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14Q BASIC

TCM DISPLAY
BOARD
Display Concept

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14Q – TCM VS
Contents

Sign
&
Definition
Customer Process Maintenance
Complaints Andon Cord Instructions Parameters Test Equipment Check the Checker Standard Tools Management Restart Labeling Scrap, Rework Fallen Parts Correct Product Remaining Items


Scrap Change- Change-
TCM Custmoer Gage SU/PY Tool Life Machine Color- Dropped
Andons PQIs Guidelines PMs Recode over Blue over
Keywords Returns Calibration Check / Pit Stop Release coded Tags Parts
Person Light Racks

③ Requirements

④ TCM
Examples
Firewall, QAs Andon lights
PQIs, Cleaning
Standards
Guidelines,
SU/PY form
Gage Cal
stickers
Go/No-Go
masters
PM
Workorders
Pit Stop Lights
Machine
Release Forms
Color-coded
Tags
Scrap/Recode
Cart
Scrap bins
Changeover
Blue Light
Changeover
Racks

 14Q Display to enhance associate embracement with 14Q Principles


 Uses comprehensive common terminologies  ②TCM Keywords
 Visualized with actual TCM example pictures ④TCM Examples
 14Q display will be posted on the wall across from Big-Blue display
board
 Contents: ① Sign & Definition ② TCM Keywords ③ Requirements ④ TCM Examples
3 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
14Q – TCM VS
Banner
14 Quality Principles for the Value-Stream  14Q Display Board
We want our customers Banner (size: 2’ x 7’)
to be happy!

 Banner design is
14 Qualitätsprinzipien für den Wertstrom
14 Quality Principles for the Value-Stream

Thema/Topic
des/of the Assessment
Reifegrad-Bewertung / Maturity-Evaluation

created from 14Q


Datum/Date Standort/Location
Assessment

Wertstrom / value stream


Fertigungsprozess / production process
in Assessment

Basics Maturity
Name Abteilung/Department Rolle/Role

Bewertung durchgeführt von


Evaluation done by

Evaluation form
Name Abteilung/Department Rolle/Role
14 Q-Basics Reifegradbewertung / Maturity Evaluation

1. Kundenbeanstandungen
Customer Complaints
14. Restmengen 3 2. Reissleine
Teilnehmer/Participant
Remaining Items Andon Cord

13. Richtiges Teil 2 3. Anweisungen


Correct Product Instructions

Vorgaben/Guidelines CDQ0519 - 14 Qualitätsprinzipien für den Wertstrom

Gesamtergebnis/Overall result, Zusammenfassung/Summary 1


Verbesserungspotenziale/Improvement potential: 12. Gefallene Teile 4. Prozessparameter
1) Fallen Parts Process Parameters
Erläuterung/Explanation 2)
der Bewertung (siehe Radarchart)
of the evaluation (see radar chart) 3)
0

Reifegrad /
Verantwortlich für das weitere Vorgehen
11. Ausschuss, Nacharbeit 5. Prüfmittel
Maturity
und die Festlegung von Scrap, Rework Test Equipment Level
Verbesserungsaktivitäten

Responsible for further proceeding and 3


defining Improvement activities

10. Kennzeichnung
6. Check the Checker 2
Labeling

Verteiler/Distribution list 9. Wiederanlauf 7. Wartunsstandard 1


Restart Maintenance Standard
8. Werkzeugmanagement
Tools Management

4 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
14Q – TCM VS
Location
 14Q display will be
posted on the wall
across from Big-Blue
display board
 Effective visibility
with heavy traffic
leads to production
floor

5 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
14Q – TCM VS
Slides
 Slides on following pages are actual posted slides

 Slides are electronically accessible so that it can be used for training

 Slides should be reviewed for update when following occurs;


