problem resolution process page 1 of 23 6-panel problem resolution process training manual
TRANSCRIPT
Page 1 of 23
PROBLEMPROBLEMRESOLUTIONRESOLUTION
PROCESSPROCESS
6-PANEL6-PANELProblem Resolution ProcessProblem Resolution Process
TRAINING MANUALTRAINING MANUAL
6-PANEL6-PANEL
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Corporate NEED
Global 6-Panel Reporting standard:
1) 6-Panel Problem Resolution is a high level problem resolution document to capture the key requirements and data to drive decisions through the problem solving phases: Define, Measure, Analyze, Improve, Control, and Replicate.
2) Assist problem solving teams with a template to guide the problem solving process using minimum required DMAIC+R steps to ensure robustness of the resolution.
3) Individual summary panels of each DMAIC+R phase that is simplified and standardized, while allowing for additional information or slides to be inserted as backup information for any of the problem resolution phases. In a high level management report out, communicate with the six summary panels. For a team or quarterback deep dive, unhide information on additional slides.
4) Standardization of problem resolution procedures combining best practices and 6-Sigma methodology on a format that is flexible enough to be used by all business units.
5) Simplified and consistent communication to management in a concise way without having to rewrite what you have done.
6) Encourages management to ask questions in line with the 6-Sigma disciplined methodology.
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6-Panel Problem Resolution is a high level problem resolution document to capture the key requirements used to drive data decision through the problem solving phases: Define, Measure, Analyze, Improve, Control, and Replicate.
Improve PhaseHow can we permanently fix the current product/process?
• DOE & ANOVA • Verification data
• Durability/CAE/VSA• Work plan
Control PhaseHow can we make the process stay fixed?
• Control Plans• SPC – Control Charting
• Audit Plans
Replicate PhaseWho else at Ford can benefit?Update corporate knowledge?
Is the gain be sustained?
• Replication / Best Practices• Core Books – SDS/VDS/FMEAs
• Validate sustain w/ data
Define PhaseWho is my customer, and what isthe current cost of poor quality?
• Voice of the Customer • Defect Definition
• Cost of Poor Quality (includeswarranty spending, as necessary)
• Project Scope & Goal
Measure PhaseWhich inputs affect ouputs?What is my current processperformance (capability)?
Are defects contained?
Analyze PhaseBy how much do X’s affect Y?
What confidence do you have?
• Graphical Analysis • Hypothesis Testing
• Regression Analysis • Additional tools
Panel 2Panel 1 Panel 3
Panel 4 Panel 5 Panel 6
• Fish Bone• Gage R&R, Baseline
Capability• Containment Plan
Process Layout
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DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
DDDD MMMM AAAA IIII CCCC RRRR
6-PANEL Header:
Identify VRT to CCC cascade of the issue in the header. The following generic fields are listed to identify project ownership (business unit), the customer, affected vehicle, process, and/or part number.
Please note: The header “VRT / VFG / CCC” information along with the footer “Project Number / BB Name” information must be updated on the SLIDE MASTER. Goto “View” then “Master” then “Slide Master” to make these changes.
CustomerCustomerVFG Team / Functional Area NameVFG Team / Functional Area NameVRT / Business Unit NameVRT / Business Unit Name
Vehicle Name & Model Year / Product NameVehicle Name & Model Year / Product Name Part / Process Name & NumberPart / Process Name & Number
CCC: L66 – Exhaust System TroublesCCC: L66 – Exhaust System TroublesVFG: V44 – Mechanical MalfunctionVFG: V44 – Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus / SableVEHICLE: 2001 Taurus / Sable PART: 5230 MufflerPART: 5230 Muffler
Manufacturing / Technical Example:
Transactional Example:
Ford Motor Company PlantsFord Motor Company PlantsGlobal CustomsGlobal CustomsMP&LMP&L
Global Customs and Trade ProcessGlobal Customs and Trade Process 9801 Duty Preference Program9801 Duty Preference Program
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DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
DDDD MMMM AAAA IIII CCCC RRRR
DEFINE PANEL (Minimum requirements):
1) Identify the Project Classification (Safety, Quality, Deliver, Cost…) objectives. Typical quality classifications will be based upon the Single Agenda for Quality data (both low time in service, 3 MIS, and high time in service, 3 YIS) from GQRS and Warranty. Include total annual warranty spending and JD Power data if available. In addition, use internal data indicators to help identify the concern including Best In Class (BIC) and Best In Ford (BIF) data to address customer concerns.
