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Quality is a key issue in the WCM system as is the Lean 6 Sigma approach.

Introduction

Like Lean and 6 Sigma, Quality is the main focus in the WCM system. In this, the precepts regarding the mindset are strictly identical : “ The following process is a client“…

1 – Define the initial conditions

The first step is to take stock of the quality system and set up the basics of quality. To do this, we must ensure that the real customer need is clearly defined using the principles of Voice Of Customer.

We will also rely on QA Matrix to start instilling a quality culture and processes fault resolutions.

Thanks to these elements and with the contribution of the elements of the matrix C of the pillar Costs Deployment, we will make a comparison between the customer need and the current state to build the quality improvement plan.

2 – Restore normal quality conditions

With regard to the plan defined above, we will deploy the actions. Most commonly, we will use the tools of standardization (5S, Visual Management, Standard) and Jidoka (Poka Yoké, Andon) to restore normal quality conditions. Sometimes it may be necessary to control the capability of our means of measurement by implementing the Gage R&R or the Kappa Test.

It will also be used to clarify the matrices of skills and build the necessary training plans.

3 – Analyze causes / effects of recurring defects

Thanks to the QA matrix, to study of EWO and HERCA / TWTTP, we will investigate the problems recurring qualities. Beyond the traditional tools of the problem solving (5 why, PDCA, Pareto, FTA…), WCM relies particularly on :

  • 4M analysis : Same as 5M of Ishikawa, it is more specific for an application on machines and does not study the Management axis proposed by the traditional 5M.
  • Processing Point Analysis : Problem solving methodology specific to WCM, it aims to solve more complex problems.
  • 5G : Related to the mindset of problem solving, the 5Gs are Gemba, Genbutsu, Gemjitsu, Genri and Gensoku.

4 – Address the causes of recurring problems

At this point, we now know the causes of the problems we want to solve. We will then implement actions to eradicate causes.

This can go through 5S, the Poka-Yoké, or even experimental plans to identify the most reliable solution.

5 – Define the 5 conditions of the 0 default

Based on the previous results, our source of problem being controlled, we will be able to develop our quality standards. Beyond the update of labor standards, we will build the matrices QM and QX. We will thus obtain a first level of standardization.

6 – Check the conditions of 0 releases

It will be ensured to maintain the actions implemented at their performance level through the implementation of a Control chart. This verification will be done through the follow-up of the control cards and the obtaining of a capability CP > 1,33.

7 – Improve conditions of 0 releases

We now have a perfect mastery of quality criteria and the means to guarantee them. Nevertheless, we are still in a process more of quality control than of quality production.

We will implement the principles of process design, develop equipment no longer capable of generating defect.

In addition, the maintenance of the quality conditions will also pass through the continuous updating of the matrices QA, QM and QX.

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