| BIQS - 25 Contamination Prevention (Powertrain): Sediment Reduction • Sediment is any foreign material found in any assembly that is not part of the blue print requirements. • Sediment negatively impacts our assemblies by: a) Causing valves to stick thus not allowing the unit to shift properly. b) Causing seals to be cut or lays on the seal thus causing internal pressure loss and/or external leakage causing slippage and loss of performance c) Mating parts may not seat, assemble easily or completely cause forced installation. Incomplete installation may result in leakage, scoring, breakage and functional failure.
| BIQS Operating Guideline BIQS Element 27 - FIFO
| BIQS – 27 FIFO Definition: • A process that incorporates a constant drive to attain a simple sequential process flow of material. Material handling racks in a good condition and maintained . Scope: • All Material – All in process racks . Purpose: • Allow traceability, reduce lead time, and easily detect problems while optimizing cost, and reducing inventory and work- in- process. • Make sure that handling rack is protecting parts from being damages . FIFO Material Handling
| What to Look for: • FIFO attains a sequential flow of material to ensure the quality of the part is not compromised. • Visual management includes process diagrams, FIFO tools, rotation schedules, etc. • Preferred storage method is flow through storage or roller racks to promote FIFO. Dead end storage should be minimized, any use should be justified. • Ask for documented FIFO process for entire plant. Team Members and Team Leaders should be able to explain the process. Process should cover material against the wall, material in flow-thru lanes, material on racks, point-of-use indirect material areas, part buffers, sub-assembly areas, and overflow areas. • Check the FIFO/ Material Handling in each department/area • Containers, racks and/or bins used for WIP storage and movement protect the parts from damage and easily identify the parts as WIP. • WIP is not kept or stored in GM returnable dunnage. BIQS – 27 FIFO
| BIQS – 27 FIFO 1) FIFO helps minimize inventory. 2) FIFO should be present in all areas. 3) Visual aids support all operations and standardized work. 4) FIFO rotation – FIFO needs to occur on a regular defined basis that ensures a first-in first-out strategy 5) FIFO should be part of layered audit process. 6) FIFO processes are documented and are part of standardized work. FIFO Key Points:
| BIQS – 27 FIFO 1) WIP MUST be managed to ensure FIFO. 2) WIP MUST be visual and incorporate a MIN/MAX process. 3) WIP MUST be continually reviewed to ensure that it is minimized and optimized. Key Point: Work In Progress
| BIQS – 27 FIFO 1)Repacking 2)Kitting, buffers 3)WIP 4)And any staging areas) Key Point: Areas where FIFO is often missed:
| BIQS Operating Guideline BIQS Element 28 – Shipping Approved Packaging
| BIQS - 28 Shipping Approved Packaging Definition: • Shipping is done according to customer requirements . Scope: • All Shipped material Purpose: • To meet customer requirements for shipping .
| What to look for: • Production intent containers are being used for any build events. • A process is in place to ensure violations of the requirement are identified and corrected. BIQS - 28 Shipping Approved Packaging
| BIQS - 28 Shipping Approved Packaging Requirement Sources: 1. Packaging requirements are located in GM1738. 2. Label requirements are located in GM1724 A/B/C. Approval Documents: 1. Packaging approval form NA GM1738 Form for both standard and expendable packaging.
