Drill Deep 6.0 modified

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1、1Drill Deep&Wide Worksheet Drill Deep&Wide Worksheet Training WorkshopTraining WorkshopMay 23,2005May 23,2005Drill Deep&Wide Workshop Training 5/18/052AgendaIntroductionsName/Department/Make of vehicle currently driving.Drill Deep Worksheet reviewGM review of completed worksheetsRead Across Matrix r

2、eviewGood Questions and stupid answersDrill Deep&Wide Workshop Training 5/18/053IntroductionsJohn MasonSupplier QualityPontiac BonnevilleDrill Deep&Wide Workshop Training 5/18/054Drill Deep&Wide PhilosophyProblem DescriptionWhat was the problem as the assembly plant saw it?Problem DefinitionWhat was

3、 the deviation to design record requirements?ContainmentWhat was the containment at the plant?Root CauseAnalysis How to predict,prevent,protect?Irreversible Corrective ActionWhat are the corrective actions?Systemic issuesWhat are the systemic issues from corrective actions?Systemic Issue CorrectionW

4、hat corrective action need to be taken?Drill Deep&Wide Workshop Training 5/18/05Deep&Wide PhilosophyDrill Deep&Wide Workshop Training 5/18/056Drill Deep WorksheetTrainingHow come somebody had to tell me the horse got out of the barn?Drill Deep&Wide Workshop Training 5/18/057Drill Deep AnalysisWhat i

5、s the intent of the Drill Deep analysis?Why did the planning process not predict the defect?Why did the manufacturing process not prevent the defect?Why did the quality process not protect GM from the defect?Drill Deep&Wide Workshop Training 5/18/058Drill Deep AnalysisKey Points:Drill Deep Analysis

6、is not used to understand what failed but rather why the system failed.Therefore,the technical root cause(i.e.,the Red X in suppliers process)should be known before the Drill Deep Worksheet is completed.3 x 5 Why Drill Deep AnalysisDrill Deep&Wide Workshop Training 5/18/059Drill Deep WorksheetGM For

7、m 1927-84Drill Deep&Wide Workshop Training 5/18/0510Date:02/24/04Issue title:Corvette Easy Key FOB detection feature inoperative Drill Deep WorksheetEnter date as:MM/DD/YYInsert title of quality concern-be short and descriptive.Drill Deep&Wide Workshop Training 5/18/0511Drill Deep WorksheetDescribe

8、the problem the customer experienced;i.e.,viewpoint of GM operator at the Assembly Plant.Examples:End cap not fully seated into window of valve,etc.Drill Deep&Wide Workshop Training 5/18/0512Drill Deep WorksheetDescribe the effects of the failure mode has on the vehicle.Examples:Operator could not i

9、nstall O2 sensor on exhaust system;Operator found loose parts in Product XYZ fuel tanks,etc.Drill Deep&Wide Workshop Training 5/18/0513Drill Deep WorksheetDescribe the root cause of the failure mode.Example:Positive stops were not adjusted correctly for the new,low permeation family insert causing t

10、he cylinder did not travel to full insertion;O2 sensor bung missing on exhaust system;No weld on terminals in relay;Cold weld on brake pedal bracket,etc.Drill Deep&Wide Workshop Training 5/18/0514Drill Deep WorksheetWhy?Why?Why?Why?Why?Enter each why below.Insert a row for each additional why if app

11、licable.The first question to ask and answer to begin is the following:Why did the manufacturing process not prevent the defect?Example:Why did the manufacturing process not prevent the end cap not fully seated into window on the valve?Why?Drill Deep&Wide Workshop Training 5/18/0515Drill Deep Worksh

12、eetOnly add a corrective action next to each Why if applicable.Keep in mind that the last Why needs a corrective action with an owner and a completion date.Also,there can be more than one corrective action for a root cause and the corrective action should include some form of verification or Check.D

13、rill Deep&Wide Workshop Training 5/18/0516Drill Deep WorksheetInsert owner for implementing each corrective action.Insert due date for implementing each corrective action.Format MM/DD/YY.Drill Deep&Wide Workshop Training 5/18/0517Drill Deep WorksheetAs a sense check,read the Whys backwards to make s

14、ure that the analysis make“sense”.Therefore.Therefore.Therefore.Therefore.Therefore.Drill Deep&Wide Workshop Training 5/18/0518Drill Deep WorksheetAlso,keep in mind that the technical root cause(i.e.,Red X in suppliers process)should be captured in the Prevent 5 Why as shown below.The last why is th

15、e underlying Root Cause.Please add a corrective action,owner,and date to the right.Does not have to be 5 Whys-ask as many Whys as necessary.Drill Deep&Wide Workshop Training 5/18/0519Drill Deep WorksheetWhy?Why?Similar question can be asked for the Predict portion:Why did the planning process not pr

16、edict the defect?Example:Why did the planning process not predict the end cap not fully seated into window on the valve?Why?Therefore.Therefore.Drill Deep&Wide Workshop Training 5/18/0520Drill Deep WorksheetWhy?Similar question can be asked for the Protect portion:Why did the quality process not pro

17、tect GM from the defect?Example:Why did the quality process not protect GM from the end cap not fully seated into window on the valve?Why?Therefore.Drill Deep&Wide Workshop Training 5/18/0521Drill Deep WorksheetAre there any other key findings?Review the 5 Why analysis above to uncover any common“th