 Maturity assessment is conducted

 14Q improvement is implemented

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Keywords

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
Requirements

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Examples

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
1 Customer Complaints

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
1 Customer Complaints

Customer
Returns
11 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
1 Customer Complaints
 Requirement  What we do?
 Customer complaints are communicated within  All MOE1 associates have access to the AdP
the production site and displayed at the station website to review customer complaints.
in question. Using problem-solving techniques,  Quality Alerts (with the Stop Sign) are placed
they are processed in a fast and systematic on any station that has caused an AdP/MOE1
manner. IPN production sites are promptly responsible failure.
informed.
 There is a bi-weekly management review of
 - A STOP sign process with all of the 8D the TCM Firewall. The review includes QMM,
elements is displayed on the shop floor. A MFE, MFO, and TEF.
standard review process involving the
production management and quality  0-mile complaint reports are sent to GS-
management takes place. TC/RBU-NA on a bi-weekly basis and to GS-
TC/QMM on a monthly basis.
 - The decision to end the STOP sign process
is taken by production management after a  The Stop Sign at the station is removed once
review of the measures’ effectiveness. improvement actions are implemented and
verified.
 - It is necessary to ensure that customer
complaints are communicated quickly within all
IPN value streams.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
1 Customer Complaints
Created on: 1/1/2016

Last Update: 8/7/2017


QAM responsible:QMM9

Approved:
Quality Assurance Matrix (QAM)

D1 D2 D3 D4 D5 D6 D7 D8
 Quality Assurance
Matrix (QAM) is
Complaint Mode

Responsible COMMENTS
Q8 Closed
Q8 Team Leader Most current Status of 8D QC / QI
Total

Score
days to Problem Product Failure description of Last (Internal) QC Created On Q8 Created
close owner Process Step issue Update Notification Entry Date Q8 Date Customer QE Q Basic Failure
CW30: Station in Safe Launch process to be complete CW32.
40 558 MOE1 EHM-GM Q8:Mfg AdP - On/Off Wire Tensile Break Miller CW30 CW25: Station debug. Tooling modification in process before station can be released. G G R R Y R R R n/a 230004549180 12/11/2015 230004583360 1/28/2016 GM Pena
CW21: Vision
CW25: Tooling installed.
sensor Station
installed. in debug.failure rate data before process is released.
Collecting

posted on AdP
40 420 MOE1 EHM-GM Q8:Mfg AdP - Incorrect Weld Ring R. Moore CW25 CW19: New loading tooling on order for field of view issues with camera. G G G Y Y R Y R n/a 230004662537 4/28/2016 230004699386 6/14/2016 GM Pena not relevant
CW6: Tooling
CW25: ordered.
Summary 8Dprovided
of issue completion expected
to TTO 4/7/2017.
with recommendation to close issue as customer
21 152 MOE1 EHM-GM Q8:Mfg AdP:Contamination across TCU lead Pena CW25 responsible since the carbon fiber contamination aligns with clutch material even if it is not clear G R R R R R R 230004831469 11/21/2016 230004919686 3/9/2017 GM Pena
how thatCorrective
CW25: material got into the
actions forshort
MRClocation.
in review with TEF3 and TEF7.
21 90 MOE1 EHM-GM Q8:Mfg AdP - FWD Traceability Ryan CW25 CW20: TRC and MRC developed. To be reviewed with GM 5/17/17 and with BV 5/22/17. G G R R Y R R R 230004964034 4/28/2017 230004972554 5/10/2017 GM Pena

21 5 MOE1 EHM-GM Q8: G R R R R R R R 230005040013 8/3/2017 230005040242 8/3/2017 GM Pena

Quality Assurance Matrix (QAM)


Quality Alert website with all
customer
complaints.
8D Management Review
Insert picture here
 Quality Alert is
AdP website
posted on the
station that caused
the customer
complaints.
AdP Key Data

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
2 Andon Cord

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
2 Andon Cord

Andons

15 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
2 Andon Cord
 Requirement  What we do?
 In the event of deviations in quality or if control  All associates are trained on how and when to
limits are exceeded in the value stream use the Andon system at the line. This system
(source, make, deliver), the employee needs to is verified using Layered Process Audit.
stop the process and escalate.  Reaction plans are defined.
 There is a system (e.g. Andon cord) in place  Deviations are documented and reviewed
that allows the operator, if he notices during the Daily Management Meeting.
deviations, to choose to stop the process and
notify his supervisor immediately.  An escalation plan is defined and is available
on the shop floor.
 Deviations can occur if control limits are
exceeded, and also based on subjective  Main failures are worked using the internal 8D
observations (for example, the power system and documented on the TCM Firewall.
screwdriver is not running smoothly, material
has been funneled into the incorrect chute, or
the associate is not working to the standards
set).
 After stopping the system there needs to be a
well-defined process governing the restarting
of the system.
 The process then has to be released by the
shop floor management.
16 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
2 Andon Cord
 The Andon System
is located at
designated stations
on each line with
separate audible
sounds and light on
for identification.
 GL is first responder
to Andon cord being
pulled.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
3 Instructions