2) Trend Charts and Breakdown of Issue (Internal or External trends, and graphical quantification and pareto formulates a means of prioritizing and help reflect the teams understanding of the major components making up the concern.) Data trend charts over time help define the severity of customer concerns. Data trend charts over time should include annotative updates. If needed, add backup slides.
3) Y=f(x) Cascade (High level Y=f(x) cascade should communicate the scope of the project).
4) CTQ (Critical to Quality) Statement - identifies customer requirements / expectations.
5) Defect Definition of Key Process Output Variable (KPOV or Y) in the form of an engineering metric.
6) Cost of Poor Quality (Cost of the Problem includes all external and internal cost, TGW, Total Warranty Spending and Unexpended Warranty, labor & overhead, etc.)
7) Problem Statement (include scope and goal)
Additional Tools: (add slide(s) to capture backup Define material)• Process Mapping (As Is), SIPOC, Is-Is Not Analysis• Unexpended Warranty Calculations• TGW Verbatim Analysis• QFD
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VOICE OF THE CUSTOMER: From AWS Verbatims “thevehicle bottoms out, exhaust noise banging on side of vehicle.”CTQ STATEMENT (Customer Requirement): Customers expect no ground out noises from the exhaust system.DEFECT DEFINITION for Y (Engineering Metric): Muffler to body clearance less than 17mm at fasciaCOST OF POOR QUALITY (TGW, Unexpended Warranty, etc.): $350,000 annually in internal repairs and external warranty. In addition, 2.5 TGWs from 3MIS GQRS surveys. PROBLEM STATEMENT, SCOPE, AND GOAL Owners of 2001 MY Taurus/Sable vehicles indicate that exhaust pipes and muffler to body side ground outs are a significant issue. These ground outs conditions, particularly around the rear fascia & lower control arm, cause noises such as rattles, knocks, bangs, clunks, dings, and rubs. Reduce ground outs by 90%.
2002 L66 Warranty by part
5230-Muffler16.36
5246-Pipe Assy 4.03
5E212-Catalyst2.22
5200-Muffler2.07
5A294-Muffler Brkt 1.22
NPF1.08
All others1.8
Y=f(x) CASCADE:
Y= L66= f (Muffler, Pipe, etc.)Muffler= f ( Ground outs, etc.)
Ground Outs= f (clearance to fascia)
Project Y
DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
DDDD MMMM AAAA IIII CCCC RRRR
3 MISR/1000
TREND CHARTS and BREAKDOWN OF ISSUE:
L66 (Exhaust System Trouble) warranty 2002 Sable
0
0.5
1
1.5
2
2.5
3
MOP
R/1
000
CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler
TOTAL WARRANTY SPENDING:$315K (2002 CY)
PROJECT CLASSIFICATION:SAQ #26 L66 - Exhaust System Troubles
’01 MY ’99 MY3 MIS 3 YIS
TGW 4 6CUST SAT LOSS 0.43 0.61CPU 0.27 2.11R/1000 1.04 3.54JD Power 0.4Consumer Reports n/a for L66
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DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
DDDD MMMM AAAA IIII CCCC RRRR
Explorer N17 (Brakes Noisy) Trend Over Time R/1000 5/31/02 Cutoff Date / 60 Day Logic
02468
1012141618
Jan-
01
Mar
-01
May
-01
Jul-0
1
Sep
-01
Nov
-01
Jan-
02
Mar
-02
Production Month
R/1
000
1MIS BIF
3MIS BIF
6MIS BIF
9MIS BIF
1MIS
3MIS
6MIS
9MIS
12MIS
Explorer N17 (Brakes Noisy) Trend Over Time CPU 5/31/02 Cutoff Date / 60 Day Logic
00.20.40.60.8
11.21.41.61.8
3689
2
3695
1
3701
2
3707
3
3713
5
3719
6
3725
8
3731
7
Production Month
CP
U
1MIS BIF
6MIS BIF
9MIS BIF
3MIS BIF
1MIS
3MIS
6MIS
9MIS
12MIS
Explorer (U152) Top 100
Overall Rank
VRT VFG CCC's CCC DescriptionCUST SAT
LOSSTGW R/1000 3MIS CPU 3MIS
JDP 2002(Problems/100)
