rotazione valvola
a/c 30-35
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M1
- M
AN
M3
- M
ET
HO
D
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
Problem Description
R5 R6 LM1 LM2 LM3 LM6 LM7
Di
CA
RP
EN
TE
RIA
FIN
IZIO
NE
CQ
A
M4
- M
AT
ER
IAL
M4
- M
AT
ER
IAL
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
GR.TELAIO INFERIORE
La
bo
ur
Co
st. Priority
So
urc
e
Fre
qu
en
cy
Pro
du
ct
N.
of
cases -
(during t
he r
efe
rrin
g p
eriod)
CQ
A S
co
re -
IF
ap
plica
ble
Ma
teri
al C
os
t
Mat.
Cost.
Fre
quency %
M1
- M
AN
M2
- M
AC
HIN
E
Linea PNB - 16/18
M1
- M
AN
Sedile, gr convogliatore,
portaoggetti 40/50, zavorra,
colonna rotazione, cofano dx,
cofano ant., coperchio, cofano
post.
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
Lab.
Cost.
Serbatoio gasolio ,
bocchettone, gruppo pedana
p.g.
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
RE
CL
AM
I / S
ICU
RE
ZZ
A
Detection
DE
LIB
ER
A
LIN
EA
OK
OL
FU
NZ
ION
AL
E
DE
AL
ER
DEFECTS BY WORKING STATION AND BY M
SOTTOGRUPPI
FISSA(GIUNTO)
LM4
M4
- M
AT
ER
IAL
Montaggio valvola shuttle,
motore diesel e radiatore
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M2
- M
AC
HIN
E
A*(B+C)*(∑Di)
Cabalggio, gruppo cruscotto
p.g., manicotto
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
PREMONTAGGIO
GR.GIUNTO DI ROTAZIONE
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
M3
- M
ET
HO
D
GR.POSTO GUIDA GR.COFANATURE
GR.BRACCIO BOOM +
GR.BRACCIO SCAVO
STD/LUNGO +UNIONE
BR.BOOM+SCAVO
GR.PEDANA POSTO GUIDA
+GR.PEDALE
DX+GR.PEDALE SX +
PREM. LEVA
ACCELERATORE E
MANIP.+GR.PANNELLO
STRUMENTI DX +
MANIPOLATORI
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
Pio
rity
IN
DE
X
M1
- M
AN
M2
- M
AC
HIN
E
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
M4
- M
AT
ER
IAL
M3
- M
ET
HO
D
M4
- M
AT
ER
IAL
ETICHETTATURE TUBI FLEX
FR
EQ
UE
NC
Y
Pio
rity
IN
DE
X
M1
- M
AN
73 Lines
20 Lines
Attacked Not Attacked
6% 7%
28%
59%
P D C A
91% Priority Index
Attacked
QA Matrix analysis AA Process Identification: MHEX
QA-Matrix format
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QUALITY GATE Concept
Human Error Management
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
The purpose of the Q-Gate is to:
1.Avoid repetitive human errors
2.Not to release any defects to the
downstream processes
The QG is only one method to
reduce HE! We need to guarantee
quality at the process! QA Network
is a very powerful tool!
The purpose of the Q-Gate
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QA-Matrix by Zone
Process of the Quality Gate
Input: INPUT Sheet/
Downstream Processes
Input List with Defects detected in
downstream processes and originated
inside Q-Gate
Input:
One Offs identified*
Input:
Plant QA-Matrix
* If the inspector is
correctly saturated (this
also includes time for
administration of the
board, time for
feedback,…)
there will only be very few
defects that he can
identify during the
checklist checks!
Still, if we can identify
such a new defect, we
need to ensure, that we
record this information, to
be able to improve our
products!
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
0
2
4
6
8
10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Defects that can be attacked
with Q-Gate and the B/C
justifies the investment
B/C of defects does not justify cost of QG:
Then the problems need to be managed
by the QA-Network
Nbr. of Repetitive Human
Errors in Workstation
What is the most
efficent way to
manage the
defect?
QA-Matrix by Zone
QG
QA-Network
Process of the Quality Gate
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
OneOffs need to be prevented with
QA-Network by solutions
developed/introduced in the past
and then extended to assemblies
with a similar risk!
Quick feedback, about the mistake, is necessary
for the operator to learn from his mistake!
Feedback needs to be given with max. 1 hour!
Quality Gate Raccomandations
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QG format: Repetitive List
Repetitive list:on this list you are showing the result of your checks performed on the units.
In the middle (A) you will have a short description of the defect, were it occured, on which model and
who will be the responsible to follow up the analysis and countermeasure against the defect.