| BIQS Operating Guideline BIQS Element 29 – Supply Chain Management
| BIQS - 29 Supply Chain Management Definition: • Supply base are managed , monitored . Supplier base is audited regularly . Quality issues are communicated and solved . Scope: • Tiered supply base . Purpose: • To reduce the risk of the sub-tier supply base to customer activities and make sure that they are controlled . Suppliers Evaluation Problem Solving & Communication System Audit
| What to Look For: • Is there a process at all Tiered suppliers for tracking internal and external issues? • Do they mandate a Fast Response process to be used? • Do they review how effective their problem solving process is at each Tiered Supplier? • Check that the supplier has periodic system audits of their suppliers to improve key tier 2 performance such as first 13 elements of BIQS or equivalent, with a clear plan and follow up to close the gap. BIQS - 29 Supply Chain Management
| BIQS - 29 Supply Chain Management Requirement Sources: 1. Supply chain statement of requirements are located in GM1927-03 SOR. 2. Risk assessment through GM 1927-07 APQP Assessment Subtier worksheet or similar 3. Sub tier audit through GM 1927-30 BIQS Subtier or similar
| BIQS Operating Guideline BIQS Element 7 – Gage Calibration/ Measurement System Analysis
| BIQS - 7 Gage Calibration / MSA Definition: • System in place to make sure that all equipment and gauges are calibrated regularly as per their standard . System in Place to make sure that MSA is done regularly when needed (New launch,....etc .) Scope: • All Gauges Purpose: • Calibrated equipment assures proper decisions are made relative to product quality standards . • MSA assure that variation of measuring process is accepted .
| BIQS - 7 Gage Calibration / MSA
| BIQS - 7 Gage Calibration / MSA
| BIQS - 7 Gage Calibration / MSA
| BIQS Operating Guideline BIQS Element 15 – Andon System Implementation
| BIQS - 15 Andon System Implementation Definition: • An operational floor process control system (that can be activated manually or automatically) to communicate the need for assistance when abnormal conditions occur. Scope: • To all team members . Purpose: • To empower operations to prevent the occurrence of passing on defects to the next process to support concept of
| What to Look For: • The Andon system enables the Team Member to call for help and supports the concept of "Do Not Accept, Build or Ship a Defect". Andon calls can be radio, pager, stack lights, Andon boards, etc. • Check the requirements of an effective Andon system are present in all production areas. • Take a few operator stations in different areas as an example. Ask Team Members and Team Leaders how the Andon is working and validate the effectiveness. BIQS - 15 Andon System Implementation
| BIQS - 15 Andon System Implementation BIQS Requirement A well functioning Andon system is implemented in all production areas to support the Team Member when abnormal conditions occur and communicate relevant information. All operational areas of the organization are using the Andon process as intended and this shows tangible results on the shop floor. The Andon system can be activated by a number of different methods: – pull cords, – buttons, and – switches of the Andon system. Andon Push Button Work Cell Example Yellow Workstation Light Run Stop Button 14 Activation Device Purpose Where Used Description Andon Pull Cord Team Member Help Call On a workstation in a moving conveyor line. Connected to a switch with a light and looped along the length of the conveyor. Andon Push Button Team Member Help Call Work Cells, such as a Body Shop or Press Line, or in a Paint Booth Switch box with a push button is located in the most convenient location of the work cell. Run Stop Switch Stop the process or conveyor immediately for safety reasons. Installed along the conveyor and on all major equipment. Placed at regular Fixed Position Stops on alternating sides of the line. (Note: Must be in accordance to all safety standards and regulations.) Manipulator Over-Travel Limit Switch Increase level of safety on the workstation by stopping the conveyor when an over-travel condition occurs. The limit switch is installed along the travel of the manipulator. To prevent manipulators, articulating arms and assist devices from dangerous overtravel conditions to increase safety on the workstations. Call for Help The Andon system enables the Team Member to call for help and supports the concept of "Do Not Accept, Build or Ship a Defect". Andon calls can be radio, pager, stack lights, andon boards, etc.
