Zero Defects
Zero Defects - Failure Strategy (First Time Quality - FTQ). This article gets a little touch on the chapter of zero defects and failure strategy.
First things first - lets define our understanding of zero defects and first time quality FTQ
First time quality (FTQ) is a comprehensive approach to the implementation of the "zero - defects strategy" in all steps of product and process development and the value chain.
The targets:
Consistent method application in all product life cycles is ensured
Error-free production (prototype > series > customer service) is achieved
The maintenance and improvement of process and series quality is guaranteed
FTQ is valid for all company processes
The processes are trouble-free
The IATF 16949 or ISO/TS 16949 requirements are fulfilled
Key elements:
Description of the process and product development, with the corresponding tools, up to series production: Advanced Quality Planning (AQP).
Levels of fulfillment - Quality Planning
Level 1
There is no system for advance quality planning (AQP).
Level 2
D-&P-FMEA’s are used sporadically and uncoordinated.
Level 3
There are standards for advance quality planning. Elements of these are used without the need to monitor measures and deadlines.
Level 4
All elements of the AQP are applied. Continuous project plans are available. An auditing does not take place.
Level 5
The AQP is continuous from product development to the customer. All AQP elements are lived and audited at regular intervals.
Fulfillment levels of quality improvement
Level 1
Problems are ignored. The blame is placed on looking for the other one. Solutions are found based on experience in the event of an error. Notices are general held and not up to date.
Level 2
Partial informal records to problems and measures. Some Data is recorded but hardly analyzed. Errors and problems already exist longer and always kick back on.
Level 3
Errors and problems are recorded and evaluated. The most important problems are being addressed by some Q-employees with a formal system edited. Problem solving projects are initiated. An audit system to ensure permanent problem solutions is installed.
Level 4
All errors and problems are controlled in a PDCA control loop. A large part of the employees participates in the team of problem solvers. Problem solving steps are documented and visualized. The improvement process is regularly audited. Quality objectives are visualized.
Level 5
Errors are potentials. All areas and employees take part in systematic problem solving approach. Problems become immediately analyzed, measures are initiated immediately. All errors and problems are solved at their "root" grabbed and released. Ambitious quality targets are agreed, developments are known and visualized.
Dealing with errors and non-conforming products
Level 1
Defective products or products that are not corresponding to the specifications, lie without marking in the shop floor area and are referred to as committee considered.
Level 2
Defective products are marked, but remain without further consideration. Partly become informal kept records.
Level 3
Daily recording of non-conforming products and sharing, analyses are carried out. Visualized representation to type and frequency of errors. Partial problem solution with internal suppliers. Regular communication with external suppliers is in place.
Level 4
Defective material / products are analyzed and systematically reduced. Errors are reduced in costs and ppm measured, visualized and connected with targets.
Level 5
Detailed elaborated handling system for deviations is introduced and is for all employees applied. Costs and trends are created for every area, determined, analyzed and visualized. Main problem points will be made by means of Poka-Yoke solutions eliminated.