18、emes”and document them to the right.A corrective action,owner,and date needs to be added for each key finding.Drill Deep&Wide Workshop Training 5/18/0522Drill Deep WorksheetExamplesMotorola Seguin MIN Spill.Motorola Nogales MIN Spill.Corvette Easy Key FOB detection issue.Drill Deep&Wide Workshop Tra

19、ining 5/18/05DDW Process FlowPRR Issued by GM SQADDW Completed by SupplierRoot Cause of failure identifiedDDW attached to PRR by supplierGM Single Point SQE reviews DDWIssuing GM SQA closes PRRGM SQE approves/rejects DDWProblem identified that impacts customerSupplier,APQP,Assembly Plant,Current Qua

20、lityRead Across Matrix UpdatedGM SQE reviews Matrix (No Red items)GM SQE approves/rejects matrixMatrix attached to PRR by SupplierDrill Deep&Wide Workshop Training 5/18/0524Drill Deep SummaryDrill Deep Analysis is not used to understand what failed but why the system failed.Technical root cause(i.e.

21、,the Red X in suppliers process)should be known before the Drill Deep Worksheet is competed.The names 3 x 5 Why and the Drill Deep Analysis mean the same thing.Drill Deep&Wide Workshop Training 5/18/0525Systemic DDW Flow ChartPRR List/Issues(25 or 12 months)Perform 5Why Analysis on all Issues(Drill

22、Deep)PREDICT Root Causes PREVENT Root Causes PROTECT Root CausesGroup&ParetoAll Root CausesGroup&ParetoAll Root CausesGroup&ParetoAll Root CausesGroup&ParetoSystemic IssuesImplement Corrective Action for individual PRR and Read AcrossImplement Corrective Action for Systemic Issues and Read AcrossDri

23、ll Deep&Wide Workshop Training 5/18/0526Systemic Issues ParetoDrill Deep&Wide Workshop Training 5/18/05Read Across TrainingIf it rains in Texas,can it rain in New York?Drill Deep&Wide Workshop Training 5/18/0528Read Across Matrix(Drill Wide)A Read Across matrix is used to evaluate if a failure mode

24、can occur elsewhere within the company.It is a tracking mechanism to monitor progress towards completing the evaluation.These four main areas will be expanded upon.1234The Header section contains Company Name,responsible location,Contact person information.Drill Deep&Wide Workshop Training 5/18/0529

25、Mark with an“O”for the Originating location LEGENDMark with an“X”all locations where the defect may occurMark with an“R”if the problem was repeated at another locationPlace a letter in each box for each line item that appliesColor code each box that has a letter in it according to this schemeRead Ac

26、ross Work Instructions1Drill Deep&Wide Workshop Training 5/18/0530Record the Part Name and full Part NumberRecord the PRR issuing locationRecord the effects of failure mode as described by the plantCreate one line for each PRR issued Record the Date the Drill Deep AnalysisWas completedRecord the fai

27、lure mode on the partRead Across Work Instructions2Drill Deep&Wide Workshop Training 5/18/0531Record the PRR number or C.A.R.#Record the number of non conforming parts Identified on the PRRIdentify the Type and Status of any Controlled Shipping action initiated as a result of this PRRIdentify the Co

28、rporateChampion responsible to ensure implementation of the corrective actions Read Across Work Instructions3Drill Deep&Wide Workshop Training 5/18/0532Identify all supplier DUNS locations with similar products and processesUse letter code with appropriate color to identify applicable locations and

29、statusRead Across Work InstructionsProduct/Process Classification2005 GMT 2222006 GMT 3332006 GMT 4442007 GMT 555COPORATE DATA BASEFrt.Seat GMT 000Frt.Seat GMT 111Frt Seat GMT 000Frt Seat GMT 333D.ReactorN/A N/A N/A N/AN/AON/AXN/AP.EnvisionN/A N/A N/A N/AXON/AXN/AD.ThwartN/A N/A N/A N/AXON/AXN/AC.Se

30、ntinelN/A N/A N/A N/AXON/AXN/AK.PinnacleN/A N/AXXXON/AXN/AK.PinnacleN/A N/AXXXON/AXN/AD#12345678/OshA.P.Q.P.D#87654321/Troy,Mi.Corporate ChampionSymbolsIdentify all lines within each duns where corrective actions may apply.Also identify newProducts to apply Lessons Learned.4Drill Deep&Wide Workshop

31、Training 5/18/0533Any RED item should be reviewed with GM on a regular basisPer GP 5 for a PRR to be CLOSED,all symbols should be yellow or green from the initial location.Drill Deep&Wide Workshop Training 5/18/05DDW Process FlowPRR Issued by GM SQADDW Completed by SupplierRoot Cause of failure iden

32、tifiedDDW attached to PRR by supplierGM Single Point SQE reviews DDWIssuing GM SQA closes PRRGM SQE approves/rejects DDWProblem identified that impacts customerSupplier,APQP,Assembly Plant,Current QualityRead Across Matrix UpdatedGM SQE reviews Matrix (No Red items at Initial location)GM SQE approve

33、s/rejects matrixMatrix attached to PRR by SupplierGM SQE reviews RED items with supplierDrill Deep&Wide Workshop Training 5/18/0535?Good Questions and Stupid answersDrill Deep&Wide Workshop Training 5/18/0536PROTECT THE DOWNSTREAM CUSTOMERPROTECT THE DOWNSTREAM CUSTOMERPERIOD.PERIOD.Drill Deep&Wide Workshop Training 5/18/05