Ｓ upplier Ｑ uality Ｒ e-engineering

　　　　Ａ ssessment Ｍ anaging team activity

September 9 ,2004

～　 Improvement activities In component quality with supplier 　～

Photo by Defense Agency (H.P.)

2

1. Background (Customer’s view)

Those discrepancies were preventing high aircraft working rate

Those discrepancies were preventing high aircraft working rate

Component discrepancies had not been decreasing

Component discrepancies had not been decreasing

＜ before SQRAM

activity＞Project A　 Delivered Discrepancy trend

component

others

2000 2001

To reduce

component discrepancies

was a pressing need

3

2. Background (Supplier’s view)

＜ The in-house sales ratio of an aerospace section at suppliers＞ A sales ratio is very

small

A sales ratio is very

small

・ Top managements did not feel big interest 　・ Suppliers could not make improvement activities, even if they wanted to do because of an insufficient resources・Motivation had not been growing up

・ Top managements did not feel big interest 　・ Suppliers could not make improvement activities, even if they wanted to do because of an insufficient resources・Motivation had not been growing up

50 100%～

10 50%～

0 10%～

What should be carried out

to the suppliers of such a situation?

MHI went into a supplier and activated quality

improvement activities

4

Team establishment (2004 FY ～ )

Team establishment (2004 FY ～ )The deputy

GM, manufacturing

Supplier 　１３

companies（ 2002FY ）

ＬｅａｄｅｒＤｉｒｅｃｔｏｒ , Procurement

SecretariatQA 　 ManagerQA 　 Assistant

Manager

Ｍａｔｅｒｉａ l Depar

tment

Production

Department

Engineering

research Departm

ent

Engineering

Department

Service Departm

ent

Quality Assuranc

e Departm

ent

3. Organization

SQRAM team

Sub-LeaderＤｉｒｅｃｔｏ

ｒ , QualitySupplier quality control team

SQRAMSQRAMSSupplier upplier QQuality uality RRe-e-

engineering engineering AAssessment ssessment MManaging teamanaging team

MHI and each supplier promote this activity by

forming a scrum

5

Between only focal points

External Go into a manufacturing process / organization

Instruction

by MHI

Experience of only in each company

Each company shares its knowledge

Knowledge

source

passive voluntaryPosition

Low motivation (less understanding for the usage and importance of components)

Improvement in consciousness (from mechanics to managers)

Consciousness

formerly ＳＱＲＡＭ

Broad communication

　

Communication

supplier

MHI supplier

MHI

4. Aim of SQRAM activityACTIVITY

Knowledge Share activitiesPeriodical general meeting to

invite all suppliers

Enlighten educational activities

MHI provides opportunities of education which targeted from the mechanics to managers of a supplier

Individual meeting with each company 　・ Activity at MHI　・ Activity at supplier

The improvement activities

(each company)

As an leading company in aerospace industry

　① Raising component

quality

of all involved

suppliers

　② Develop spirit of

working

together

6

4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3

Kick/ off interim Final Kick/ off interim Finalgeneral meeting ▼ Report Report Report Report Project A (51) ▼ (32) ▼ (35) ▼ (56) ▼ ▼

Project B ▼ (37） ▼ (31) ▼ (47) ▼ ▼

Project C ▼ (21)

(36)▼ (7) ▼ (6) ▼ ▼

MHI Training ▼ (74) ▼ Pilot lecture

The improvement３．activities

Individual meeting

2003FY2002FY

Knowledge Share１．activities

Improvement２．activities

16times 15times 26times

5. Schedule

Supplier 274

MHI 168

( ) shows attending supplier number

Supplier 65

MHI 170Supplier 97

MHI 83

7

Plan by each companyPlan by each company

General Mtg (Interim report)General Mtg (Interim report)

Implementing each company’s plan

Implementing each company’s planIndividual Mt

gIndividual Mtg

General Mtg (Final report)General Mtg (Final report)

General Mtg (Plan presentation)

General Mtg (Plan presentation)

StepStep

Implementing each company’s plan

Implementing each company’s planIndividual Mt

gIndividual Mtg <Scene of the General

Meeting>

6-1 share of supplier’s action (1/2)6. Activities

8

ResultResult

(1) showed MHI’s initiatives for the suppliers

(2) let the suppliers have the consciousness of the importa

nce of quality

(3) boosted the concern of each company’s top manageme

nt

(4) provided suppliers with trigger of self PDCA managemen

t

(5) shared each company’s good points and failure experien

ce

(6) stimulated each other

(1) showed MHI’s initiatives for the suppliers

(2) let the suppliers have the consciousness of the importa

nce of quality

(3) boosted the concern of each company’s top manageme

nt

(4) provided suppliers with trigger of self PDCA managemen

t

(5) shared each company’s good points and failure experien

ce

(6) stimulated each other

6-1 share of supplier’s action (2/2)

