Simple

Rapid

Permanent

Early Warning & Information system For Quality

Problems

Defect Escalation Model

7/22/2011 1Sameer Kadam

Defect Escalation Model

No

Yes

No

Section ManagerManufacturing Engineer

8 Info to Coordinator (+ TEF1 if neccessary)

Can the problem solved?

(Max 45 min.)Can be waited for effectivity if very sure of solution

max 1 shift.

CoordinatorMax. 90’

6. Start simple problem solving activity (Operator+Supervisor)

4. Give info to Supervisor. (Pull the cord)

ProductionSupervisor Max. 45’

Is the red area

reached?

1.Defective part

AIM:- Early detection of the quality problems- Permanent solution in a short period after the detection

2. Recorded into the tally chart

Mxx Deparment managerQMM Department managerMax Time

BCE

Important note:Defined time frames are maximum times. If it is sure that the defined period will be exceeded Escalation is made without waiting.

0 1 2 3 4 5Escalation Level

Responsible

Max. 120’

16. Inspect the reached point and provide detailed expert input to he problem solving Process.

Yes

13. Relevant section manager informed.

5. Keep on production

3. Stop the machine

Max. 1’

7. Record the measure to the problem tracking form

If necessary contact machine manufacturer and TEF1

Is a deviation from the

production plan

expected?

17. Inform Cordinator of the situation and give a approximate solution time

15. Follow the problem closely

12. Informing the necessary sides(LOG, Assembly)

Yes No

9. Keep on production

10. In case of unavailability block all charges and 100% control.

14. Relevant QMM section manager is informed.

18. Inform the one upper level manager

19. Provide organisational support to the problem solving process

Is a serious deviation

expected in the production plan?

Is there risk to stop the

customer?

20. Organising the resource need, Communication with customer side, informing PT if necessary

11. Take the subject to the Go to Genba

Yes

Training should be given to all levels about their duties7/22/2011 2

Sameer Kadam

Defect Escalation ModelSample Tally Chart (Step 2 In Flow)

Form Is Used Daily & Designed For Each Machine7/22/2011 3Sameer Kadam

Defect type

Defe

ctive

part

amo

unt

DateMachine/

Equipment

Possible

cause

Immediate

measure

Results of

immediate action

(Sorting etc.)

Root cause Permanent measureDue

date

Responsibl

e

Defect Escalation ModelProblem Tracking Form (Step 7 In The Flow)

Can Be Used During Daily Meeting On A Review Board7/22/2011 4Sameer Kadam

Possible effects which could be changedChanges on the

Machine

Changes on

the

Material

Changes on the

Method,

Procdures

Changes on the

Measurement

system

Changes on the

Human

factor

Others

What (part, type)

Where ( which machine,

place in the machine)

When (time information)

How much(quantitiy info)

Simple Problem Solving Form (Process 6 In The Flow)

Defect Escalation Model

Please Fill All Possible Areas7/22/2011 5Sameer Kadam