2002 MY High Miles
(CPU)
21 Chassis V21 N17 Brakes Noisy 0.25 67 3.43 0.37 6.3 1.8540 (BIC) .42 (BIF) .03 (BIF) 3.9 (BIC)
Trend Charts ofExplorer BrakeNoise-N17:
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MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY
DDDD MMMM AAAA IIII CCCC RRRR
MEASURE PANEL (Minimum requirements):
1) Fishbone (Cause & Effect Diagram). Identify the key process input variables (KPIV or Xs) that affect your KPOV (Y) most (display ranking). (This is the first stage of root cause analysis, in the analyze phase you will validate the root cause with data).
2) MSA – Measurement System Analysis. Validate the Measurement System for your KPOV (Y), Gage R&R stated as % Study. (May be needed for both Ys and Xs performed in other stages of the project.)
3) Determine the Baseline Process Capability of your KPOV (Y)
4) Containment Plan - state actions taken to protect the customer, including statistical evidence validating action (before and after data). If containment is not needed, state why.While the team is working on permanent solution, containment actions are required to protect the customer 100%. Example of actions include Stop-ship, 100% inspection, Quarantine stock, QR’s supplier. Use additional slides with visual aids to this panel to drive home your containment resolutions. Effectiveness of containment actions must be shown with Before and After indicator. Containment Plans should include: 1. Metric/Indicator that is used to find the issue at: (a) Supplier facility, before shipping to Ford facility, (b) Assembly plant, before shipping to customers.2. Before and after statistical data evidence showing the issue is contained (Cpk, defect rate, etc)
Additional Tools: (add slide(s) to capture backup Measure material)• Cause & Effect Matrix• P-Diagram• PFMEA and/or DFMEA• SPC• Rolled Throughput Yield
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10 15 20 25 30
LSLLSL Target
FASCIA CLEARANCE TO MUFFLER OLD- ALL
USL
Target
LSL
Mean
Sample N
StDev (Within)
StDev (Overall)
Cp
CPU
CPL
Cpk
Cpm
Pp
PPU
PPL
Ppk
PPM < LSL
PPM > USL
PPM Total
PPM < LSL
PPM > USL
PPM Total
PPM < LSL
PPM > USL
PPM Total
*
30.0000
17.0000
19.2162
37
3.12746
3.36607
*
*
0.24
0.24
*
*
*
0.22
0.22
216216.22
*
216216.22
239276.82
*
239276.82
255141.04
*
255141.04
Process Data
Potential (Within) Capability
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Within
Overall
CONTAINMENT (state reasoning if not required): Process Owner Date Before Data After Data
100% audit (clearances at fascia / lower control arm. John Smith 10/17/01 0.24 Cpk 1.23 Cpk• When necessary, reposition muffler assembly to obtain adequate clearance.• If muffler does not shift to desired position, loosen joint attachment & reposition assembly.
MSA & Process Capability: Engineering Test Requirement
Muffler to Body Clearance (17-30 mm)
Gage R&R = 15 % Study Baseline Capability (Oct. 15, 2001):
• Z = 0.72• DPMO = 255,141• Cpk = 0.24 (note: short
term)
Data Collection plan includes all circled, highly ranked X’s
MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY
DDDD MMMM AAAA IIII CCCC RRRR
Process ElementsElement OK AInvestigating BElement Not Capable CElement Removed D
A
A
B
B
B
B
B
A
B
CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler
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MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY
DDDD MMMM AAAA IIII CCCC RRRR
• Fishbone diagram is one of the most widely used tools in quality management.