On the righthand side (B), you will see the daily tracking result of the defect, when it occured/how
often/by whom, or when it was closed.
On the lefthand side (C) you have the total results/history of defects occured by month.
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QG format : Repetitive Checklist
Repetitive checklist: this checklist will be the working document, that you use during your
inspection around the unit, looking for reoccurence of defects and is the basis for your data
entries on the repetitive list.
By evaluating the time for each check item, you are able to saturate the inspector for the full
takt time and ensure maximum utilization of the available time to check.
This checklist will also be the inspectors certification, if a unit was without defects, or which
defects occured.
Checks need to be organized in a efficient way!
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Detection
of defect!!!
QG format : INPUT list
Input list: if a defect was detected by another Q-Gate or responsable further down in the process,
but caused by a station, that is under control of the q-gate, the inspector needs to check first, if this
was a defect already included on his repetitive checklist.
Example
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QG format : OUTPUT list
Output list: if you detect, during your inspections, a defect that was originated in an area
outside the workstations, which are under control of the Q-Gate, you need to put them on the
output list.
Example
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
FTQ format - Quality Gate Performance
* This graph takes
under consideration
all defects on
the inspectors checklist!
M T
50
5
45
90%
3
96%
Volume (#)
Nbr of Units With Defect (#)
Input/Escapes
% FTQ In Updated
% FTQ Out Updated
Nbr of Unit Without Defect (#)
% FTQ In
Unit Fixed
% FTQ Out
FTQ: Only the Items, that are on the Checklist of the Inspector are included
FTQ-In: to show the improvements of the operators
FTQ-Out: to show the performance of the QG-Inspector
(reduced by escapes of the inspector, detected in downstream processes)
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
QUALITY GATE MHEX ASS.Y LINE
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Takt time: 50 minutes
Model Mix:
16 36
640
1. Product family
2. TT – Technical
type
3. Option
MA
NP
OW
ER
PR
OB
LE
MS
San Mauro Mhex ass.y line complexity: 8 workstations in Assy line
15 workstations for subgroups
MAN-Quality Gate Mhex
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Models: WHEX CHEX MHEX MIDI TLB .. ..
Total volume: 77 252 375 40 692 .. ..
Models: WHEX CHEX MHEX MIDI TLB .. ..
CQA volume: 9 26 55 1 200 .. ..
Referring period:
Q2_Q3 - 2011
Help A Help A A Help B B Help C C
n. % R=1:5 € R=1:5 min R=1:5 1 2 3 4 4 5 7 8 30
CHEC
K Plan Do Check ActBefore
5Q0D
After
5Q0D
Reclamo Mhex Rotture braccio mono Mhex12 3,2 3 800 4 240 4 30 720 12 12 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
ReclamoTLB Bracci TLB con verniciatura NOK (segn. Lecce)
45 6,5 3 300 3 120 3 30 540 45 45 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Bracci
Reclamo Chex Rottura braccio mono tra mozzo e fiancata (modello E245B) 6 2,4 2 3.000 5 360 4 30 540 6 6 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura braccio 3 in prossimità del mozzo (modello E385B) 3 1,2 2 3.000 5 360 4 30 540 3 3 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Vernice sfogliata (cilindri chex segn. ODB)4 1,6 2
2503 120 3 30 360 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Cilindri
ReclamoTLB Bracci TLB non a disegno (lavorazioni meccaniche)
18 2,6 2 150 2 120 3 30 300 18 18 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Progetto SPC
Reclamo TLB Bracci TLB non a disegno (saldature NOK) 10 1,4 2 150 2 120 3 30 300 10 10 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x SOP & OPL
Reclamo Chex Verniciatura ralla-ripari inferiori sfumata (segn. UK) 3 1,2 2 150 2 120 3 30 300 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
Reclamo Chex Rottura braccio in prossimità del mozzo (modello E215B) 1 0,4 1 3.000 5 360 4 30 270 1 1 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura saldatura fondello cilindro benna (11E-0218)1 0,4 1 1.500 5 180 4 30 270 1 1 0% 0% 0% 0% 0% 0% 0% 0% 100% 0% x Kaizen saldat, cilndri
ReclamoChex Perdita da tubo flex 87664902 (Raccordo mot. traslaz. e giunto centrale)
3 1,2 2 60 1 80 3 30 240 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore+ kaizen
