Shop Floor Management Audit - Process Assurance

Purpose :
To Confirm and Enhance the Critical Items in Shop affecting Quality. Eg:Oil filling,Equipment Breakdown,Kaku-S items, Abnormality Management, etc

Background :
Problems in field/ final inspection/ Audits due to :--
1. Change Point
* Manpower Change
* Equipment breakdown/ Change /Modified from existing.
2. Deviation from Standardized Work.
* System not followed/Dilution in Standard Work.
(eg- Oil filling not done, Damages to functional parts/Mis-Handling, Scratches and Dents)
* Standards not Clear and Effective.

Objective :
1.To ensure Zero defects during Change Points by Confirming and enhancing Quality sysytems
2.To ensure Zero Defects during regular Standardized Work by confirming and enhancing Quality Sytems
3. Level Up Systems related to changes.

Scope :
Total Plant (P,W,T,A) other than Line Standard Work.

Thinking Way :
Monthly Theme Based Activity :--

Methodology :--
Change Point Audit Regular Audit

Schedule :
Sl. No. Activity June '10 July '10 August '10 September'10 October'10 November'10 December'10 January'10 February'10 March'10 April
1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w 1W 2w 3w 4w

MAJOR
1 SQA New Model
EVENTS Quality Launch Manpower EFC Launch
Month Corolla Diesel Change Point

S Assembly
Special Parts
THEMES (Cases)

Regulation In-house (Other than Feedback

Regular Oil Filling Final Repair
Items
Audit (as per
Transport Line Std. System
Tightening Dwg.)
Audit Work)
2
Storage&
Working Abnormality
Change Manpower Machine
Condition(4M) Rules &
Point Change Effect Breakdown
Handling
Checksheet Checksheet Checksheet Checksheet Checksheet Checksheet Checksheet
Checksheet Checksheet Checksheet
3 QCD ACTIVITY
QCD Audit QCD QCD Audit QCD QCD Audit QCD QCD Audit QCD QCD Audit QCD
ReAudit ReAudit ReAudit ReAudit ReAudit

Shop AuditCounter
SHOP Shop Audit Counter Shop AuditCounter Shop AuditCounter Shop AuditCounter
4 Measure Measure
ACTIVITY Measure Measure Measure

Procedure to Sustain :
* Clear Understanding of New Countermeasures & Revisions by Team Members for Acceptance
(Both QI and Line Members)
* Comparing the Standardized Work Between both Working Shifts.
* Regular audits.
 Act
Plan
ANALYSE
COUNTERMEASUR
E
4 1

AUDIT PREPARE
CHECKSHEETS
Check 3
2

Do

Confirm &
Problem Analysis & Restrengthen
Identification Audit by QCD

Outflow Shopfloor Audit Countermeasure

Prevention

Occurence Standardized Daily Management Standardized Work

Prevention Work of process parameter

Zero Defect & Standardized System Workability & Any Difference ??

Best Quality Work Inspection Assurance

Once in 6 months
(By Top Mgmt.)

Re-Audit by Top Mgmt &

Once in 3 QCD
months
Once Every Month by QCD
Self Audit By Shop Damages to Functiona
Once Parts/Mishandling etc
QCD Audit Every
Improve Shopfloor Month
Activities & Case by Case Kaku-S other than
Countermeasure Tightening and Joints

Plan & Confirm Oil Filling Methodology

Current Condition and Standards

l EFC
Launch

Checksheet Checksheet Checksheet Checksheet Checksheet Checksheet Checksheet Checksheet

QCD Audit QCD Audit QCD Audit QCD Audit QCD Audit
QCD Audit QCD Audit QCD Audit QCD Audit QCD Audit
Re-Audit
Re-Audit Re-Audit

Shop Audit Shop Audit Shop Audit Shop Audit Shop Audit Shop Audit Shop Audit

Counter- Counter- Counter- Counter- Counter- Counter- Counter- Counter- Counter-

measure measure measure measure measure measure measure measure measure

Fuel, Brake,

D P
Special Parts Abnormality
Clutch Oil Filling Storage and Feedback
Final Repair Audit As per Rules &
Related Stations 4S condition System
Drawing Handling
Kaku-S Parts
Regulation Items Assembly (Other than line Std.Work)

C A
C A
Damages to Functional
Parts/Mishandling etc...