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
3 Instructions

PQIs
(Process and Quality Instructions)

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
3 Instructions
 Requirement  What we do?
 Safety, health, production, and inspection  HSE information is posted on the MOE1 Safety
instructions are complied with. 5S standards Firewall.
are put in place and observed.  Relevent HSE information is posted on each
 The production and inspection instructions are station.
clearly visible at every station.  Production and test instructions are available
 A consistent set of symbols is available, the electronically at each manufacturing line.
right/left hand movement becomes evident  Production and test instructions are derived
from the instruction. from the control plan and PFMEA.
 The error modes from the FMEA and special  Monthly 5S line walks are completed by a
characteristics from the control plan are taken crossfuncational team.
into account.
 5S activities for each line are defined and
 Detailed photos support the process. audited using Layered Process Audits.
 There is a feedback loop in place that ensures
the consistency of the control plan and FMEA.
 Health and safety instructions are carried out
according to the plan. Participation is
compulsory and will be documented.
 All deviations shall be resolved using the 8D
method.
20 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
3 Instructions
 PQIs. Process and
Quality Instructions are
provided for each Process
to achieve desired Quality
along with critical
characteristics.
 All operators are trained to
PQI’s so that the product
maintains consistent
Quality. Training results
are tracked by Work
Station Training Data
Base.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
4 Process Parameters

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
4 Process Parameters

Guidelines

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
4 Process Parameters
 Requirement  What we do?
 The target values/tolerances for all stated  Process parameters are documented in the
process parameters are observed. control plan via a series of guideline
 All process parameters that affect product references.
quality are clearly defined and systematically  Verification of process parameters is
checked on basis of the control plan. completed during intervention activities
 All required inspection criteria are implemented (maintenance, breakdown, or trials) with the
according to specification. process parameter guideline

 Process validations are performed to  Many critical processes must satisfy control
determine whether target values/tolerances of limits for part to be considered good. If
the defined parameters have been observed. process operates outside of programmed
limits, part will be coded bad and cannot be
 Deviations are systematically recorded and processed at subsequent stations.
eliminated.

24 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
4 Process Parameters
 Guideline show the
Technician the
specific settings for
the machine set up.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
5 Test Equipment

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
5 Test Equipment

Gage Calibration

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
5 Test Equipment
 Requirement  What we do?
 Measuring and test equipment is defined, and  Gages are controlled by the AdP Gage Recall
monitoring intervals are observed. System.
 The type of measuring and test equipment and  Gages are not always called out by their
its uses is defined for all processes in the unambiguous name in the control plan.
control plans.
 All measuring and test equipment is calibrated
and only utilized with valid inspection certificate
sticker.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
5 Test Equipment
 All gages and test
equipment are
released after gage
capability is verified.
 Test equipment and
Gages are
controlled through
the Gage Calibration
System .
 Gage Calibration is
performed at a
defined interval.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
6 Check the Checker

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
6 Check the Checker

SU/PY Check (Start up / Poka Yoke Check)

31 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
6 Check the Checker
 Requirement  What we do?
 The “check the checker” principle is applied,  Verifications of poka yoke devices are
and the “checker’s” suitability is ensured. completed according to a plan.
 The suitability of processes used to prevent or  Completion of the verification is covered with
detect errors (e.g. camera-monitored Layered Process Audits at each line.
processes, sensor-based measurements,
inspection processes) needs to be checked
according to a predefined standard.
 Possible errors, such as loading the incorrect
camera software/testing program or improper
sensor calibration, need to be prevented by
carrying out the inspection.
 These inspection processes, as well as
maintenance and set-up processes, need to be
evaluated using appropriate methods (e.g.
FMEA).
 Generally speaking, mistake-proofing is always
preferable to error detection (e.g. Poka Yoke).

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
6 Check the Checker
 Start Up/Poka Yoke
Checks (SU/PY’s)
are performed at the
beginning of each
shift by the
operators.
 If SU/PY fails, a
response plan is
initiated.
 Masters are
controlled in Gage
Calibration System.