Example – Brake Cold Squeal Fish Bone Diagram
FISHBONECause and Effect diagram is a problem solving tool used to identify and graphically display all possible causes of a problem or effect. It helps a team to discover root cause(s). Additional tools can and should be used to deep dive in the measure phase to help prioritize the KPIV – Key Process Input Variables: causeand effect priority matrix, fault tree / contribution analysis, process / design FMEAs, is/is not analysis, process mapping, etc.
Environment
Customer Usage
System Interactions
Piece to Piece Vartiation
Aging Wear Design
Brake application (line pressure)
Vehicle speed
Braking distance
Driving habits (D)
Cooling of Brake System (D)
Pad modal parameters (A)
Material Property Variation
Surface Friction Variation
Manufacturing misassembly (D)
Rotor/Hub Alignment
Pad Geometric Variations
Pad Damping Deterioration
Running Clearance
Sys Damping Deterioration Pad/Lining Wear/Cracked
Aging of Slide Pin Wear Shape of
lining (A)
Uneven Rotor Wear
Lining material Characteristics (A)
Humidity(wet/dry)/water/Moisture
absorption (A)
Contaminates
Corrosion
Road salts
Solvents
Temperature
Road inputs
Customer’s Maintenance Schedules
(D)
Incorrect Maintenance (D)
Road Quality (D)
Lot RotDeceleration rate Suspension
Interactions (D)
Body Sensitivities (Acoustic/Vibration(D)
Rotor
Warping
Rotor Scorching
Booster Noise Filter Wear
Rotor Geometric Variations
Thickness of lining material (A)
Pad/Rotor pressure distribution (even/uneven)when apply brake (B)
Chamfers in lining (A)
Slots in lining
Insulator type
Insulator damping/damping material (A)
Caliper design
Rotor modal
parameter
Process ElementsElement OK AInvestigating BElement Not Capable CElement Removed D
Important: Look for Internal
Indicator at Supplier
facility and Assembly plant
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MEASURE CTQ (y) CAPABILITYMEASURE CTQ (y) CAPABILITY
DDDD MMMM AAAA IIII CCCC RRRR
Example of Additional Tool – U152 Brake Cold Squeal Is/Is Not Analysis
IS IS NOT
U152 4X4U152 4X2
Foundation brake (caliper, rotor, pads, insulator)
Other chassis component or other component of the brake system
DefectBrake squeal dominated at 6.6-6.8kHz range.
Groan, grind, or rattle
Foundation brake (caliper, rotor, pads, insulator)Squeal can be observed outside/ inside vehicleFront and rear brakes. Front noise is dominant
Isolated to the front or rear axle.
First observed
Normal morning braking, cold dyno test
Dyno testing (brake and vehicle)Normal customer, public road
First observed
GQRS
Dealer, fleet, and various dyno/vehicle tests, JD Power, R/1000, GQRSUsually in the morning with cold temperature and high humidity
Hot/warm noise or low humidity conditions
Noise on the first few brake applies and then goes away.
Repeatable after first few stops or continuous
Brake rotor temperature -10°C < t < 20°C
Hot
Low mileage and high mileage Isolated to low or high mileage.All U152 vehicles built through 4/2/02 Some Production months
Trend
It is cold squeal and depends on temperature and humidity. The TGW's typically range from 60-70.
It is not warm/hot noise or observed in low humidity conditions
Problem Statement: Brake squeal/audible noise.