| BIQS - 15 Andon System Implementation BIQS Requirement All operational areas of the organization are using the Andon process as intended and this shows tangible results on the shop floor. • Leaders should use the Andon downtime tracking to analyze problem areas and identify waste in the current process. • The focus should be on the pulls with the highest frequencies. It means that the root cause of the problem has not been addressed. Also it absorbs a lot of the team leaders time and effort. • Downtime data should be analyzed after a predetermined period of time ( weekly, bi-weekly, monthly ) and problem solving process needs to be started. • During the problem solving we need to recognize the root cause of the problem, define and implement countermeasures to tackle the root cause, and then implement a follow-up process to make sure the root cause has been eliminated. (Example)
| BIQS Operating Guideline BIQS Element 16 – Alarm and Escalation
| BIQS - 16 Alarm and Escalation Definition: • Alarm limits are identified based on risk and occurrence , standardized and followed , also if reached escalation path is clear and reachable Scope: • All Manufacturing operations at least . Purpose: • Avoid building NC material – feel special causes when happened on time – Empower team member – standardize process of escalation
| What to Look For: • Verify that nonconforming material has sufficient alarm limits with escalation. • Confirm that alarms are responded to and the response is documented. BIQS - 16 Alarm and Escalation
| BIQS - 16 Alarm and Escalation
| BIQS - 16 Alarm and Escalation
| BIQS - 16 Alarm and Escalation Alarm Trigger 1st Alarm 2nd Alarm 3rd Alarm Alarm Notifier Gate Keeper Gate Keeper Gate Keeper Alarm Notifier 1. Notify Alarm Responder over Radio 1. Notify Alarm Responder over Radio 1. Notify Alarm Responder over Radio Responsibilities 2. Properly Document Alarm. 2. Properly Document Alarm. 2. Properly Document Alarm. Alarm Responder Team Leader Group Leader Shift Leader (OR) Group Leader Shift Leader Area Mgr/Senior Shift Leader Alarm Responder 1. Document acknowledgement within 1. Initial Alarm Sheet at V/S. 1. Initial Alarm Sheet at V/S. Responsibilities 15 minutes of alarm time at internal gates and within 30 minutes at downstream gates. 2. Investigate point of cause 2. Contacts Group Leader to 2. Contacts Shift Leader to discrepancy per the problem solving understand what has been done. understand what has been done. process 3. Initiate containment action. 3. Investigates why corrective actions 3. Investigates why corrective actions or containment failed. or containment failed. 4. Notify Supplier Action Center if root 4. Make decision concerning next 4. Make decision concerning next cause is supplier based. step. step. 5. Document corrective action on alarm response sheet by end of shift. 6. Document confirmation of feedback to Team Member by end of shift. NOTE: If no response by Responder within 15 minutes escalate. NOTE: Any recurrance of problems between the 1st alarm and the break point or the 15 min. limit are considered part of the 1st alarm. NOTE: Quality Technician will circle any alarm that has no documentation at the daily gate review. NOTE: Shift Leader is responsible to verify all alarms are answered promptly and are documented on the response sheet on a shift bases. NOTE: If escalation is required beyond the Third Alarm notify Assistant or Plant Manager on day shift or Senior Shift Leader on Evenings or Nights. Verification Station Escalation Process Clear Alarm Process Instructions
| BIQS - 16 Alarm and Escalation Process drives Production and Quality accountability: review and understand actions taken Gatekeeper Responder
| BIQS - 16 Alarm and Escalation Establishing Alarm Trigger Limits: Alarm Trigger of 1: • Past customer issues relying on any visual inspection • Higher customer severity failure modes relying on any visual inspection • GP-12 failures • CS failures • Abnormal and unexpected findings Supplier Consideration of Alarm Limits Higher than 1: • Lower customer severity issues not discernible to most customers (drive to maintain boundary) • Issues with sufficient customer protections, tracked daily with data/ problem solving on the shop floor • Issues driving Supplier waste but no issues to the customer
| BIQS Operating Guideline BIQS Element 17 – Visual Controls
| BIQS - 17 Visual Controls Definition: • Visual standards should be standardized , controlled , and updated regularly based on new issues and new risks . Scope: • All visual standards . Purpose: • To standardize process to identify difference of what is considered good Vs what is considered nonconforming as per customer requirements .
