module 10 - web.purinfo.ford.com · map your service process identify misidentification “escape...
TRANSCRIPT
Module 10
Module 10 Misidentification
Misidentification
Module 10 Misidentification
Where is
Misidentification?
What is
Misidentification?
How can
Misidentification
be prevented?
2
Most Common Areas for Misidentification
◦Engineering
◦Production
◦Material Handling/ Labeling
◦Misidentification is the leading cause of
PPM for FCSD
Module 10 Misidentification
3
Map your Service Process Identify Misidentification “Escape Points”
Module 10 Misidentification
Analyze Assess Implement
The process flow map assists devolvement of the process Failure Mode and Effects Analysis, and Control Plan
4
Root Causes◦ WERS Releasing of Serviceable Parts Errors
Improper coding of Service End Items in WERS
Miscommunication of design records to your plant from your
Corporate Engineering Department
Manual set up of the supplier Parts Registry allows transcription
errors
Supplier not in sync with DDL
Manage the Change errors – Service Interchangeability of
Replacing parts errors
No PPAP or PSW approval of Service Unique Parts
Module 10 Misidentification
5
Root Causes◦ Wrong Part Shipped
Warehouse or Line Picking errors caused by inadequate
training of regular or replacement personnel (out of process)
Wrong part picked due to inadequate master parts records
(Parts Bible)
No poke-yokes or detection activities are established in your
service processes
Supplier does not verify part or ship “to release”
Module 10 Misidentification
6
Root Causes◦ Wrong Label
Sub-supplier “pass through” parts are not contained at your site
Manual or Batch Parts Labeling Process allows mislabeling of
product
Lack of master parts and label identification records allow
escape of non-conforming product
Module 10 Misidentification
7
Module 10 Misidentification
8
0
2
4
6
8
10
12
14
16
18
Recommended Actions Verify the engineering Design Records & Part Numbers at PPAP
Verify Suppliers parts list matches QIM
Service to Engineering cross reference
Employ Production Poke-yokes in your service process
Install Bar coding for part and labeling processing
Prior to Shipping verify you meet the FCSD Release
Track Internal PPM and drive continuous improvement using the 4-panel
Methodology
Module 10 Misidentification
9
Action Plan: Process which will help you to focus your ideas
and to decide what steps you need to take to achieve particular
goals that you may have.
Trend Chart- Illustrates the trend of the Supplier's PPM by
graphing the history of past PPM scores.
Pareto Chart- Orders number of occurrences from highest to
lowest in order to focus attention to areas of need.
Paynter Chart- Based on the Pareto principle, which focuses
on the areas of priority and quickly puts them in a simple graphical
form by subgroups. It helps your team focus their efforts where they
can have greatest impact.
10
Module 10 Misidentification
Module 10 Misidentification
11
Fault item Date
Root
Cause-
Action
Person
Responsible
Target
Complete
Date
Start Date CompleteExpected
Improvement
Jan Feb Mar Apr
WERS Error 0 0 11 0
Manual Process
34 0 0 0
Manage Change
0 0 0 0
DATA Entry Error
31 0 24 0
No Process 0 0 0 0
No Part Record
0 0 0 0
No Verification 0 0 0 0
Batch Label 0 0 0 0
Module 10 Misidentification
Faultitem
DateRoot Cause-
ActionPerson
Responsible
TargetComplete
Date
Start Date
CompleteExpected
Improvement
Fault item
Date
Root Cause and Action
Person Responsible
Target Complete Date, Start Date, Complete Date
Optional Items:
% Complete to Target
RYG to Target (Red, Yellow, Green)
Comments
12
(Example)
Module 10 Misidentification
13
0
500
1000
1500
2000
2500
Jan Feb Mar Apr May Jun
PPM
(Example)
PPM
Objective
Module 10 Misidentification
14
0
2
4
6
8
10
12
14
16
18
20
Engineering Labeling Production
# O
F O
ccu
rre
nce
s(Example)
Module 10 Misidentification
15
Jan Feb Mar Apr
WERS Error 0 0 11 0
Manual Process 34 0 0 0
Manage Change 0 0 0 0
DATA Entry Error 31 0 24 0
No Process 0 0 0 0
No Part Record 0 0 0 0
No Verification 0 0 0 0
Batch Label 0 0 0 0
(Example)
1. Engineering Part Number
2. Service Part Number
3. Service Part Label
4. Release Quantity
5. Timing (Ship on Time)
Module 10 Misidentification
16
◦Help FCSD Detect and Contain
Misidentified Parts
◦Report Sightings to your FCSD STA
◦Protect your Q-1 Status
Module 10 Misidentification
17