Problem solving worksheet ("Is/Is Not Profile")
HO
W B
IG
Problem description
WH
ER
EW
HE
NW
HA
T Object
How many affected
On Object
NOTE: ONE THING WE SHOULD MAKE CERTAIN IS THAT WE SHOULD NOT LET THE IDENTIFICATION OF THE ROOT CAUSE (ANALYZE PHASE) BE A DETRIMENT TO THE TIMELY COMPLETION OF THE CONTAINMENT PLAN. AN INSPECTION, SORTING, STOP SHIP, ETC. MAY BE REQUIRED TO PROTECT THE CUSTOMER WITHOUT KNOWING THE "ROOT CAUSE".
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ANALYZE y=f(x)ANALYZE y=f(x)
DDDD MMMM AAAA IIII CCCC RRRR
ANALYZE PANEL (Minimum requirements):
1) Which Inputs (Xs) affect my Outputs most (with data)?
2) How many samples do you need to draw conclusions?
3) What level of confidence do you have in your conclusions?
Additional Tools: (add slide(s) to capture backup Analyze material)• Graphical Analysis & Hypothesis Testing
• Regression Analysis
• Correlation Analysis
• Process FMEA
• P-Diagram
• Contribution Analysis
• Multi-vari studies
• Shainin Analysis
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86420
LSLLSL
Fascia locating holes on snow shoe
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (Ov erall)
StDev (Within)
Sample N
Mean
LSL
Target
USL
0.18
*
0.18
0.04
*
0.04
0.00
*
0.00
1.70
1.70
*
*
*
1.79
1.79
*
*
1.19547
1.13172
41
5.08993
-1.00000
*
*
Exp. "Ov erall" Perf ormanceExp. "Within" Perf ormanceObserv ed Perf ormanceOv erall Capability
Potential (Within) Capability
Process Data
Within
Overal l
HOLE # 2HOLE #1
0.8
0.4
0.0
MUFFLER HANGER BRACKET - HOLE LOCATION (means are indicated by solid circles)
ANALYSIS OF VARIANCESource DF SS MS F PFactor 1 0.0038 0.0038 0.05 0.826Error 48 3.7236 0.0776Total 49 3.7274
FASCIA LOCATING HOLE & MUFFLER HANGER LOCATING HOLE DETERMINED AS INSIGNIFICANT “X”
y=f(x)
The current design muffler assembly aid positions the pipe to the center of tunnel, which is 4.2 mm from design position. This translates 13 mm muffler body movement toward the fascia area.
y=f(x)
Muffler assembly aids used during installation require detailed 4.2 mm offset positioning feature to meet design intent.
REDESIGNED ASSEMBLY AID • incorporated the 4.2 mm design
CURRENT ASSEMBLY AID • 4.2 mm offset from design allows pipe position to vary when installed
ANALYZE y=f(x)ANALYZE y=f(x)
DDDD MMMM AAAA IIII CCCC RRRR
CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler
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IMPROVE y=f(x)IMPROVE y=f(x)
DDDD MMMM AAAA IIII CCCC RRRR
IMPROVE PANEL (Minimum requirements):
1) What is the optimal Y=f(x) solution?
2) How was optimal solution verified? (Statistical proof that the solution works.)
3) Key actions taken and work plan to improve. Work plan must include:a. Permanent/Interim actions,b. Sample size,c. Next steps if trial is successful,d. Next steps if trial is NOT successful,e. Part availability if trial is successful,f. Additional actions pending.
4) Validation of fix after implementation. Before and after process capability of Y, showing variable data histograms, attribute data, etc.