| What to Look for: • Look for a documented process which is common and valid for the plant. Document must be controlled by the Quality Management System. A local procedures describes the process. • Look for engineering changes (Product Engineering) and if they are reflected in the Visual Standards. • Confirm Visual Standards are updated as a result for the Fast Response process where required. BIQS - 17 Visual Controls
| BIQS - 17 Visual Controls Key Points: • Visual controls are established to quickly identify inspection points and operating conditions to reduce the time and increase the effectiveness of maintenance tasks. • Inspection points are grouped into inspection locations to improve efficiency. • A visual control grabs one or more of our senses in order to; alert us to an abnormality, help us recover quickly, promote adherence and prevention. • Visual controls reduce error and waste by making problem visible. It identifies the gap between the standard and the actual condition. • When visual controls are easy to see and understand, operators can respond as soon as problems occur. Promoting a quick recovery. • Visual controls should be built into engineering specifications and designs.
| BIQS - 17 Visual Controls Tightening positions marked on nuts/bolts for easy visual inspection Valve Position Marked & Tagged Gauge Range Marked Visual controls are important for operators, maintenance and other plant personnel making quick determinations on “normal” or “abnormal” conditions. Abnormal conditions can be returned to a normal condition in a timely and efficient manner. Production TPM shadow boards. Tools are clean and organized at the work station.
| BIQS – 17 Visual Controls Inspection Points Operators can quickly determine machinery and equipment status at a glance, and are responsible for reporting its condition.
| BIQS - 17 Visual Controls Floor Marking
| BIQS Operating Guideline BIQS Element 18 - Visual Standards – Communicated and Understood
| BIQS - 18 Visual Standards–Communicated & Understood Definition: • Visual standards are understood and used when needed by team member level Scope: • All team members assigned to use the visual standards . Purpose: • Support team member in understanding customer & process visual standard
| What to Look for: Team members shall know the content of Visual Standards. Interview a minimum 3 operators. All shall fulfill the requirements. Visual Standards (checking plans) shall be referenced in standardized work documentation. Confirm Visual Standards are clearly differentiated from good to bad; are clearly identified as a Product Quality Standard document and are clearly referenced in the standardized work. BIQS - 18 Visual Standards–Communicated & Understood
| BIQS - 18 Visual Standards–Communicated & Understood • Visual standards should be clearly communicated to team members • Auditor should interview a minimum 3 operators. • Team members should be knowledgeable of the visual standards. Traditionally, communication only focuses on the “WHAT” and maybe the “HOW”, but people deserve to know the “WHY”! WHAT - HOW - WHY? EVEN IF THEY DON’T AGREE AT LEAST THEY WILL UNDERSTAND! It is essential for team members to have daily structured communication!
| BIQS - 18 Visual Standards–Communicated & Understood Visual Standards to help differentiate “Good from Bad” must satisfy customer requirements. Visual Standards should be incorporated and referenced in standardized work.
| BIQS Operating Guideline BIQS Element 23 – Feedback / Feedforward
| BIQS - 23 Feedback / Feedforward Definition: • The communication of expectations and results between internal /external customers through standardized communication pathways. Scope: • At least Fast Response issues – issues occurred in floor such as exceeding alarm limits , results from inspection gates . Purpose: • To ensure that information reaches those who need it on the right time .
| Quality Alert • Quality Alert should be issued once concern is found at FR . • Quality Alert is posted in inspection locations and point of cause Communication • Issues found in quality gates communicated to areas of cause BIQS – 23 Feedback /Feedforward
| What to Look For: • Look for fast feedback / feed forward flow between the Verification Station. • Confirm quality alerts are posted at the operation for issues detected downstream (e.g. Fast Response, Verification Station (Final Inspection /CARE / GP12)). BIQS - 23 Feedback / Feedforward
| Customer/Supplier relationship • Expectations are clearly understood (product quality standards). • Correct and accurate information flows in a timely manner. • Problem resolution is expedited. Integrity of Data • Focus resources based on customer feedback. • Data-driven problem solving. Improved response time • Unresolved issues are escalated. • Actions are implemented in a timely manner to prevent the flow of defects. Benefits: BIQS - 23 Feedback / Feedforward