Reclamo Chex Verniciatura zavorra con RAL non corrispondente a RAL sportelli (segn. ODB) 1 0,4 1 1000 4 180 4 30 240 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Ruggine su valvola martello (serie C)4 1,6 2
1002 60 2 30 240 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Azione su fornitori
Reclamo Whex Ventola radiatore, montata al contrario 1 1,3 2 20 1 120 3 30 240 1 1 100% 0% 0% 0% 0% 0% 0% 0% 0% 0% x OPL
Reclamo Mhex Cingoli in gomma danneggiati 3 0,8 1 2.400 5 120 3 30 240 3 3 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Mhex Perdità olio dall’ o-ring 72283052. Segnalazione dealer modello E39B5 1,3 2 70 2 60 2 30 240 5 5 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Quality Gate
Reclamo Mhex Radiatore sostituito perchè ammaccato / rovinato 1 0,3 1 1.000 4 120 3 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL + Azioni p.to GAP
Reclamo Mhex Perdita refrigerante da radiatore: componente sostituito1 0,3 1 1.000 4 80 3 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL + Azioni p.to GAP
Reclamo Mhex Motore non si avvia: motorino in corto.1 0,3 1 1.100 5 60 2 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL (lay out cablaggio)
Reclamo Chex Ruggine su braccio boom causa pallini di granigliatura3 1,2 2 40 1 60 2 30 180 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
Reclamo Chex Motore con difficoltà di funzionamento causa cablaggio fornitore NOK1 0,4 1 150 2 180 4 30 180 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Vernice graffiata su sportelli laterali (Chex segn. ODB)5 2,0 2 15 1 60 2 30 180 5 5 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Kaizen logistica/fornitore/8
step
Reclamo Chex Ruggine sul distributore idraulico (fori e parti lavorate ossidate)11 4,4 3 10 1 30 1 30 180 11 11 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine mancorrente (scrostatura vernice /vernice saltata per urto)10 4,0 3 10 1 30 1 30 180 10 10 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine su motore di rotazione (fori e parti lavorate ossidate)20 7,9 3 10 1 30 1 30 180 20 20 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine su staffa specchio10 4,0 3 1 1 30 1 30 180 10 10 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Reclamo Mhex Cavo danneggiato su impianto elettrico: la macchina improvvisamente si blocca1 0,3 1 250 3 120 3 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL
Reclamo Mhex Macchina consegnata con mancante configurazione carichi sospesi1 0,3 1 700 4 60 2 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Attività su f lusso rew ork
Reclamo Mhex Rottura cinghia pompa acqua puleggia ventola dovuto a mancato serraggio viti ventola1 0,3 1 550 4 60 2 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Quality Gate
Delibera Whex Ritocchi vari di verniciatura telaio/torretta/ braccio77 100,0 5 75 2 640 5 5 175 77 77 100% 0% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Delibera Chex Ritocchi vari di verniciatura telaio superiore/torretta / braccio252 100,0 5 75 2 480 5 5 175 252 252 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Funzionale Midi Ritocchi vari di verniciatura telaio superiore / torretta / braccio80 200,0 5 85 2 480 5 5 175 80 80 0% 0% 100% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Funzionale Mhex Flex scoppiato su valvola anticaduta (flex invertiti)3 0,8 1 1 1 180 4 30 150 3 3 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x QG & OPL
Reclamo Mhex Sostituita elettrovalvola/pressostato su distributore 1 0,3 1 500 3 60 2 30 150 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Funzionale Chex Vernice scheggiata su cilindri causa movimentazione interna 45 17,9 4 500 3 180 4 5 140 45 45 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Funzionale Mhex Ritocchi vari di verniciatura telaio / torretta / bracci / lama375 100,0 5 60 1 150 4 5 125 375 375 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Reclamo Chex Contaore non funziona3 1,2 2 5 1 15 1 30 120 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x OPL nr 747
Reclamo Chex Vernice graffiata su tubi rigidi braccio boom3 1,2 2 5 1 30 1 30 120 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
WHEX
Asem
bly
CHEX
Assem
bly
MHEX
Assem
bly
CARP
ENTER
IA BRA
CCI
CILIND
RI
CLIEN
TE/SIC
UREZZ
A
QA MATRIX - PLANT Referring period: Q2_Q3 - 2011
CARP
ENTER
IA TOR
RETTE
CARP
ENTER
IA TELA
I
Processes - n. of cases
VERN
ICIATU
RA
A*(B+C)*
(∑Di)
Responsible
Priority
Index
Di
CARP
ENTER
IA
FINIZIO
NE
CQA
MIDI As
sembly
TAGLIO
Problem Description
LINEA
OKOL
FUNZ
IONALE
DEALE
R
CHEX
Assem
bly
MIDI As
sembly
TAGLIO
MHEX
Assem
blySource
Lab. Co
st.
