Drill_Deep & Wide

nullDeep & Wide ProcessUnderstanding Root Cause And Applying Lessons LearnedDeep & Wide ProcessProblems are a key driver for Current SQ!Problems are a key driver for Current SQ!Problems are the bases of what we do. Understanding the problem, identifying the root cause, and implementing corrective action is fundamental. So, why do we and our suppliers end up solving the same or similar problems over and over? So, why is it so hard to actually implement lessons learned?Maybe there is a better way?Maybe there is a better way?Maybe, we need to rethink the process. Maybe, there is a more effective way. Maybe, we need to dig deeper to identify the entire root cause. Maybe we need to dig deep and wide?What is Drill Deep and Wide?What is Drill Deep and Wide?Per GP-5, these are required for all PRRs 3 X 5 Why Analysis (Drill Deep) 3x5 Why is understanding of the root cause: Manufacturing – Why was it not prevented? Quality Systems – Why was it not detected? Planning – Why was it not predicted? Process Read Across (Drill Wide) Process Read Across is driving lessons learned across the facility/supplier/company Visual aid SQ Recurrence Prevention ModelSQ Recurrence Prevention ModelIdentify Metric & Threshold Supplier Identification Toolbox ApplicationPredict (FMEA, PCP) Prevent (Error Proofing, STW) Protect (Error Detection, Responsiveness)Identify Issues Identify same Process Implement LessonsBuild the BaseDrill Wide (Read Across)Drill Deep (3x5Why)Recurrence Prevention ModelRecurrence Prevention ModelPrevention should start hereWide Implementation (Read Across)Deep Investigation (Drill Deep analysis) Supplier Quality ModelSupplier Quality ModelDrill Deep VisualWhy did the planning process not predict the defect?Why did the manufacturing process not prevent the defect? Why did the quality process not protect GM from the defect? Defect on PartP1P2P3P4PnPredict Root CauseWhy?Why?Why?Why?M1M2M3M4MnPrevent Root CauseWhy?Why?Why?Why?Q1Q2Q3Q4QnProtect Root CauseWhy?Why?Why?Why?PredictCorrective ActionPrevent Corrective ActionProtectCorrective ActionDrill Deep VisualnullWorkshop Flow ChartWorkshop Flow Chart PREDICT Root Causes PREVENT Root Causes PROTECT Root CausesGroup & Pareto All Root CausesGroup & Pareto All Root CausesGroup & Pareto All Root Causes Key Findings Root CausesGroup & Pareto All Root CausesDrill Deep AnalysisWhat is the intent of the Drill Deep analysis? Why did the planning process not predict the defect? Why did the manufacturing process not prevent the defect? Why did the quality process not protect GM from the defect?Drill Deep AnalysisDrill Deep AnalysisHow is the Drill Deep analysis structured? Supplier Quality Model 5 Whys Action plansDrill Deep AnalysisDrill Deep AnalysisKey Points: Drill Deep Analysis is not used to understand what failed but rather why the system failed. Therefore, the technical root cause (i.e., the Red X in supplier’s process) should be known before the Drill Deep Worksheet is completed. Drill Deep AnalysisDrill Deep WorksheetGM Form 1927-84Drill Deep WorksheetDrill Deep WorksheetDrill Deep WorksheetDescribe the nonconformance on the part. Example: End cap not fully seated into window on valve; O2 sensor bung missing on exhaust system; No weld on terminals in relay; Cold weld on brake pedal bracket, etc. Drill Deep WorksheetDrill Deep WorksheetEnter each why below. Insert a row for each additional why if applicable. As a sense check, read the Whys backwards to make sure that the analysis make “sense”.Perform the 5 Why to the right. The first question to ask and answer to begin the Prevent 5 Why is the following: Why did the manufacturing process not prevent the defect? Example: Why did the manufacturing process not prevent the end cap not fully seated into window on the valve? Note: row height can be adjusted on this form as needed. Why?Drill Deep WorksheetDrill Deep WorksheetOnly add a corrective action next to each "Why" if applicable. Keep in mind that the last "Why" needs a corrective action with an owner and a completion date. Also, there can be more than one corrective action for a root cause and the corrective action should include some form of verification or "Check“.Drill Deep WorksheetDrill Deep WorksheetAlso, keep in mind that the technical root cause (i.e., Red X in supplier’s process) should be captured in the Prevent 5 Why as shown below.The last "why" is the underlying Root Cause. Please add a corrective action, owner, and date to the right.Does not have to be 5 Whys - ask as many Whys as necessary.Drill Deep WorksheetDrill Deep WorksheetWhy?Similar question can be asked for the Predict portion: Why did the planning process not predict the defect? Example: Why did the planning process not predict the end cap not fully seated into window on the valve?Why? Therefore. . .Drill Deep WorksheetDrill Deep WorksheetWhy?Similar question can be asked for the Protect portion: Why did the quality process not protect GM from the defect? Example: Why did the quality process not protect GM from the end cap not fully seated into window on the valve?Why? Therefore. . .Drill Deep WorksheetDrill Deep WorksheetAre there any other key findings? Review the 5 Why analysis above to uncover any common “themes” and document them to the right. A corrective action, owner, and date needs to be added for each key finding.Drill Deep WorksheetDrill Deep WorksheetRead Across Read Across nullnullRead Across Matrix (Drill Wide)nullnullRecord the GM Owner (I.e. Supplier Process Development Metallic, Chemical, Electrical) or CS2 Provider name and information. Record the Supplier InformationFor CS2 provider onlyRead Across Work InstructionsnullRecord the Part Name and full Part NumberRecord the PRR issuing locationRecord the issue as described by the plantCreate one line for each PRR issued Record the Date the Drill Deep Analysis Was completedRecord the DEFECT on the partRead Across Work InstructionsnullRecord the full PRR number Record the number of non conforming parts Identified on the PRRIdentify the Type and Status of any Controlled Shipping action initiated as a result of this PRRIdentify the Corporate Champion responsible to ensure implementation of the corrective actionsRead Across Work InstructionsnullIdentify all supplier DUNS locations with similar products and processesIdentify all lines within each duns where corrective actions may apply. Also identify new Products to apply Lessons Learned.Use letter code with appropriate color to identify applicable locations and statusRead Across Work InstructionsnullRoot Cause ParetoRoot Cause ParetoRoot Cause MatrixRoot Cause MatrixTransfer the Root Causes for Predict, Prevent and Protect from the 3x5 Drill Deep Worksheets to this form. Include any Key Findings Include all PRRsRoot Causes GroupedGroup Like Root Causes and Key Findings within each Column. Account for all PRRsRoot Causes GroupedRoot Causes GroupedRoot Causes GroupedSystemic Issues Read AcrossSystemic Issues Read AcrossSystemic Issues Read AcrossSystemic Issues Read AcrossnullPredictPreventProtectKeyThe TOP Bar of each Pareto represents the Systemic Issues which will require an initial Read AcrossSystemic Issues RA ExampleSystemic Issues RA ExampleSupplier identificationThe highest frequency root cause from each Pareto chart is transferred here. Include the Key FindingAssign a Champion and record a due dateRead Across to Each PlantDefine the Corrective Actions for each Systemic IssueIn SummaryInputs to Deep and Wide starts with PRRs The Drill Deep and Wide Process matures with the use of Internal Quality Data Maybe we found a more effective way!In Summarynull