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