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Perfect QRQC - Prevention, standardization, coaching

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QRQC (Quick Response Quality Control) is one of the most powerful tools of Quality Management. It makes it easier to solve most of the manufacturing and functional problems in a simple and logical way.


Volume 1 presented QRQC initial steps (Detection, Communication, Analysis and Verification), as well as the first step of the approach ("RESOLUTION").


In Volume 2, three steps are explained in detail: "Prevention", "Standardization" and "Coaching".


The step "PREVENTION" aims to permanently eradicate problems, including on other production lines or in other locations or at other customers'.


The step "STANDARDISATION" involves building on experience from past mistakes through technical reviews, standardizing new robust design standards by using formalisation or updates, then implementing 100% of these design standards to 100% of the projects.


Finally the third step "COACHING" is probably one of the most important steps in the approach. It presents a practical method of understanding and a training on the "Perfect QRQC" approach as a whole.


With this second book, the author remains true to the principle that contributed to the success of his previous book: to provide simple and educational guidance that is easy to understand by managers and technicians, and to enable a practical implementation with positive and measurable results in terms of customer and staff satisfaction. Remember that the management of problems is fundamental to the building of expertise and know-how in a company. Increase product reliability and product design which are the root cause of mutual trust between a supplier and its client.


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EAN13 9782818806104
Language English
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PERFECTQRQC
2

Hakim Aoudia
Foreword by Stéphane Rambaud-Measson
Chaiman of the Management Board and CEO of Faiveley Transport

PERFECTQRQC2

Prevention
Standardization
Coaching

Hakim Aoudia graduated from theCommercial Institute of
Nancy(France). He is an expert in the field of Quality management,
particularly in the automotive industry. After having spent a few
years in the United States, he held several Quality Management
positions at Valeo for over ten years. He is now working as
GroupEnvironment,Safety, Health & Quality Director at Faiveley
Transport, one of the worldwide leaders In the railway industry.
He can be reached at
hakim.aoudia@maxima.fr

Acknowledgements

I wish to thank the following people more particularly: my
wife,Fatima-Zohra andmy son,Farès, for their patience
during the writing of this book.
Stéphane Rambaud-Measson, for his active promotion of
the QRQC approach within Faiveley Transport.
Christophe Périllat-Péritoinefor his support.
My friendKazuo Kawashima.
Stéphane Dervillefor his continued support.

www.maxima.fr
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Join us on facebook.com/EditionsMaxima

8, rue Pasquier – 75008 Paris
Tél. :+ 33 1 44 39 74 00 – infos@maxima.fr

© Maxima, Paris, 2015.
ISBN :

All rights reserved. No part of this publication may be reproduced in any form or by any
means without the permission of the publishers.

Table of contents

Foreword ...................................................................................

Introduction..............................................................................

1.0
1.1




1.2

2.0
2.1
2.2




2.3

1. Prevention.......................................................

Purpose of the “Prevention” step...........................
The various Steps of Prevention .............................
• Learn........ ......................................................................
• Share.......................................................... ....................
• Respect.................... ...... ................................................
• Use.................................................................................
Synopsis and Key Points............................................

2. Standardization............ ................. ..............

9

13

19

21
23
27
38
55
60
67

69

Purpose of the “Standardization” step..................71
Standardization Organization ..................................72
The various Steps of Standardization.................... 76
• Capitalize................6 7........................................... ............
• Standardize................................................................... 80
• Publish 97............................. ..............................................
• Apply.............................................................................. 100
Synopsis and Key Points............................................115

Table des matières

5

6

3.0
3.1




3.2


3.3
3.4

3. Coaching............................................................ 119

Purpose of the “Coaching” step..............................121
The Various Steps of “Coaching” ............................125
• Explain........................................................................... 127
• Demonstrate........................................ ....................9. 12....
• Observe.......................................................................... 132
• Assess............................................................................. 134
“On Job Training” Principles..................................... 147
• “Stop at First No”.......................................................... 147
• “Stop at First Disagreement”................................51 .0.... .
Technical Training ........................................................154
Synopsis and Key Points............................................155

4. True/False Test............................................. 157

Conclusion ................................................................................163
Bibliographic References......................................................165

Perfect QRQC 2

To Ouardia and Chabane Aoudia

Foreword

th
orn in the 19century, the railway industry was a
driving force for the industrial revolution and later
coBntradictory circumstances it is now facing many challenges
became a pillar of world economic development. Due to
and transformations as part of the newRailvolution.

Urbanisation and the need for mobility have boosted the industry
over several decades. More recently, the search for cleaner, more
sustainable transportation has also encouraged spending on
railways.

But since the financial crisis of 2007, the budgetary constraints
faced by many governments as well as owners and operators of
public transport, has limited investment in rail infrastructure and
rolling stock.

The competitive pressure on rail manufacturers and equipment
suppliers is growing as a consequence.