Additional Tools: (add slide(s) to capture backup Improve material)
• Design of Experiments (Main Effect & Interaction Plots, ANOVA Tables)
• Regression Analysis
• Correlation Analysis
• Hypothesis Testing
• Cost / Benefit Analysis
• Process Mapping (should be)
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454035302520
TargetLSLLSL
IMPROVEMENT VALIDATEDSable Muffler Clearance to Facia -
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (Overall)
StDev (Within)
Sample N
Mean
LSL
Target
USL
0.00
*
0.00
0.00
*
0.00
0.00
*
0.00
2.03
2.03
*
*
*
2.63
2.63
*
*
3.25054
2.51058
120
36.8375
17.0000
30.0000
*
Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability
Potential (Within) Capability
Process Data
Within
Overall
3025201510
TargetLSLLSL
BASELINE PERFORMANCESable Muffler Clearance to Facia -
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (Overall)
StDev (Within)
Sample N
Mean
LSL
Target
USL
255141.04
*
255141.04
239276.82
*
239276.82
216216.22
*
216216.22
0.22
0.22
*
*
*
0.24
0.24
*
*
3.36607
3.12746
37
19.2162
17.0000
30.0000
*
Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability
Potential (Within) Capability
Process Data
Within
Overall
Improved y=f(x)A. Incorporate trimmed fascia and sheet metal for clearance.
B. Muffler hanger bracket design modified, along with fascia and sheet metal change improved clearance 15 mm.
Hypothesis Testing Statistically Confirms Improvement of YOne-way ANOVA: FASCI-END (IMPROVEMENT), FASCIA-PRE (BASELINE)
Analysis of VarianceSource DF SS MS F PFactor 1 8781.3 8781.3 822.74 0.000Error 155 1654.4 10.7Total 156 10435.6 Individual 95% CIs For Mean Based on Pooled StDevLevel N Mean StDev ----------+---------+---------+------FASCI-EN 120 36.838 3.244 (*) FASCIA-P 37 19.216 3.343 (-*-) ----------+---------+---------+------Pooled StDev = 3.267 24.0 30.0 36.0
Implementation WorkplanPermanent / Before/AfterInterim Actions Who/When IndicatorsConcern C11298746 Robert Bryer 0.2 Cpk (B)Revised Sable Fascia (AAP-PVT) 1.2 Cpk (A)and sheet metal for In productionadditional clearance. Jan., 2002
Concern C11272097 Steve Hornby 1.2 Cpk (B)Redesigned muffler (PTSE D&R) 2.0 Cpk (A)assy aid to meet design March, 2002y and z specification.
All trails successful, see sample size above. All actions and parts in house and implemented, March 5th, 2002.
IMPROVE y=f(x)IMPROVE y=f(x)
BEFORE: Oct. 15, 2001 AFTER: March 1, 2002
DDDD MMMM AAAA IIII CCCC RRRR
CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler
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IMPROVE y=f(x)IMPROVE y=f(x)
DDDD MMMM AAAA IIII CCCC RRRR
Example of Weibull Plotting B10 Life Improvement
FRONT AND REAR BRAKES CHASSIS ROLL DYNO-NOISE BEFORE AND AFTER DESIGN CHANGED
0.30%
17.80%
0.00%
5.00%
10.00%
15.00%
20.00%
Front Baseline Front New Insulator &Chamfer
Per
cent
Occ
urre
nce
of N
oisy
Sto
ps
Additional Improve Phase Examples – Verification Data requires solid statistical evidence using adequate sample size showing the fix is permanent.
Two Sample T-Test and Confidence IntervalTwo sample T for Rr Base vs Rr Verif.
N Mean StDev SE MeanRr Base 22 34.46 1.40 0.30Rr Verif 29 32.27 1.31 0.2495% CI for mu Rr Base - mu Rr Verif: ( 1.41, 2.96)T-Test mu Rr Base = mu Rr Verif (vs not =): T = 5.69 P = 0.0000 DF = 43
Mean is at the Target of 32 Sones
P-Value is less than .05Therefore, there is a statistical difference between means
Two Sample T-Test and Confidence IntervalTwo sample T for Rr Base vs Rr Verif.
N Mean StDev SE MeanRr Base 22 34.46 1.40 0.30Rr Verif 29 32.27 1.31 0.2495% CI for mu Rr Base - mu Rr Verif: ( 1.41, 2.96)T-Test mu Rr Base = mu Rr Verif (vs not =): T = 5.69 P = 0.0000 DF = 43
Mean is at the Target of 32 Sones
P-Value is less than .05Therefore, there is a statistical difference between means
Example of hypothesis testing. U152 Explorer wind noise level is significantly improved.
