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TRC's emphasis on quality has always used the most
effective
elements of Lean
Manufacturing.
5S, Kaizen
events and
Kanban are just
a few
examples. Our
most recent
addition to our
Lean tool box
has been the
addition of Built In Quality-BIQ for short
BIQ drives home best in class quality by being proactive
rather than
reactive. The
basic principle
of BIQ is to
stop the flow of
defects as close
to their source
as possible;
with no defects
leaving the
production environment.
This is
accomplished via
use of "gates"
and visually
driven
checklists at
critical areas
of the
remanufacturing
processes.
Resources are
then deployed to
eliminate the
cause of the
defect
using proven
lean
technologies.
Early benefits
to the roll out
of BIQ in our
remanufacturing
facilities has
been a reduction
in warranty
claims, improved
efficiency as a
result of
reduced rework
and improved
working conditions
for our
technicians.
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Stop the
defect
-
Get a
detailed
description
of the
defect
-
Pareto the
defects to
target the
most
problematic
-
Share defect
detail with
the offender
-
Conduct RCCA
(Root Cause
Corrective
Action)
-
Drive
feedback to
all
technicians
-
Drive RCCA
into
standard
work
documents
-
Repeat the
process
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BIQ Checklists
* Details of key components require a Pass or Fail
* "Fails" are returned to the offender for immediate
correction.
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Process relies on IPV (In Process Validation)
* A technician's "thumbs up" to indicate the processes were
completed
accurately
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Whiteboard Documentation
* "Live Feed" concept * Open communication * Guarantees
documentation to
improve standard
work
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Stopping The
Flow Of Defects
Guarantees Customer
Satisfaction
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