9

Confirm each company’s detailed plan and status

Confirm each company’s detailed plan and status

Confirm purpose and member

Confirm purpose and member

Listen desiresListen desires

Discuss quality

improvement

Discuss quality

improvement

Check “3-Gen” together(onsite, products,

actualities)

Check “3-Gen” together(onsite, products,

actualities)

StepStep

Discussed topics

　 Corrective actions, Preventive actions

　 Improvement of work instructions

　 FAI, Change management

　 Competence management and training

　 Visual management

Discussed topics

　 Corrective actions, Preventive actions

　 Improvement of work instructions

　 FAI, Change management

　 Competence management and training

　 Visual management

Professionals from both parties[tasks of MHI side]　 Engineer ： coordinating engineering requirement　 Research ： advising element techniques　 Manufacturing ： Requesting from next process position　 Service ： transmitting voices of final customers　 Procurement ： coordinating contract matter　 Quality ： advising quality improving　

Professionals from both parties[tasks of MHI side]　 Engineer ： coordinating engineering requirement　 Research ： advising element techniques　 Manufacturing ： Requesting from next process position　 Service ： transmitting voices of final customers　 Procurement ： coordinating contract matter　 Quality ： advising quality improving　

6-2. Improving of each company (1/2)

10

ResultResult

(1) Improved by reviewing source working　　　・ checked “3-Gen” by MHI each section’s professio

nals　　　　 (recurrence prevention, similar discrepancy preve

ntion)　　　・ required reinforcing organization, if necessary　　　・ advised project management, schedule manage

ment, risk management etc

(2) Activated quality improving activities as unity　　　・ manufacturing process review and investigating

improving plan by both professionals　　　・ developed sense of unity by broad communicatio

n　　　・ act for actual (true) voice　　　・ learned mutually from other companies’ presenta

tion

(1) Improved by reviewing source working　　　・ checked “3-Gen” by MHI each section’s professio

nals　　　　 (recurrence prevention, similar discrepancy preve

ntion)　　　・ required reinforcing organization, if necessary　　　・ advised project management, schedule manage

ment, risk management etc

(2) Activated quality improving activities as unity　　　・ manufacturing process review and investigating

improving plan by both professionals　　　・ developed sense of unity by broad communicatio

n　　　・ act for actual (true) voice　　　・ learned mutually from other companies’ presenta

tion

6-2. Improving of each company (2/2)

112001 2002 2003

could not find actual cause due to no reappearance at supplier(less information for reappearance)

could not find actual cause due to no reappearance at supplier(less information for reappearance)

frequent discrepancies for flight control computerfrequent discrepancies

for flight control computer

Could reappear at supplier and then finally solved the problem

Could reappear at supplier and then finally solved the problem

Collect MHI internal data and request customer to collect data

Collect MHI internal data and request customer to collect data

Picked up necessary information for reappearance (Flight situation, test situation)

Picked up necessary information for reappearance (Flight situation, test situation)

Example

1

Example

1

Non reappearance

items

With MHI

engineers

solved problem

by discussing in detail

stiffer relationship

12

Checked engineering requirement and production process in the individual meeting

Checked engineering requirement and production process in the individual meeting

Flight suspension due to control stick sensor discrepancyFlight suspension due to control stick sensor discrepancy

Found insufficient reflection of production know-how of an American license manufacturer

Found insufficient reflection of production know-how of an American license manufacturer

Example

2

Example

2

Onsite investigation with supplier member and MHI member (engineer, quality)

Onsite investigation with supplier member and MHI member (engineer, quality)

Reestablish improved production process

without nonconforming potential

Reestablish improved production process

without nonconforming potential

Traced back together

to original manufacturer

Ensured quality

production

13

polic

y

polic

y

actionaction

・ established nonconformance knowledge database・ share the data among all suppliers・ reflected nonconformance potential into design/production process in each company 　　　

・ established nonconformance knowledge database・ share the data among all suppliers・ reflected nonconformance potential into design/production process in each company 　　　

Nonconformance prevention for a coming project B(16 companies)　　・ recurrence prevention for prototype nonconformance　　・ nonconformance prevention in a change portion from prototype model to production model　　・ deployed experienced nonconformance from project A

Nonconformance prevention for a coming project B(16 companies)　　・ recurrence prevention for prototype nonconformance　　・ nonconformance prevention in a change portion from prototype model to production model　　・ deployed experienced nonconformance from project A

