WABCO TEAM MEMBERS
• Mr. Amiya Kumar – Site Leader
• Mr. Amit Kumar Singh – Site Quality Leader
• Mr. Kundan Kr. – Value stream leader
TML TEAM MEMBERS
• Mr. Shyam Kishore
• Mr. Vinay Rai
WCSQ AUDITORS
• Mr. Kunal Mehta
• Mr. Utkarsh Aroakar
WCSQ JOURNEY
WABCO Confidential and Proprietary 1
WCSQ ROAD MAP
WABCO Confidential and Proprietary Information - For internal use only
Assessment done by
TML team for WCSQ
Certification
Dec’15
Pre assessment
Internal assessment done by tml and
Internal assesment done by tml gaps closed the issue.
done and identified
find and closed Nov’15
the improvement.
WABCO internal Sep’15 and Nov’15
training to all Sep’15 – Oct’15
WCSQ concerned
Training by Aug’15
TML team
WCSQ Kick off Aug’15
@ WABCO by
TML top
management .
July ‘15
2
WCSQ BOARD IN SHOP FLOOR
WABCO Confidential and Proprietary Information - For internal use only
Plant level WCSQ
Plan Vs Actual
displayed in Central
Board
3
1. QUICK RESPONSE TRACKING
QRTB for external & Internal Issues Daily/Monthly monitoring
WABCO Confidential and Proprietary Information - For internal use only
Since Nov15 no external issues.
4
CLAIMS INFO/LESSON LEARNED
Display of BAD parts for claims
in shop floor entry for awareness
WABCO Confidential and Proprietary Information - For internal use only
QUALITY ALERTS
5
COST REDUCTION PROJECTS - 2015
WABCO Confidential and Proprietary Information - For internal use only
Achieving 11%
conversion cost
productivity
6
2.CONTROL OF NCP MATERIALS
Rework Procedures in Lines CFT for Process scrap reduction
WABCO Confidential and Proprietary Information - For internal use only
Identification in parts
7
3.QUALITY GATE - VERIFICATION
QUALITY GATE With Good BAD QUALITY GATE DRM & MONITORING
Photo and Bench inspections
WABCO Confidential and Proprietary Information - For internal use only
8
4. STANDARDIZED OPERATION
OPERATING STANDARD IN STATIONS CT & BOTTLENECK DISPLAY IN STATION
WABCO Confidential and Proprietary Information - For internal use only
WASTE REDUCTION – 3S Concept
9
4. STANDARDIZED OPERATION
INCOMING MATERIAL STORAGE WITH CLEAR 5S and FIFO CONTROL
Dedicated trolley for finished goods
WABCO Confidential and Proprietary Information - For internal use only
Pick me first ,second etc concept in raw materials and finished goods storage.
KANBAN SYSTEM followed by SAP and bar code to be pasted as per pull.
10
5. STANDARDIZED OPERATING TRAINING
ANNUAL TRAINING PLAN FOR OPERATORS
WABCO Confidential and Proprietary Information - For internal use only
Operator certification done for CTQ stations.
WB & YB Certification provided to operators
after completion of QR6S Projects.
Monthly Award system for best
suggestions/Kaizen
6 .POKA YOKE VERIFICATION
CENTRALISED POKA YOKE
MONITORING SYSTEM
WABCO Confidential and Proprietary Information - For internal use only
VISUAL MONITORING OF PY IN
POKA YOKE REVIEW & MONITORING STATION ITSELF
12
7. LAYERED AUDIT
LAYERED AUDIT PLAN & MONITORING FINAL LAYERED AUDIT NCS STATUS
WABCO Confidential and Proprietary Information - For internal use only
NCs DETAILS
8. RPN RISK REDUCTION
MONTHLY PLAN FOR RPN REDUCTION O/S MATRIX FOR IMPROVEMNT
WABCO Confidential and Proprietary Information - For internal use only
PY IMPLEMENTATION AS PER PLAN
14
9. CONTAMINATION CONTROL
KAIZEN FOR CONTAMINATION CONTROL
WABCO Confidential and Proprietary Information - For internal use only
15
9.CONTAMINATION CONTROL
CONTAMINATION CONTROL PROCEDURES WITH FREQUENCY AND RASCI
WABCO Confidential and Proprietary Information - For internal use only
16
10. SUPPLIER CHAIN MANAGEMENT
SUPPLIER RATING - COMBINED INDIVIDUAL SUPPLIER SCORE CARD
WABCO Confidential and Proprietary Information - For internal use only
17
10. SUPPLIER CHAIN MANAGEMENT
SUPPLIER AUDIT PLAN VDA 6.3 process audit report
WABCO Confidential and Proprietary Information - For internal use only
SUPPLIER PERFORMANCE MONITORING
18
10. SUPPLIER CHAIN MANAGEMENT
WABCO Confidential and Proprietary Information - For internal use only
19
FACILITIES TO SUPPORT QUALITY
ULTRASONIC CLEANING PROCESS FOR MILIPORE TESTING FOR CLEANED PARTS
CRITICAL PARTS AND TRACKING FOR EFFECTIVENESS
WABCO Confidential and Proprietary Information - For internal use only
20
FACILITIES TO SUPPORT QUALITY
LIFE CYCLE TEST FOR PARTS IN SALT SPRAY TEST FOR
ENDURANCE LAB CHECKING PLATING QUALITY
WABCO Confidential and Proprietary Information - For internal use only
IMPREGENATION PROCESS TO AVOID CASTING POROSITY
21
QUALITY FIRST WORKSHOP -
TARGET REVIEW IN DRM 4
QUALITY IS AN
ATTITUDE
WABCO Confidential and Proprietary Information - For internal use only
Consolidated
actions
SIX SIGMA CULTURE
QR6S ( QUICK RESPONSE SIX
Function Wise Certification percentage
SIGMA ) YB+WB certification trend
120%
100%
100% 93%
WABCO Confidential and Proprietary Information - For internal use only
77%
80%
60% 50% 50%
40%
20%
0%
0%
VS Site Quality PAM LPO HR IT
• Total running GB six sigma projects = 7.
• 4 People certified in GREEN BELT.
• All Trained GB are indulge on GB
projects
23
REACTIVE & PROACTIVE ACTION
Robust Firewall- WIN Packing modification Process Up gradation
Carton Boxes
(Before)
WABCO Confidential and Proprietary Information - For internal use only
Manual assembly process
Bulk packing
(After)
Prevention pokayoke with feed back tightening control
100% Recyclable Bins
Champion nominated to ensure
effective firewall for all parts
Testing standardization in-line with Stainless steel bin for easy to clean
customer testing – 100% Automatic ok punch for testing completion
Align, detect, assign, resolve and improve 24
WORKSHOP ON BEHAVIOR
Workshop on
Behavior
WABCO Confidential and Proprietary Information - For internal use only
organized and
prepared “TO
DO LIST” for
improving our
behavior
25
TPM – QM INITIATIVES
WABCO Confidential and Proprietary Information - For internal use only
JH
KK PM
SHE QM
E&T
2015 YTD
plan
23 12
1200 978
98.5 98.1
1200 878
Setting the goals…
WIN 2.0 INITIATIVE
WABCO Confidential and Proprietary 27
WABCO Confidential and Proprietary 28
