PeaCe

Gábor Bárdos PeaCe – The new MINDSET of Gumiművek Phoenix Hungária Ltd.

Why? ,[object Object],[object Object],[object Object],[object Object],PeaCe – The new MINDSET

I. Based on Data ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

II. 5S ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

II. 5S: Seiri – sorting and removing unnecessary items ,[object Object],[object Object],[object Object],[object Object],[object Object]

II. 5S: Seiton – put in the real place ,[object Object],[object Object],[object Object],[object Object]

II. 5S: Siketsu – visual controls and guidelines ,[object Object],[object Object],[object Object],[object Object],II. 5S: Shitsuke – follow the rules ,[object Object],[object Object],[object Object],II. 5S: Seiso – cleaning ,[object Object],[object Object],[object Object],[object Object]

II. Standardized workplaces, methods, instructions ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Standardized working areas Quality in the documentation Nr1 High level document design

III. Communication ,[object Object],[object Object],[object Object],[object Object],[object Object]

III. Communication – Planned meeting Goal: Effective handling of the customer complaints and internal problems, structural improvement actions and effective follow up Key figure: Continually decreasing of the internal and external ppm results ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Output: Action plans Input (sample): ,[object Object],[object Object],[object Object]

III. Communication ,[object Object],[object Object],Daily ppm results from the main processes Customer complaint table Open PeaCe actions

II. Communication ,[object Object],[object Object],Daily ppm results ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Good/Bad parts

II. Communication ,[object Object],[object Object],Customer complaints (pcs and ppm) Lists, actions Last complaints with Ishikawa

II. Communication ,[object Object],[object Object],Good/bad parts ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Dailiy ppm results per shift Weekly ppm results Process spec. statistics

II. Communication ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

IV. Failure detection – based on data ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],1 2 3

IV. Failure detection – self control ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

V. Protective measure ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],1 2 3

VI. Factors ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

VI. Factors – 5Why ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

VI. Factors - FMEA ,[object Object],[object Object],[object Object],Factors Customer RPN Process RPN Product RPN Factor failure Effect on the process Effect on the product Effect on the customer

VI. Factors – FMEA ,[object Object],[object Object],Spray head Spray head damage Viscosity Viscosity too high Temperature Pressure Temp. too high Press. too high

VI. Factors ,[object Object],[object Object],[object Object],Factors Causes, sub factors Fail Cause 1 Cause 2 Cause 3 Cause n

VI. Factors ,[object Object],[object Object],Material surface Factors Glue type Glue quantity Place of gluing Time Causes Polluted clamp Cause 2.1 Cause 3.1 Cause 2.2 Polluted hose Missing rough Missing process step No sandpaper Run out, No order No minimum check Not in the stock system High RPN / complaint 5Why

VII. Analysis, reproduction ,[object Object],[object Object],[object Object]

VIII. Actions ,[object Object],[object Object],[object Object],[object Object],[object Object]

VIII. Actions - ActionMan ,[object Object],[object Object],[object Object],[object Object]

VIII. Actions - ActionMan ,[object Object],Factors from the Factor FMEA = Guided Brain Storming Actions Factors analysis, root causes

IX. Efficiency check ,[object Object],[object Object],[object Object],[object Object],[object Object]

IX. Lessons Learned Card ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],1 2 3 3 4

IX. Efficiency check – internal audits ,[object Object],[object Object],[object Object],Manag Start of prod and complaint audit Supplier audit Complete mindset audit PeaCe audit Actions and factor audit Complaint close audit Work station audit Quick audit Complete audit on 5 parts Product audit Production and stock processes Process audit Complete system audit System audit Area manag Description Type

IX. Efficiency check – internal audits ,[object Object],[object Object],[object Object],[object Object],Questions Result Action Check Process

IX. Efficiency check – internal audits ,[object Object],[object Object],Questions Layout Results Process

IX. Efficiency check – internal audits ,[object Object],[object Object],Question daily self audit results QM check of the daily self audits Plant man. check of the complete process Process Well done audit Not well done audit

X. Peace in the Customer Complaint Handling 4. Failure detection 5. Protective m. 3. Communication 5. Protectiv m. 4. Failure detection 6. Factors 7. Analysis 8. Actions 1. Communication 3. Communication 3. Commication 9. Efficiency 2. Standardization 9. Efficiency 1. Communication

Thanks! Gábor Bárdos Head of Quality & Environment Management Gumiművek Phoenix Hungária Kft. Continental ContiTech Group Heating/Cooling/Turbo charger H-2600 Vác, Külső Rádi út 290/1 [email_address] Tel.: +36 27 513 528 | Fax: +36 27 513 550 | Mobil: +36 70 314 9144

PeaCe

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