LLC_and_STABILITY_RATE_Suppliers_Training_Module.pdf

Version 3 – April, 2009 SUPPLIERS Lessons Learnt Cards, LLC Audits, Stability rate in Incident Management System June 20082I What is a lesson Learnt Card (LLC) ?It is the capitalization of experience : what have we learnt from an incidnet? ?It is a synthesis of acquired experience classified by root cause Why LLC? ?To capitalize experience on C1, recurrent incidents , Warranty returns … ?To help Suppliers to structure their experience Why LLC stability rate? ?The action taken are not strong enough (not ever implemented on the suppliers assembly lines) ?The criteria to be respected are not clear enough ?The operators are not fully trained ?The action taken are not stable (not respected on the supplier lines) ?The verification is not done Lessons Learnt Cards in SRM Lessons Learnt Cards June 20084I LLC becomes automatic for all incidents : no need to request for a LLC at PD step . The LLC in SRM will be now the Valeo LLC excel standard IMS – Mandatory LLC OptionalC2 OptionalC3 MandatoryWR MandatoryL1 Logistics IncidentsOptionalL2 OptionalL3 Mandatory MandatoryC1 Quality Incidents NowBefore Supplier fills in LLC Excel Template Supplier attaches LLC Excel file Supplier enters data on-line and attaches LLC pictures PDF generated automatically by SRM based on data entered Process XLSPDFFormat NowBefore June 20085I IMS – New LLC : excel file June 20086I To whom :lineWhen? APU :When? To whom?When? PROCESS 1. - Proces is modified according to Before/ After sheet 2.- All documents have been updated and has been validated with the operators 2.1.- Procedures and work instructions 2.2.- Maintenance instructions 2.3.-Records (start-up checklists,reaction sheets,preventive maintenance.) 3.- Visual aids are posted 4.- Operators and other functions are trained 4.2.- Operators can correctly describe what they must do 4.2.1.- Manufacturing process steps 4.2.2.- Maintenance steps WHAT HAS BEEN MODIFIED ? Who What is non-conform? CRITERIA What is conform? Where When 4.1.- Proof of training is avalaible (records,5 ' meeting) Potential applicability WHAT WE LEARNED What DOCUMENTATION How VISUAL AIDOPERATOR METHOD Which standard has been updated (Valeo Norme, generics FMEAs, procedures…)? ITEM (Control Factor) Did you share the LLC with the branch ? Describe, what you have learnt and what needs to be put under control Explain what, how, when, who to perform correct measurement of the Control Factor To be able to judge the result of the factor measurement, specify : what is in conformance what is not in conformance? IMS – New LLC : excel file June 20087I IMS – LLC Creation All 5W2H LLC fields are removed, except “What happened” and “why is it a problem” for search LLC Template available for download Mandatory attachment of LLC Excel file June 20088I Availability of previous PDF-format LLCs For closed and/or already existing incidents with LLC, the PDF version is available in the “LLC Attachments” section of the Check-Act screen. June 20089I VALEO CLOSURE SRM INCIDENTS: step modified Approved by Valeo QC (Quality Control) QR (Quick Response) Incident notification 24h ? 5 days ? 10 days ? ???? Notification to Supplier ? Quick Response ?Immediate action plan to protect Valeo & customer ? Plan Do ?Analysis of issue ?Corrective action plan for each root cause ? Analyse Check Act Approved by Valeo Approved by Valeo Analysis Plan Do ? Check Act ?Update of standards ?Lesson Learnt ?Card Submitted by Supplier Approved by Valeo ? Check Act Update of standards Lesson Learnt Card ? Stability rate June 200811I What are the expectations? ?To make sure all corrective actions implemented to solve a Quality incident will stay in place and be respected all along the time (STABLITY) ?To put in place an audit based on the concerned LLC: LLC Stability Rate audit ?To make sure the results will always 100% What will be the benefits? ?To define robust and concrete criteria's to close a Quality incident by putting critical factor under control ?To avoid any recurrence by making sure actions taken and promised to VALEO are stable (always in place) ?To make sure the experience of Supplier will be formalized and used for future ?To make sure all operators are aware and know the new rules ?To make sure documentation keep up to date according new rules ?To improve the standards used and the pertinence of LLC established (criteria defined on the LLC have to be audited) WHAT ACTION TO TAKE ? : EXPECTATIONS & BENEFITS Supplier’s efficiency will be measured by the stability rate and the level of recurrences of incidents LLC Audits on Suppliers plants June 200813I In the workshop , at the workstation All shifts, all workstations are concerned Ask to the operators Check the instructions, the records Check if the criteria is conform and respected : ?LLC have to be audited during all the serial life ?A SRM incident could not be closed before the stability has been demonstrated during 4 consecutive weeks: Stability Rate = 100% (result will be attached through SRM) ?T。