Freque
ncy %
N. of ca
ses - (d
uring th
e
referrin
g perio
d)
Freque
ncy
CQA S
core -
IF appl
icable
Materi
al Cost
Mat. C
ost.
Labour
Cost.
Detection
DELIB
ERA
Produc
t 5Q0DActivities progress
Processes - % of cases
WHEX
Asem
bly
CARP
ENTER
IA BRA
CCI
CARP
ENTER
IA TOR
RETTE
CARP
ENTER
IA TELA
I
CILIND
RI
VERN
ICIATU
RA
TWTTP
HERCA
Human
Error ?
Standardize &
Expand
Material
Method
Machine
1
4
3
2
1
3
2
TWTTP 2
Interview
Root cause analysis
Not work related
Technical instrumental problems
Work place organization
Weakness
Process procedure
Concetration
Customers CQA End of line Funct. Test Q-Gates
Countermeasure
Effectiveness
verification
through Q-Gates
MAN – Human Error Root Cause Flow Analysis
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Models: WHEX CHEX Midi
Total volume: 13 47 0
Models: WHEX CHEX Midi
CQA volume: 12 36 0
Referring period:
Marzo - Maggio 2010
DR
R
Help A Help A A Help B B Help C C
n. % R=1:5 € R=1:5 min R=1:5 1 1 2 3 3 4 7 8 30
tot
Plan Do Check Act
DRR CHEX Impianto Elettrico batteria Non funziona/Funzionament 48,5 3 189,145 5 60 5 0 0 0 0 0 0 0 8 0 240 Frequency 4 4 0% 100% 0% 0% 0% 0% 0% 0% 0% x
Applicata QA.14. In fase di emissione
documentazione dedicata.
DRR WHEX Telai/Carpenterie/Zavorre telaio superiore Assemblaggio Errato1 7,7 3 5000 5 6000 5 0 0 0 0 0 0 0 8 0 240 Frequency 1 1 0% 0% 0% 0% 100% 0% 0% 0% 0% x
Opl 513 per standard tolleranze accetabilità
prodotto; avviato kaizen carpenteria
DELIBERA CHEX Telai/Carpenterie/Zavorre telaio Vernice difettosa/Incompl6 12,8 4 100 5 3000 5 0 0 0 0 0 4 0 0 0 160 Frequency 6 6 0% 0% 0% 0% 0% 0% 0% 100% 0% x Kaizen verniciatura in progress
CQA WHEX Allestimenti e decals targhette identificazione Non nelle specifiche 3
25,0 5
1
1
30
3 0 0 0 0 0 0 7 0 0 140 Frequency 3 3 0% 0% 0% 0% 0% 0% 0% 0% 100% x
Revisionati distinte e disegni progettuali:
aggiunta in BoM targhetta ROPS come da
normativ CE; emettere opl per std check.
CQA WHEX Impianti Idraulici tubi flex Assemblaggio Errato7 58,3 5 1 1 30 3 0 0 0 0 0 0 7 0 0 140 Frequency 7 7 100% 0% 0% 0% 0% 0% 0% 0% 0% x Interferenza vano motore opl 247
CQA WHEX Impianto Elettrico cablaggi Assemblaggio Errato3 25,0 5 1 1 25 3 0 0 0 0 0 0 7 0 0 140 Frequency 3 3 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Fissaggio cavi elettrici in vano motore nc.
Norma qualità e montaggio Q244
CQA WHEX Confani/Serbatoi sportello confano Sx Disallineato 216,7 4
11
303 0 0 0 0 0 0 7 0 0 112 Frequency 2 2 100% 0% 0% 0% 0% 0% 0% 0% 0% x Allineamenti opl 163
CQA WHEX Confani/Serbatoi sportello confano Dx Disallineato2 16,7 4 1 1 30 3 0 0 0 0 0 0 7 0 0 112 Frequency 2 2 100% 0% 0% 0% 0% 0% 0% 0% 0% x Allineamenti opl 163
CQA WHEX Telai/Carpenterie/Zavorre ripari Arrugginito/Corroso 216,7 4
11
303 0 0 0 0 0 0 7 0 0 112 Frequency 2 2 0% 0% 0% 0% 0% 0% 0% 0% 100% x
Attività di selezione e ricondizionamento parti
lungo stock fornitori; opl 511- 512
CQA CHEX Telai/Carpenterie/Zavorre zavorre Vernice difettosa/Incompl1 2,8 2 15 4 45 4 0 0 0 0 0 0 7 0 0 112 Frequency 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% x
Attività di selezione e ricondizionamento parti
lungo stock fornitori; opl 511-513
FUNZIONALE CHEX Impianti Idraulici tubi flessibili Trafilamento/Perdita olio7 14,9 4 32,2143 4 688,571 5 0 0 0 3 0 0 0 0 0 108 Frequency 7 7 0% 100% 0% 0% 0% 0% 0% 0% 0% x
Chiusua flex deviatore. Opl 307, Sop 28-29-
30.
