Definition QRQC - Quick Response Quality Control - A problem solving tool

M

mikedavies1

#31
attached is a flow chart for reporting abnormalities we use, from a quality point of view giving an allowable % defect figure hinders continual improvement, as once % figure reached there is a tendancy not to try and improve process and reduce defects further. I tend to try and convert defect data into costs, as our management look more closely at $ than other indicators.
Any hope the flow chart helps
 

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S

sylwester

#33
.......
In my company, we experienced some problems when trying to implement the QRQC approach :
- the Line QRQC is more adapted to production lines dedicated to one product than single machines (like stamping presses, welding cells ..) with continual production changes.
- Our operators and supevisors are much less educated than Valeo's to be able to deal with problem Solving matters by themselves (some Valeo supervisors are Engineers). Besides, we have a high employees turnover.

So I reckon that you should have an efficient production organizational structure and well educated & trained production personnel to be able to implement efficiently the QRQC approach.

Feel free to correct me if I am wrong somewhere.

Francois
Francois

Did You implemented lineQRQC ? I have similar problem - my task is to implement QRQC line on the press shop and frankly saying I have no idea how to do it with frequent changes of production on the presses.

Sylwester
 
M

minitehnicus74536

#34
Hi everybody,
I'm in charge with quality in a french company whom has a production site in Romania.
My french boss tell me today if I know about QRQC ... I look at him and said no ... Browsing on net I found some explanations but ... I'm still puzzled ... :confused:
Usually, I solve my quality problems using fishbone or FMEA ...
There are some specific documents about this QRQC?
Thank you in advance for clarifications
 

Stijloor

Staff member
Super Moderator
#35
Hi everybody,
I'm in charge with quality in a french company whom has a production site in Romania.
My french boss tell me today if I know about QRQC ... I look at him and said no ... Browsing on net I found some explanations but ... I'm still puzzled ... :confused:
Usually, I solve my quality problems using fishbone or FMEA ...
There are some specific documents about this QRQC?
Thank you in advance for clarifications
Look at the posts and attachments in this thread QRQC - Quick Response Quality Control - A problem solving tool.

Stijloor.
 

delorfra

Involved In Discussions
#36
Hi Minitehnicus,

What is important in QRQC is not exactly the type of problem solving tool you use.

It is rather the organisation implemented to handle problems on the shopfloor that is the scope of QRQC.
QRQC, originally from Nissan, has been modified in France by Valeo which added a few more principles to it.

According to Valeo, there are 6 pillars in QRQC :
1/ Real Workplace : investigating problems on the shopfloor where they arise with the people involved (operator, Line leader ...)
Trying to reproduce the problem ...
2/ Quick reaction : deal with problems as soon as they arise e.g. within 24Hrs (for simple problems)
3/ Real parts : investigating NOK parts & OK parts to identify the problem
4/ Logical Thinking : using whatever rational problem solving method
5/ Real data : using data & facts instead of opinions (e.g. to determine if standards are met, to plot NOK parts qty against time, shifts or mould cavity No. ....) to help investigating the problem
6/ On the job coaching : management coaches QRQC teams to improve their understanding of QRQC & efficiency

Concerning the QRQC organisation, there are 3 QRQC levels :
1/ Line QRQC (for simple problems arising at the workstation ...)
The team leader stops the line and gathers with team members to investigate & solve the problem on the spot or within maximum 24hrs. All data related to the problem are written on a QRQC board (date, time, part No, NOK Qty, defect description and once known, causes & corrective actions)
=> Usually simple problems are the ones where some characteristics have derived from standard
2/ Autonomous Production Unit (APU) QRQC
Problems not solved by line QRQCs (usually more complicated problems where some standard is not relevant) and daily Customer complaints related to the APU are dealt following a much more formal problem solving method (e.g. FTA, 5 Whys ...) by a problem solving multi-disciplinary team within 1 or 2 weeks
Daily meetings around the APU QRQC board are held to monitor/follow up the QRQCs progress with the APU manager, the APU Quality engineer(s), QRQC leaders ....
3/ Plant QRQC
Almost the same as the former, but for critical customer complaints (e.g. for safety & regulation NOK characteristics ....)
Meeting are held around the plant QRQC board and involve the plant manager, the quality manager, the production manager, QRQC leaders ....

But beside this specific Valeo approach, what is important is to understand the basics of QRQC and adapt it to your production organisation & maturity. In fact, many companies have their own approach to QRQC. So you can find contradictory training material concerning QRQC depending what company it originates from.


Some links in French inspired from Valeo for further explanations :

http://www.consulting-centre.com/iso_album/qrqc_conference1.pdf

http://www.bcf-consultants.fr/pdf/exemple-qrqc.pdf

Hope this helps :D

Francois
 
Last edited:
M

minitehnicus74536

#37
I presumed that I need a strong quality department ... but for the moment, quality in our company is one man show (guess expression "plus cher" is familiar to you). it's up to me to improvise something ... we romanians are genius in "bricolage" ...
thank's a lot
 
#38
So it's the end of day one and I must recant on my "definition" of above. QRQC is more than a problem solving tool. It is more of a culture or mindset which is applied to all aspects of your business. It emphasizes the "top / down" approach and also utilizes the "bottom / up" approach (with regards to communication avenues). The basis of QRQC is the rapid response to a quality/manufacturing issue, whether it's an external/internal customer or a supplier. It tries to drive C/A to the operator level, where they have control of the "event" and what they can't/don't have control over gets driven upward for necessary resources to fix the issue. One of the tools my customer has employed for documenting what happened is called the "PDCA" form which uses Factor Tree Analysis (very detailed and is directly linked to the PFMEA), 5-Why Analysis (to get to root cause), and some verification forms (along with documenting sorting/containment activities, etc.). As I mentioned before, this form "forces" you to look at all aspects of your system. This is nothing new - it is just the way our French owned customer expects (would like to see) us address issues for them.

Pretty tedious day today, and I'll review my notes closer after tomorrow's session and "finish" what my take is on what this is all about.

NOTE: My only "negative" is that this is geared more to the upper levels of management and it is only one of our customers' expectations. Many of our customers have their own, specific, means of indoctrinating a "newer" culture into the entire workforce. Hopefully my management will take what I bring back, compare it to other customers' expectations, and meld them together for a "system" that makes sense for our business.
DA,
I already have the form in our plant. But not sufficiently useful due to what procedure should be proof to regulate this form, some how I have also disput when the problem coming from our supplier, should we complete this form until get the rootcause and then let our my current operators know what is the problem happened on the supplier?
In fact I use 8D report issue than qrqc form. And temporarly we used qrqc to manage internal rejection than supplier feedback form by 8D report.

Does anybody help me to understand clearly this form and how to manage it, procedure?

Best Regards,
Harojak
 
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