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.
BIQ in 8 Steps
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
The BIQ Process
BIQ Checklists
* Details of key components require a Pass or Fail
* "Fails" are returned to the offender for immediate
correction.
Process relies on IPV (In Process Validation)
* A technician's "thumbs up" to indicate the processes were
completed accurately
Whiteboard Documentation
* "Live Feed" concept * Open communication * Guarantees
documentation to improve standard work
Stopping The Flow Of Defects
Guarantees Customer Satisfaction