DELIBERA CHEX Telai/Carpenterie/Zavorre telaio superiore Vernice difettosa/Incompl3 6,4 3 17,3333 4 200 5 0 0 0 0 0 4 0 0 0 108 Frequency 3 3 0% 0% 0% 0% 0% 0% 0% 100% 0% x Kaizen verniciatura in progress
CQA WHEX Allestimenti e decals decalcomanie Assemblaggio Errato 18,3 3
11
303 0 0 0 0 0 0 7 0 0 84 Frequency 1 1 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Materiale non a disegno forntiro da AVERY;
decals no easy to apply. Cambiato specifica:
ok
CQA WHEX Attrezzo tubi flex Assemblaggio Errato1 8,3 3 1 1 30 3 0 0 0 0 0 0 7 0 0 84 Frequency 1 1 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Perdita raccordo flex martello con sup. br.3
opl 140
CQA WHEX Cabina sportello Arrugginito/Corroso1 8,3 3 1 1 30 3 0 0 0 0 0 0 7 0 0 84 Frequency 1 1 0% 0% 0% 0% 0% 0% 0% 0% 100% x
Attività di selezione e ricondizionamento parti
lungo stock fornitori_ opl 511/512
CQA WHEX Confani/Serbatoi cassetta attrezzi Assemblaggio Errato1 8,3 3 1 1 30 3 0 0 0 0 0 0 7 0 0 84 Frequency 1 1 100% 0% 0% 0% 0% 0% 0% 0% 0% x Tool box da regolare; opl 163
CQA WHEX Telai/Carpenterie/Zavorre telaio inferiore Presenza graniglia/pallin 18,3 3
11
303 0 0 0 0 0 0 7 0 0 84 Frequency 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% x Asportazione graniglia non completa. Sop 37
FUNZIONALE WHEX Cabina comandi/leve/manipolatori/pedaliNon funziona/Funzionament 538,5 5
11
424 0 0 0 3 0 0 0 0 0 75 Frequency 5 5 100% 0% 0% 0% 0% 0% 0% 0% 0% x Manipolatori-pedipolatori NC (fornitore)
FUNZIONALE WHEX Cabina luci/catarinfrangenti Non funziona/Funzionament3 23,1 5 1 1 35 4 0 0 0 3 0 0 0 0 0 75 Frequency 3 3 100% 0% 0% 0% 0% 0% 0% 0% 0% x Connettori errati (fonitore)
FUNZIONALE WHEX Impianti Idraulici tubi flessibili Assemblaggio Errato 6
46,2 5
1
1
40
4 0 0 0 3 0 0 0 0 0 75 Frequency 6 6 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Sviluppare opl per flex invertiti (flex power
boost non montato correttamente, flex su
valvola anticaduta penetrazione invertiti, flex
invertito su cilindro posizionatore)
FUNZIONALE WHEX Impianto Elettrico connettori Scollegato (Cablaggi)3 23,1 5 1 1 40 4 0 0 0 3 0 0 0 0 0 75 Frequency 3 3 100% 0% 0% 0% 0% 0% 0% 0% 0% x Connessioni scollegate opl 47 sop 4
CQA CHEX Confani/Serbatoi sportello confano Sx sportello confano Sx1 2,8 2 1 1 45 4 0 0 0 0 0 0 7 0 0 70 Frequency 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% x Allineamento sportelli. Kaizen e sop 41-44
FUNZIONALE WHEX Cabina spazzola Non funziona/Funzionament6 46,2 5 1 1 30 3 0 0 0 3 0 0 0 0 0 60 Frequency 6 6 100% 0% 0% 0% 0% 0% 0% 0% 0% x Funzionalità tergi opl 180
FUNZIONALE WHEX Impianto Elettrico connettori Assemblaggio Errato5 38,5 5 1 1 25 3 0 0 0 3 0 0 0 0 0 60 Frequency 5 5 100% 0% 0% 0% 0% 0% 0% 0% 0% x Connessioni invertite opl 47 sop 4
FUNZIONALE WHEX Impianto Elettrico connettori Connessione invertite10 76,9 5 1 1 30 3 0 0 0 3 0 0 0 0 0 60 Frequency 10 10 100% 0% 0% 0% 0% 0% 0% 0% 0% x Connessioni invertite opl 47 sop 4
OKOL CHEX Cabina aria condizionata Non funziona/Funzionament 24,3 3
116,255
3605 0 0 2 0 0 0 0 0 0 60 Frequency 2 2 0% 100% 0% 0% 0% 0% 0% 0% 0% x
Perdita da raccordi flex Ac: serraggio nc.