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TCM Value Stream
7 Maintenance Standard

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
7 Maintenance Standard

PMs
(Preventive Maintenances)

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
7 Maintenance Standard
 Requirement  What we do?
 A maintenance standard is installed and  TEF3 and MFO technicians own TPM program
observed at every station. utilizing AdP PM System (SAP).
 The four-pillar TPM model, particularly the  PM Work Orders are created for every station
autonomous and preventative maintenance, is in order to define PM instruction and interval.
instituted at every station.  Weekly PM Planning meeting sets a schedule
 This contains both the roles and and technician(s) for each PM Work Orders
responsibilities for production and the that are due for the week.
supporting areas.  Critical delinquent PM Work Order is escalated
 Systematic damage and dirt built-up on for management approval.
machinery and device components need to be  EC (Equipment Coordinator) and LT (Lead
consistently analyzed, recognized, and technicians) review PM Work Orders
remedied. periodically for effectiveness and
improvements.
 Autonomous PM is carried out by OPs.
(Recognition of abnormal condition)
 PQIs define Autonomous PM instruction and
interval. (Pit-Stop)

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
7 Maintenance Standard
Sta 745 Opti Temp Chiller
 SAP PM work order
Tech Planned PM
Frequency: Monthly

Line Name:7000 PM Work Order system is used to


control PM activities.
Station: 745

Duration: .25

WARNINGS: Ensure all movement inside equipment has halted before

 MFO ops and tech


entering.

Reminders (Insure all gages and tool calibration stickers are current)

PPE: (safety glasses)

Required Tools:
are assigned PM
1. Paint brush (clean the fins)

Ref. Drawings, Manuals, ETC…

Resource List/OEM Contact Phone #'s Op Planned PM


work orders with
1. Sam Storey
2. Ken Crompton
3. defined instruction
and interval.
Required Components (OEM Description, OEM#, OEM Name and SAP Material
#'s)
1. Distilled water: F00H.A20.023

Verification Process:

 Autonomous PM is
1.
Freq.
2. Change Dates:
(Annual)
3.
ISO 14001 INFORMATION
E.g., IMMEDIATELY REPORT ANY SPILLS OF ZESTRON LARGER THAN 5 GALLONS TO
SECURITY AT EXTENSION 8922. carried out by OPs
DESCRIPTION OF WORK TO BE PERFORMED

Note: Please evaluate pm on initial completion and note all changes


that should be made on original copy. Please submit all pm changes to
with PQI
lead tech. and engineering for further evaluation.

(Step By Step Instructions) instructions.


1. Check water at sight glass. If below the maximum, add water to
maximum line. If level can’t be seen at sight glass, remove cap and Operator Autonomous PM
look in the tank to check level.
2. Remove cover underneath the controls to clean the fins/coils with
paint brush. Install cover back after cleaning.
for Laser Weld fixture

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
8 Tools Management

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
8 Tools Management

Tool Life
/ Pit Stop
39 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
8 Tools Management
 Requirement  What we do?
 Each tool has a defined service life; the current  Tools are identified in SAP WBS structure and
status must be recognizable. A quality controlled with Crib# system in order to ensure
evaluation must be carried out during removal correct tool are used for correct process.
or disassembly.  Tool service life is defined in time-base,
 The current service lives of all tools have been quantity-base or condition-base.
recorded.  Tool service is controlled with SAP PM
 A warning system promptly displays when workorder or Station PLC system.
tools need to be serviced or replaced.  When service life is achieved, SAP triggers
 Each tool needs to be inspected when techs, or PLC triggers techs/OPs to execute
removed or disassembled to check for defined service work.
damage/ wear and tear.  Completion of tool service is tracked by SAP or
 In case of deviations, it is necessary to follow PLC/TCAR system.
measures to ensure product quality is  Critical product characteristics are verified after
maintained. tool service is complete. (i.e., Destructive
 Restart is performed according to clearly testing, Visual inspection)
defined rules (see Principle 9);
 the standard is regularly reviewed.