0Subgroup 10 20 30 40 50
2829303132333435363738
Ind
ivid
ual V
alue 66
X=33.22
3.0SL=37
Baseline
Noise Level (Base vs Modification)
Modification
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IMPROVE y=f(x)IMPROVE y=f(x)
DDDD MMMM AAAA IIII CCCC RRRR
0.033
0.004
0.000
0.025
0.050
0.075
0.100
Baseline New Insulator & Chamfer
Obj
ectiv
e N
oise
Inde
x
0
2
4
6
8
10
0 5000 10000 15000 20000 25000 30000 35000 40000 45000
Cumulative Test Mileage / Vehicle
Cu
mu
lati
ve I
nci
den
ts /
Veh
icle
Example of APG Durability Reliability AnalysisCumulative Incidents vs Cumulative Mileage
APG or CAE/Lab test can be used for this Slot)
Additional Improve Phase Examples – Verification with Durability Data
DYNO: SAE J2521 & Simulated LACT operating conditions
Les s
is
bet t
er
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IMPROVE y=f(x)IMPROVE y=f(x)
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• Develop a work plan is to include detailed course of actions to fix the problem, including permanent/ engineering/process/quality actions, Plant trial schedule and sample size, next step after the trail, etc
Example - Work Plan
WORKPLAN DETAIL TIMELINE CHARTAn overall plan showing improvement timelines for implementing containment, interim and permanent corrective actions.
Problem Definition - The GQRS and AWS indicator pointed out the following area of concern:
The PERMANENT/INTERIM engineering/process/quality actions we are working on is/are:
Item Date Before After Indicator
1 4/2/02 17% 0.30% % Noisy stop
We are running a trial of ___________ piecesNo trail needed in assembly plants. Development and Test carried out at Dyno Lab
If all goes well, we will have parts in house on 4/02/02 (date)
Explorer Customer experienced Brake Squeal after vehicle sitting at rest over night. Noise on the first few brake applies and then goes away.
Project ImprovementAction
New Rubore insulator and chamfer
Additional Improve Phase Example – Workplan detail timeline chart
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CONTROL X’sCONTROL X’s
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CONTROL PANEL (Minimum requirements):
1) Graphical (SPC Charts) or analytical proof showing that the process is in control over time, using internal indicators.
2) What actions are taken to sustain the gains? (Example: Standard Operating Procedure changes (including control plan), permanent design or tooling change, etc.)
Additional Tools: (add slide(s) to capture backup Control material)
• Process or Design FMEAs
• Control Plans for Process and Gage
• Statistical Process Control
• Standard Operating Procedures
• Visual Factory
• Preventative Maintenance
• Prevent Recurrence
• Poka Yoke / Mistake Proofing
• Document special cause actions (Global 8-D), as necessary.
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252015105Subgroup 0
41.540.539.538.537.536.535.534.533.532.5
Sam
ple
Mea
n
Mean=36.91
UCL=40.67
LCL=33.15
15
10
5
0
Sam
ple
Ran
ge
R=6.521
UCL=13.79
LCL=0
IMPROVEMENT SUSTAINED AND IN CONTROL!Xbar/R Chart for Muffler Clearance to FaciaITEM CONTROL
DATE RESPONSIBLE
C11298746 Revised Sable Fascia and sheet metal for additional clearance.
In production J an 2002.