Realizzare Opl
CHEX OKOL CHEX Telai/Carpenterie/Zavorre telaio superiore Gioco non corretto2 4,3 3 1500 5 4000 5 0 0 2 0 0 0 0 0 0 60 Frequency 2 2 0% 100% 0% 0% 0% 0% 0% 0% 0% x In fase di realizzazione kaizen torretta chex
CHEX OKOL CHEX Telai/Carpenterie/Zavorre viti/bulloni Bloccato/Grippato4 8,5 3 150 5 2400 5 0 0 2 0 0 0 0 0 0 60 Frequency 4 4 0% 100% 0% 0% 0% 0% 0% 0% 0% x Realizzato Major Kaizen n.400 viti ralla
Lo
gis
tica
/Pro
ge
tta
zio
ne
WH
EX
Ase
mb
ly
CH
EX
Asse
mb
ly
Ca
rp
en
teria
bra
cci
Ta
glio
Ve
rn
icia
tura
Activities progress
Processes - % of cases
WH
EX
Ase
mb
ly
CH
EX
Asse
mb
ly
Ca
rp
en
teria
bra
cci
Ca
rp
en
teria
te
lai
Ca
rp
en
teria
to
rre
tte
Cilin
dri
Ve
rn
icia
tura
Ta
glio
Pro
do
tto
Descrizione non
conformità
So
rg
en
te
Co
sto
del la
voro
del sin
golo
difetto
Frequ
en
cy %
N. d
i ca
si - (
durin
g t
he r
efe
rrin
g
perio
d)
Fre
qu
en
cy
CQ
A S
co
re
- I
F a
pp
lica
ble
Ma
te
ria
l C
os
t
Co
sto
del m
ate
ria
le d
el sin
golo
difetto
Di
INI
OK
OL
Fin
izio
ne
RE
CL
AM
I
Priority
Index
CQ
A
La
bo
ur C
os
t.
DetectionF
UN
ZIO
NA
LE
DE
LIB
ER
A
ME
Zo
na
ma
cc
hin
a
Co
mp
on
en
te
QA MATRIX - PLANT
Ca
rp
en
teria
te
lai
Ca
rp
en
teria
to
rre
tte
Processi - n. di casi
Cilin
dri
Lo
gis
tica
/Pro
ge
tta
zio
ne
A*(B+C)*(∑
Di)
Responsible
MHEX Assy Line Q GATE BLU Q GATE GIALLO
MAN – Quality Gate
47
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
July 2011 – QA
Matrix Q2
Oct 2011 – QA
Matrix Q3
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
LM2LM1 LM5 LM6 LM8LM4LM3 LM7 Yellow QG QG
Results
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
LM2LM1 LM5 LM6 LM8LM4LM3 LM7Blue QG Yellow QG
812
476
294
0
100
200
300
400
500
600
700
800
900
May 2011 Sep. 2011 Dec. 2011
No
. o
f re
p.H
.E
.in
wo
rksta
tio
n (M
he
x A
ss.y
)
- 42%
- 37%
H.E. May '11 VS Dec '11
-64%
MAN – Quality Gate
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
San Mauro plant
Working
instruction: OK.
Human Error
due to lack of
attention. OPL
to renforce
working
instruction
Models: WHEX CHEX MHEX MIDI TLB .. ..
Total volume: 77 252 375 40 692 .. ..
Models: WHEX CHEX MHEX MIDI TLB .. ..
CQA volume: 9 26 55 1 200 .. ..
