We Win En 2 0

WOCO Ipartechnika Kft. - Budapest

THE BASICS
Gábor Bárdos [Managing Director]
WOCO Ipartechnika Kft. – Woco Group2

THE BASICS
Gábor Bárdos [GM]

I. BASED ON DATA

I. BASED ON DATA
 Global databases for the following processes (e.g.)
 Scrap collecting card (part number specific)
 Scrap data collecting + complete analysis in one database
 SPC data collecting + analysis
 Incomming Material Control Center = Incoming check + results + complaints +
evaluation
 MSA database
 Injection moulding setup parameter database
 Maintenance databases
 Handling of non conform material database
 Customer complaints database
 ActionMan = Global project/action database
 …

I. PROCESS MAP WITH THE SPECIAL
DATABASES
IM Setup sheets
Scrap collector card
Scrap stat
CMR | SOFA |
Log. complaints
Training
center
Incoming Material Control Center
Planned maintenance
Interventions
Internal audits
Customer complaints
SPC
MSA
ActionMan
Doc manager
PEP
Productiv times
Score Card
Drying follow up
Tool exchange

II. STANDARD PROCESSES
 Goal:
 Maximum support of the production with standardized, high quality
instruction, standard working places, comparable working, quality work and
cleanliness
 To say HOW, not just WHAT!!
 Tools:
 Best practice industrialization
 OK for economy, safety and quality
 easy to understand the process
 Unification of the same process points
 Regular check
Nr1
High level
document
design

III. COMMUNICATION
 Goal:
 quick, based on data, transparent, planned and team building communication
(meeting) methods
 Tool:
 Daily WeWin meeting
 Daily overview of the results from the day before
 Daily analysis of the TOP 3 failure (according to scrap rate and/or scrap cost)
 Complete statistical analysis with all relevant data (Scrap database)
 Analysis at the failure place (workstation, line, area …)
 INFO Board

III. COMMUNICATION - INPUTS
1
2
3
4
4
4
1 – ppm and scrap cost per lines
2 – ppm per shift leaders
3 – part number pareto (ppm)
4 – TOP 3 part number failure list
Daily report

III. COMMUNICATION – INFO/FOLLOW UP
BOARD

III. COMMUNICATION – INTERNAL
„NEWSPAPER”
5 minutes for the quality:
•explaining of one implemented quality tool
•Newspaper style to make the understanding easier

IV. FAILURE DETECTION
 Clear failure description, limits
 Based on data
 Clear visualisation
 Compaire the good and the bad parts, issues
 Based on factor and data
 Failure history from database
Nr1
High level
Photo quality

IV. FAILURE DETECTION
 Goal:
 Improve the efficiency of the self
control and degrease the not added
value final control activities
 Tools:
 Integrated scrap analysis databases
with automatic self-control statistic
modules.
 Regular feedback to the TOP failure
types
 Improve the visualization of the failure
descriptions, catalogues.

V. PROTECTIVE MEASURE – 24H
 Goal: protect the customer till the analysis and the final solution!
1
2
3
1. failure description (what, when, how
many, who produced…)
2. Clear action plan per process +
worker signatures
3. Identification of the good parts

VI. FACTOR ANALYSIS
 Goal:
 Understand the processes!
 Tools:
 Factors (FT)
 The atoms of the processes …
 5 Why
 Ask as the children …
 FMEA
 Failure Method and Effect Analysis

VI. FACTOR ANALYSIS
 Factors - definitions
 Those points, phase of the process or product, which are clear isolable, definable
and measurable
 The factors are the atoms of the process, which can be defined with parameters,
and to cut to smaller units is not possible, or hasn’t got sense.
 The factors are the blocks of the flowchart.
 The factors are the setup parameters of a machine
 In all cases the attributes of the factors have to be defined with parameters
(Yes/No can be also parameter).
 The factors has to be splitted – especially in case of non conformity – into the 2
following groups:
 Occurrence
 Not detection

VI. FACTOR ANALYSIS – 5WHY
 5Why
 Systematical method to find the real root cause. The five is not a law. You have to
ask so many times, till you find the real root cause.
 Example:
 Surface damage on the Washington monument.
 Why? – Hard, aggressive liquid onto the surface.
Why? – Clean the pigeon guano.
Why (lot of guano)? – They eat from the lot of spiders.
Why (lot of spider)? – They eat from the lot of mosquito
Why (lot of mosquito)? – They comes onto the light at nightfall.
 Solution: switch on the lights just after dark!
www.isixsigma.com

VI. FACTOR ANALYSIS – FMEA
Factors
Customer
RPN
Process RPN
Product RPN
Factor
failure
Effect on the
process
Effect on the
product
Effect on the
customer
Function
Process

VI. FACTOR ANALYSIS – FMEA
 Sample
Factor FMEA
Spray head
Spray head
damage
Viscosity Viscosity too high
Temperature
Pressure
Temp. too high
Press. too high
Temp. too low
Viscosity too low
Press. too low

VII. ACTIONS
 Goal:
 On the real root cause defined, easy follow up, documented action handlings
 Tools:
 WeWin boards and forms + ActionMan database

VII. ACTIONS – FACTOR SHEET
1
3
4
2
1 – Failure data
2 – immediate actions (Protective measure)
3 – Factor analysis
4 – Actions
5 - Validation
5

VII. ACTIONS – FACTOR ANALYSIS IN THE
ACTIONMAN
1 – Failure (issue) data
2 – Factor analysis
3 – Actions
1
2
3

VII. ACTIONS – EFFICIENCY
 Status of the actions (automatic PDCA report from the ActionMan
database)
 LLC efficiency check diagram from scrap database – daily overview

VII. ACTIONS – EFFICIENCY : AUDITS
 Type of audits - responsibilities
Type Description
Area
manag/
Prod
QS
Manag
System audit Complete system audit
Process audit Production and stock processes
Product audit Complete audit on 5 parts
Quick audit
LAYOUT
Work station audit
Complaint
close audit
Actions and factor audit
WeWin audit Complete mindset audit
Supplier audit Start of prod and complaint audit
Layered

 Goal:
 Regularly self and management check
 Tool:
 Internal audit database program
 All questioners in one platform
 All results in one database
 Complete statistic module

 Layered Layout audit system
Clear visualisation
of the workstation
The Basics
(questionary)
Results

 Layered Layout audit system
Daily self audit
Well done audit
Not well done audit
Weekly QS audit Monthly PM audit

 Statistic modul (e.g.) of the database
 Weekly results per workstation or production line
 Visualisated reports from the Layout audit results

Thank you!
Gábor BÁRDOS
Managing director
Woco IPARTECHNIKA Magyarország Kft.
Újhegyi út 25 - 31.
1108 Budapest - Hungary
47°28'03.26"N - 19°10'11.62" E
Center: +36 1 431 0580 | Tel.: +36 1 434 2734 | Fax.: +36 1 431 0598 | Mobil: +36 20 826 0992
Mailto: gbardos@hu.wocogroup.com | Internet: www.wocogroup.com

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