Meanwhile, technical standards are becoming increasingly
challenging, driving up costs and the time needed to put
equipment into service.

In fact, according to the industry, standards regarding safety,
reliability and quality have never been so high. Recent rail
accidents, thankfully few but sadly tragic, have led to toughening
of standards with targets ofzero mistakes.

Foreword

9

10

To address environmental, financial and safety challenges, and
to meet the expectations of its customers, Faiveley Transport has
had to adapt its offer and operating methods.

With a turnover of more than one billion Euros, over 6,000
employees working in 24 countries, and with over 90 years
experience, Faiveley Transport is a global player in the rail
industry. Closeto its customers, both car-builders and railway
operators, and being present worldwide, Faiveley Transport
decided to launch an ambitious programme of improvement,
theFaiveley Worldwide Excellence(FWE).

The FWE approach goes far beyond a simple improvement
programme. The innovation can be seen through the integration
of a consistent and complete set of requirements both in terms
of operational implementation and in terms of environmental,
financial and safety control. All functions within the company
are involved.

This programme of excellence consists of three parts:
1. Settingclear qualitative and quantitative objectives for
improvement on a multi-year basis,
2. Deployment of tools, processes and methods inspired by the
best industrial practices and internal auditing,
3. The implementation of information systems.

The progress of the FWE programme is objectively measured
on each of our locations through an exhaustive questionnaire
focusing on the best industrial standards and the requirements
of our customers. It assesses the level of development of each
functional area in the company. Each site receives a certification
for its good results, confirming the successful implementation
of the methods and tools as well as the achievement of quality
targets. More than only graduating, certification reconciles
processes with the operational and financial results and social
responsibility.

It is in this context that an objective of excellence was deployed
within Faiveley Transport in the form of theQuick Response

Perfect QRQC 2

Quality Control(QRQC) approach. The application of QRQC Step
1 has, for example, led to a fivefold reduction in the number of
incidents affecting our customers, when delivering equipment
under warranty.

Today we are in the process of deploying QRQC Step 2, which
is certainly the most important step. As described in this book,
the first step mainly focuses on solving problems in a logical
and systematic way. This second step aims to establish a system
enabling one to learn from one’s mistakes, once the problems
have been solved, before sharing them, then include them into
more robust design standards. They will then be used as part of
design reviews planned during the project development.

As Hakim Aoudia explains in an educational manner in this book,
this second step responds to some fundamental stakes for the
future of industry beyond methodology: our ability to learn from
our experience and increase our expertise, our ability to retain
and transfer this expertise, our ability to design new robust
projects, to reduce costs due to poor quality while involving and
motivating our teams, all this in view of our client satisfaction in
the long run.

Foreword

Stéphane Rambaud-Measson
Chairman of the Management Board
and Chief Executive Officer of Faiveley Transport

11

Introduction

must say I was very surprised by the warm welcome given
1
to my first book on QRQC (Perfect QRQC, the Basics) and
iIn th e world for their observations and encouraging feedback.
I would like to take this opportunity to thank all the readers
So far no reference book dealing with QRQC existed and it is
a pleasure for me to be able to help many managers to better
understand the QRQC approach and provide them with the key
to a simple, but rigorous implementation.

Volume 1 ofPerfect QRQCconsisted of describing the fundamental
bases for a quick, logical and effective problem solving that any
company can face. These “foundations” relate to the “D-C-A-V”
steps of QRQC approach:Detection,Communication,Analysis,
Verification. All of these being based on the San Gen Shugi
attitude.

This foundation is both the base of QRQC and also the starting
point of the virtuous circle represented by the “Perfect QRQC”.
This then includes the first step “Problem Solving” as described
in the volume1, followed by the 3 steps of “Prevention”,
“Standardisation” and “Coaching” that are going to be studied in
detail in this second book.

1. Aoudia, Hakim and Quintin Testa:Perfect QRQC, the Basics, Maxima,
2012.

Introduction

1

3

14

4. Coaching

1. Problem
Solving
(Volume 1)

Perfect
QRQC

3. Standardization

2. Prevention

The San-Gen-Shugi Attitude

As a matter of fact, the purpose of this book is to explain each
one of these steps continually using an educational approach
and simplicity, for immediate and practical implementation.

The step “PREVENTION” aims to eradicate problems definitively,
striving to never having to face them again, including on other
production lines, or in other locations or when dealing with
other customers’. This step implies 4 types of activities:

Learn from past mistakes through the filling out of “Lessons

learnt” cards;

Share the lessons learnt with other entities of the group
to avoid the same problem on processes or other similar
products;

Respect the lesson learnt over time;

Use “Lessons learnt” cards to train the teams and use them
again for the updating or the creation of standards.

The old saying according to which “an ounce of prevention is worth
a pound of cure” is well-known, and among the manufacturing
world too. However, when it comes to implementing them, it is

Perfect QRQC 2