Referring period:
Q2_Q3 - 2011
Help A Help A A Help B B Help C C
n. % R=1:5 € R=1:5 min R=1:5 1 2 3 4 4 5 7 8 30
CH
EC
K
Plan Do Check ActBefore
5Q0D
After
5Q0D
Reclamo Mhex Rotture braccio mono Mhex12 3,2 3 800 4 240 4 30 720 12 12 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
ReclamoTLB Bracci TLB con verniciatura NOK (segn. Lecce)
45 6,5 3 300 3 120 3 30 540 45 45 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Bracci
Reclamo Chex Rottura braccio mono tra mozzo e fiancata (modello E245B) 6 2,4 2 3.000 5 360 4 30 540 6 6 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura braccio 3 in prossimità del mozzo (modello E385B) 3 1,2 2 3.000 5 360 4 30 540 3 3 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Vernice sfogliata (cilindri chex segn. ODB)4 1,6 2
2503 120 3 30 360 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen vern. Cilindri
ReclamoTLB Bracci TLB non a disegno (lavorazioni meccaniche)
18 2,6 2 150 2 120 3 30 300 18 18 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Progetto SPC
Reclamo TLB Bracci TLB non a disegno (saldature NOK) 10 1,4 2 150 2 120 3 30 300 10 10 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x SOP & OPL
Reclamo Chex Verniciatura ralla-ripari inferiori sfumata (segn. UK) 3 1,2 2 150 2 120 3 30 300 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
Reclamo Chex Rottura braccio in prossimità del mozzo (modello E215B) 1 0,4 1 3.000 5 360 4 30 270 1 1 0% 0% 0% 0% 0% 100% 0% 0% 0% 0% x Kaizen carp. Bracci
Reclamo Chex Rottura saldatura fondello cilindro benna (11E-0218)1 0,4 1 1.500 5 180 4 30 270 1 1 0% 0% 0% 0% 0% 0% 0% 0% 100% 0% x Kaizen saldat, cilndri
ReclamoChex Perdita da tubo flex 87664902 (Raccordo mot. traslaz. e giunto centrale)
3 1,2 2 60 1 80 3 30 240 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore+ kaizen
Reclamo Chex Verniciatura zavorra con RAL non corrispondente a RAL sportelli (segn. ODB) 1 0,4 1 1000 4 180 4 30 240 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Ruggine su valvola martello (serie C)4 1,6 2
1002 60 2 30 240 4 4 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Azione su fornitori
Reclamo Whex Ventola radiatore, montata al contrario 1 1,3 2 20 1 120 3 30 240 1 1 100% 0% 0% 0% 0% 0% 0% 0% 0% 0% x OPL
Reclamo Mhex Cingoli in gomma danneggiati 3 0,8 1 2.400 5 120 3 30 240 3 3 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Mhex Perdità olio dall’ o-ring 72283052. Segnalazione dealer modello E39B5 1,3 2 70 2 60 2 30 240 5 5 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Quality Gate
Reclamo Mhex Radiatore sostituito perchè ammaccato / rovinato 1 0,3 1 1.000 4 120 3 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL + Azioni p.to GAP
Reclamo Mhex Perdita refrigerante da radiatore: componente sostituito1 0,3 1 1.000 4 80 3 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL + Azioni p.to GAP
Reclamo Mhex Motore non si avvia: motorino in corto.1 0,3 1 1.100 5 60 2 30 210 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL (lay out cablaggio)
Reclamo Chex Ruggine su braccio boom causa pallini di granigliatura3 1,2 2 40 1 60 2 30 180 3 3 0% 0% 0% 0% 0% 0% 0% 0% 0% 100% x Kaizen verniciatura
Reclamo Chex Motore con difficoltà di funzionamento causa cablaggio fornitore NOK1 0,4 1 150 2 180 4 30 180 1 1 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Reclamo Chex Vernice graffiata su sportelli laterali (Chex segn. ODB)5 2,0 2 15 1 60 2 30 180 5 5 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x
Kaizen logistica/fornitore/8
step
Reclamo Chex Ruggine sul distributore idraulico (fori e parti lavorate ossidate)11 4,4 3 10 1 30 1 30 180 11 11 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine mancorrente (scrostatura vernice /vernice saltata per urto)10 4,0 3 10 1 30 1 30 180 10 10 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine su motore di rotazione (fori e parti lavorate ossidate)20 7,9 3 10 1 30 1 30 180 20 20 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Reclamo Chex Ruggine su staffa specchio10 4,0 3 1 1 30 1 30 180 10 10 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Reclamo Mhex Cavo danneggiato su impianto elettrico: la macchina improvvisamente si blocca1 0,3 1 250 3 120 3 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x OPL