Example

3

Example

3

Frontloading by sharing

failure experiences

before production

Nonconformance

prevention

14

Result(audiences’ impression)

Result(audiences’ impression)

6-3 Enlightenment

MHI onsite trainingMHI onsite trainingTraining by inviting supplier mechanics to MHITraining by inviting supplier mechanics to MHI

Technical training (engineering): aircraft system and component

Plant observation :installation and usage of components

Interchange session :discussed for a theme in a small group

Technical training (engineering): aircraft system and component

Plant observation :installation and usage of components

Interchange session :discussed for a theme in a small group

Pilot lecturePilot lecture

MHI test pilot lectured his flight experience （mechanics and managers)

MHI test pilot lectured his flight experience （mechanics and managers)Attend lecture of an actual voice of pilot

Attend lecture of an actual voice of pilot

・ understood its functions and effeteness when failed of our component

・ understood jobs in MHI for our component

・ felt tension and severeness at final line and flight area

・ developed sense of unity by broad communication between persons in charge

・ understood its functions and effeteness when failed of our component

・ understood jobs in MHI for our component

・ felt tension and severeness at final line and flight area

・ developed sense of unity by broad communication between persons in charge

<Scene of the pilot lecture>

15

Example :　 Pilot lecture at supplier

factory

Example :　 Pilot lecture at supplier

factory<Message of Pilot>

・ “ People” is mostly a main cause of nonconformance

・ to make much of “feeling”

・ Never fly until consent on the flight affecting matter

<Message of Pilot>

・ “ People” is mostly a main cause of nonconformance

・ to make much of “feeling”

・ Never fly until consent on the flight affecting matter

<audiences’ impression> (74 attendees)

・ understood our component truly constitutes the aircraft

・ felt real tension

・ recognized we handle the pilot’s life

<audiences’ impression> (74 attendees)

・ understood our component truly constitutes the aircraft

・ felt real tension

・ recognized we handle the pilot’s life

Recognized

how our component is used

Developed sense of

responsibility and pride

16

7. Result (1/3)

<Project A : component nonconformance>

quantitative resultquantitative result

Work

errorDesign

error

Part

error

others

Non

reappearance

・ decreased component error in flight test ・ showing decreasing trend in flight test times

・ decreased component error in flight test ・ showing decreasing trend in flight test times

<company flight test times>

・ dramatically decreased component nonconformance(especially, design error decreased)・work error and part error

should be targeted to decrease from now

・ dramatically decreased component nonconformance(especially, design error decreased)・work error and part error

should be targeted to decrease from now

Surplus flight

times

Component error

Related result (@

MHI)

Related result (@

MHI)

2001 2003 2001 2003

17

7. Result (2/3)

(1) raised component quality in all suppliers　　・ started moving to put in good quality at source ph

ase(2) Developed spirit of working together 　　・ synergy for common goal (good quality in final pro

duct)　　・ each company’s independent participation

(voluntary action, constructive idea)　　・ develop sense of unity by removing walls between

companies and between sections

(1) raised component quality in all suppliers　　・ started moving to put in good quality at source ph

ase(2) Developed spirit of working together 　　・ synergy for common goal (good quality in final pro

duct)　　・ each company’s independent participation

(voluntary action, constructive idea)　　・ develop sense of unity by removing walls between

companies and between sections

improved final customer’s working rate by removing nonconformance potential and

raising dependability

Reliance from customers, then continuous contract

improved final customer’s working rate by removing nonconformance potential and

raising dependability

Reliance from customers, then continuous contract

18

7. Result (3/3)

Voices of

customers

Voices of

customers・「 Project A working rate has now been raising, we expect further effort for improvement to MHI 」

・「 We expect MHI this kind of essential activity indeed. We want to fully support this activity. 」

・ MHI was invited to make a presentation of this activity at a customer’s maintenance seminar.

　　 (111 organization participated)

・「 Project A working rate has now been raising, we expect further effort for improvement to MHI 」

・「 We expect MHI this kind of essential activity indeed. We want to fully support this activity. 」

・ MHI was invited to make a presentation of this activity at a customer’s maintenance seminar.

　　 (111 organization participated)

19

8. Continuous activity

Started SQRAM

Frequent nonconformance supplier （ 13）

ExpandedSQRAM

+ essential component 　（ 14 ）

StartedSQRAM-Ⅱ 　　　

Back-shops(detail, assy) （ 25 ）

2002 FY 2003 FY 2004 FY ～

ACT

Check

Check

Continue by

improving

Continue by

improving

CHECKPLAN ・ DO