Robert Bryer Body Structures Engineer AAP-PVT
C11272097 Redesigned muffler assembly aid to meet design y and z specification
March 2002 Steve Hornby PTSE design engineer, Andrew Schmid BB, Pat Swann BB
Submit for financial approval and order new parts
In plant May 2002
Tuan Nguyen Randy Wright AAP PVT
Audit Plan On going 4 Poster test, M-10 drive, WRAP On line clearance checks Monitor daily
Ongoing V.O. 4-poster test M-10 drive, WRAP performed at AAP/CAP
Follow up audit during full production with new aid
May 2002 Ken Eckert/John Kamph/Patricia Swann
SDS-FMEA-DVP review
Confirm system design requirements in place -ER-0052 Ver 15 Clearances Around the Exhaust System
Req Details 17164 20328 20331 20332 21239 21240
Verification Method DVM-0033-ER –ER-0005 Ver 11 Exhaust Static Location
Req Details 23094/23484 Verification Method 10675
SDS identified for update –ER-0039 Design for Assembly
Req Details 8624 Verification Method DVM-0033-ER
April 2002 Pat Swann, Steve Hornby, Hank Newsome Dan Valle/Mark Dixon
CONTROL X’sCONTROL X’s
L66 (Exhaust System Trouble) warranty trend chart for 2002 Sable
August 27, 2002
0
0.5
1
1.5
2
2.5
3
MOP
R/1
000
Containment 10/17/02
Fascia Change 1/2/02
Muffler Aid Revised 3/1/02
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CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler
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DEFINE VOICE OF THE CUSTOMERDEFINE VOICE OF THE CUSTOMER
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Total Warranty Spending andUnexpended Warranty Savings:
• Unexpended roadmap opportunities for all affected model year coverage periods:
• Warranty-spending savings with roadmap actions:
• Top spending parts for this CCC: (for each part, please explain)
• Problem fixed in production
• Optimized solution availability
• Supplier is in Warranty Reduction Program
Yes No
Yes No
Yes No
1) What are your unexpended roadmap opportunities for ’00, ‘01, ’02, and ’03 MY?
2) What is your warranty-spend savings with road map?
3) What are your top spending parts for this CCC? For each part:
• Is the problem fixed in production?• Is there an optimal solution?
• Labor time: More efficient repair process, special service tool
• Part pricing: Does it meet 70% guideline?
• Other: Efficient repair procedure (part vs. subassembly) Improved diagnostics-reduced TNI, Policy changes, Customer education to prevent failure
• Does the supplier participate in Warranty Reduction Program (WRP)?
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REPLICATEREPLICATE
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REPLICATION PANEL (Minimum requirements):
1) Who else at Ford could be affected or could benefit? (Replication at another Plant or on another vehicle line?)
2) Are there any larger business unit or even global intellectual capital effects? (SDS, FMEAs, VDS, etc. in need of updates?)
3) After 6 months, is the process still in control and the improvement in Y and X sustained? (Control Charts, Proof from Warranty or GQRS, etc.)
Additional Tools: (add slide(s) to capture backup Replicate/End material)• SPC, Control Charting
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PROJECT END – PROOF OF SUSTAINMENT: Re-validated Process in Control Process Owner (8/27/02 Randy Wright-Atlanta Assembly Plant) Improvement Data proves sustainment ( 8/27/02 Capability – 0 DPMO, Cpk=2.82) AWS Analysis indicates Financial Data Sustained ( Warranty Savings = $152,000/yr, 2.1 R/1000 )
REPLICATION (who else across Ford Motor Company could benefit?): Key Actions Is this Replicable? If Yes, Where? Responsibility
• Design Change to Assembly Aid Yes, at sister Plant (CAP) Chicago, ILL Orlando
Ventura
• Design Change to Fascia No, specific to Taurus/Sable designUPDATES TO CORPORATE KNOWLEDGE BASE (who else across Ford Motor Company could benefit?):
Core Book Change Made Owner Document # Completed Attribute FMEA Design FMEA Process FMEA SDS Changed clearance specs. Dan Valle ER-0039 ver 11 8/2/2002 VDS FDVS <other specify here>
REPLICATEREPLICATE
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CCC: L66 - Exhaust System TroublesCCC: L66 - Exhaust System TroublesVFG: V44 - Mechanical MalfunctionVFG: V44 - Mechanical MalfunctionVRT: Powertrain / FuelVRT: Powertrain / Fuel
VEHICLE: 2001 Taurus/SableVEHICLE: 2001 Taurus/Sable PART: 5230 MufflerPART: 5230 Muffler