Reclamo Mhex Macchina consegnata con mancante configurazione carichi sospesi1 0,3 1 700 4 60 2 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Attività su f lusso rew ork
Reclamo Mhex Rottura cinghia pompa acqua puleggia ventola dovuto a mancato serraggio viti ventola1 0,3 1 550 4 60 2 30 180 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Quality Gate
Delibera Whex Ritocchi vari di verniciatura telaio/torretta/ braccio77 100,0 5 75 2 640 5 5 175 77 77 100% 0% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Delibera Chex Ritocchi vari di verniciatura telaio superiore/torretta / braccio252 100,0 5 75 2 480 5 5 175 252 252 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Funzionale Midi Ritocchi vari di verniciatura telaio superiore / torretta / braccio80 200,0 5 85 2 480 5 5 175 80 80 0% 0% 100% 0% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Funzionale Mhex Flex scoppiato su valvola anticaduta (flex invertiti)3 0,8 1 1 1 180 4 30 150 3 3 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x QG & OPL
Reclamo Mhex Sostituita elettrovalvola/pressostato su distributore 1 0,3 1 500 3 60 2 30 150 1 1 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Azione su fornitore
Funzionale Chex Vernice scheggiata su cilindri causa movimentazione interna 45 17,9 4 500 3 180 4 5 140 45 45 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
Funzionale Mhex Ritocchi vari di verniciatura telaio / torretta / bracci / lama375 100,0 5 60 1 150 4 5 125 375 375 0% 0% 0% 100% 0% 0% 0% 0% 0% 0% x Kaizen verniciatura
Reclamo Chex Contaore non funziona3 1,2 2 5 1 15 1 30 120 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x OPL nr 747
Reclamo Chex Vernice graffiata su tubi rigidi braccio boom3 1,2 2 5 1 30 1 30 120 3 3 0% 100% 0% 0% 0% 0% 0% 0% 0% 0% x Kaizen logistica
WH
EX
Ase
mb
ly
CH
EX
Asse
mb
ly
MH
EX
Asse
mb
ly
CA
RP
EN
TE
RIA
BR
AC
CI
CIL
IND
RI
CL
IEN
TE
/SIC
UR
EZ
ZA
QA MATRIX - PLANT Referring period: Q2_Q3 - 2011
CA
RP
EN
TE
RIA
TO
RR
ET
TE
CA
RP
EN
TE
RIA
TE
LA
I
Processes - n. of cases
VE
RN
ICIA
TU
RA
A*(B+C)*
(∑Di)
Responsible
Priority
Index
Di
CA
RP
EN
TE
RIA
FIN
IZIO
NE
CQ
A
MID
I A
sse
mb
ly
TA
GL
IO
Problem Description
LIN
EA
OK
OL
FU
NZ
ION
AL
E
DE
AL
ER
CH
EX
Asse
mb
ly
MID
I A
sse
mb
ly
TA
GL
IO
MH
EX
Asse
mb
ly
So
urc
e
Lab.
Cost.
Fre
quency %
N.
of
cases -
(during t
he
refe
rrin
g p
eriod)
Fre
qu
en
cy
CQ
A S
co
re -
IF
ap
plica
ble
Ma
teria
l C
os
t
Mat.
Cost.
La
bo
ur C
os
t.
Detection
DE
LIB
ER
A
Pro
du
ct
5Q0DActivities progress
Processes - % of cases
WH
EX
Ase
mb
ly
CA
RP
EN
TE
RIA
BR
AC
CI
CA
RP
EN
TE
RIA
TO
RR
ET
TE
CA
RP
EN
TE
RIA
TE
LA
I
CIL
IND
RI
VE
RN
ICIA
TU
RA
Eliminazione
difetto!!
B/C = 7,2
QA matrix – Radiator leakege due wrong washer assembling
Quality Gate Check
OPL & training
0
0,5
1
1,5
2
settott
novdic
genfeb
Wrong radiator washer assy
MAN – Example # Human Error
MAN – HE Management
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
San Mauro plant
21
15
13
4 4
3 3
0
5
10
15
20
25
PROCESS PROCEDURE WEAKNESS
LACK OF KNOWLEDGE
TECHNICAL INSTRUMENTAL
PROBLEMS
WORKPLACE/ WORKING
ENVIRONMENT
PRIVATE LIFE PROBLEMS
INATTENTIVENESS &
FORGETFULNESS
ATTITUDE & BEHAVIOUR
HUMAN ERROR STRATIFICATION:
COUNTERMEASURES:
• Process
procedure
weakness: OPL /
SOP
• Lack of
Knowledge : MTS
training
MAN – Human Error Results
74
15
5 3
0
10
20
30
40
50
60
70
80
OPL SOP VISUAL AID POKA YOKE
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
Thanks for the attention
Next Step: Plant Visit
This document contains information which are proprietary of CNH Global N.V. Neither this document nor the information contained herein shall be used,
duplicated nor communicated by any means to any third party, in whole or in part, except with the prior written consent of CNH Global N.V
