1. Quality Ownership Engagement Program (Manual Checking Approach)
Andon System
Peer – to – Peer Product Confirmation

2. Sub Assy Main Assy Fitting
Quality Ownership Engagement Program – Manual Checking Approach
1.0 OBJECTIVE
Sub Assy
Main Assy
Fitting
Objective
Interface
Concept
Instill ‘right at the first
time’ culture
Enhance problem solving
skill
Enhance product & process quality ownership among workers
Product confirmation
Quick response to BIW
requirement
SOP – Self checking
Product audit
Peer –to- peer product confirmation
Andon system

3. Quality Ownership Engagement Program – Manual Checking Approach
BIW Area
System
Station
External
Appearance
Fitting
Part variation
Andon
Line stoppage for quality problem
Fitting line
Product Confirmation
Main Assy line
Internal
Weld nut / hole missing / offset
Part variation
New self check methodology
Confirm peer product before next process
Peer – to – peer product confirm
Sub Assy line

4. Final line & related groups Final line & related groups
Quality Ownership Engagement Program – Manual Checking Approach
3.0 ANDON SYSTEM CONCEPT
LINE ON
LINE STOP
LINE ON
Pull Andon
> Call related group
> Discuss containment
action
> Decide repair – Online /
offline
> Investigate root
cause
> Plan for
countermeasure
Quality Problem?
Repair
affected
body
Insert at DL1B
Interface
Pull station stop string
Preliminary
report
Problem solving
report
Certificate of repair
Filling
Final line & related groups
Final line & related groups
Final line
Related groups
QIT
PIC

5. Quality Ownership Engagement Program – Manual Checking Approach
4.0 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT
STAGE #1
STAGE #2
LAST STAGE
Product Confirm Stage #1
Process
Product Re-Confirm Stage #1
Product Confirm Stage #2
Process
Process
Product Re-Confirm # X
Method
Place marker to
specified points
Remove marker
Place marker to
next specified points
Remove marker & put in the box
Proposed Tools
Magnet Marker
Simple gauge
Bolt / screw
Hole plug

6. Quality Ownership Engagement Program – Manual Checking Approach
4.1 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT [CASE STUDY] 1
Fitting Line
To confirm correct closure parts
(RHS) installed to body
Tool – magnet marker
Date – Mar ‘12 [start]
Rear door #5
(Closure) 5 2
Fitting #4
Fitting #9 3 4
Fitting #5
Fitting #8

7. Quality Ownership Engagement Program – Manual Checking Approach
5.0 IMPLEMENTATION PLAN NO
SYSTEM
STATION
FOCUSED AREA 1
Andon
Fitting Line
Final
Appearance
Major repair
Part variation 2
Peer – to – Peer Product Confirmation
Sub Assembly Line
Side Structure
Front End
Weld nut / hole missing / offset
TF rejection

8. Quality Ownership Engagement Program – Manual Checking Approach
5.1 PEER – TO – PEER PRODUCT CONFIRMATION PROGRESS – FRONT END

9. Quality Ownership Engagement Program – Manual Checking Approach
5.2 PEER – TO – PEER PRODUCT CONFIRMATION PROGRESS – SIDE STRUCTURE
S/Structure Line
To confirm assist grip (front & rear ) nut not offset
Tool – Hand gauge
Date – July‘12 [start] 3
S/Struc Line #30 2
S/Struc Line #20
Check and Remove Gauge 1
Sub Assy #50
Install & Check Rear Side Nut
Install & Check Front Side Nut

10. Thank You