40 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
8 Tools Management
 Autonomous
maintenance of the
Resistance weld
electrode change
during a pit stop.
Resistance weld electrode  Pit stops occur
change – Operator Autonomous based off of the
number of parts
produced.
 Technician tool
Leak tester O-ring change
– Operator Autonomous
management is
based off of time
Over mold tool
Management – Tech PM such as weekly or
monthly.
41 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
9 Restart

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
9 Restart

Machine Release

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
9 Restart
 Requirement  The standard also includes the analysis of
critical wear parts (for example, drill bits or
 Restart after disruptions is clearly regulated for welding electrodes).
all machinery and equipment.  Following longer disruptions (e.g. station
 Each disruption to the continuous production upgrade), it is necessary to newly release the
process (set-up, break, shift change, process and carry out a process audit.
maintenance, power failure, upgrade) presents
a potential risk to quality.
 Downtimes can alter process parameters,
workflow sequences may change, and the
 What we do?
consistency of material and supplies can  Machine Release Verification (MRV) is
change. performed at Restart after line disruption.
 A predefined standard for post-restart is  MRV form is completed by responsible
therefore necessary. associate (i.e., techs, DTA) and submitted to
 This should detail how to deal with products in GL for verification.
the process after a disruption.  Upon successful verification, GL restarts the
 All devices have been inspected according to a line.
defined standard for quality risks in connection
with disruptions.

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© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
9 Restart
BOSCH Machine Release Verification
BOSCH Machine Release Verification
Quality Assurance
Quality Assurance
Line:
Line:
Equipment:
OnOff Coil
OnOff Coil

Prosys Welders 1, 2,
 Machine Release
Verification Form
Welders Equipment: 3, & 4
Prosys Welders 1, 2,
Do not run production on welder until all verification steps are completed with Time: Date: / /
positive results.
Welders 3, & 4
Operator Shift: 1 2 3 4 5
Do not run production on welder until all verification steps are completed with Time: Date: / /
Technician Name / WO#

Task done by Tech


positive results. Operator Shift: 1 2 3 4 5
Brief description of repair/maintenance:

completed by
Technician Name / WO#
Brief description of repair/maintenance:

Electrode adjustment/replacement
1 4 2
Electrode adjustment/replacement
Weld Head replacement

technician, GL
1 4 2
3 1 4 2 7 8
Weld Head replacement
Weld Controller and/or transformer replacement
3 1 4 2 7 8
1 2 3 4 7 8
Weld Controller and/or transformer replacement
Weld Head Air Pressure Regulator change
1 2 3 4 7 8

verifies results, GL
3 4 2

Line down
Weld Head Air Pressure Regulator change
Arbor Clamp adjust or replacement
3 4 2
5 4 1 2
Arbor Clamp adjust or replacement
Adjustment or replacement any cylinder on the Arbor clamp tooling

- Andon on
5 4 1 2
5 4 1 2
Adjustment or replacement any cylinder on the Arbor clamp tooling

signs MRV, and


Replacing Valve for one of the outputs
5 4 1 2
6 4
Replacing Valve for one of the outputs
Replacing pallet stop cylinder.
6 4
6
Replacing pallet stop cylinder.
Welder parameter change

then ONLY GL
6
3 1 4 2
Welder parameter change
3 1 4 2

Release Verifications
restarts the line by
initials
oper tech
initials 1 Visually check the alignment between the top and bottom electrodes, replace electrodes instruction PQI
oper tech 2 Pull automated SPC to check three coils for peel & pull per PQI AI472041 - Do NOT resume production until
1 Visually
3 check
Refer the alignment
to process guidelinebetween
for inputthe top and
values and setup
bottom electrodes,
procedure. replace
Check off onelectrodes instruction
all applicable PQI
parameters in

turning light off and


2 Pull
4 automated
Check 10SPC to check
consecutive three
parts fromcoils for for
welder peel & pullweld
correct per placement
PQI AI472041 - Do NOTper
and alignment resume production until
PQI AI472006
3 Refer
5 to process
Check andguideline for input values
verify the alignment and setup
of the clamp to theprocedure.
arbor Check off on all applicable parameters in
4 Check
6 10 consecutive parts from welder for correct weld placement and
Visually monitor the station running for 10 cycles, verify that there are no faultsalignment per PQI AI472006
5 Check
7 and verify the alignment
Pull automated SPC everyofhour thefor
clamp to thetoarbor
four hours check three coils for peel & pull per PQI AI472041
6 Visually
8 monitor
Monitor the station
Vision failures running
(CNC6 W3/W6)for 10 cycles, verify
every hour for that there are no faults
four hours.

instructing line
7 Pull
9 automated SPC every hour for four hours to check three coils for peel & pull per PQI AI472041
8 Monitor
10 Vision failures (CNC6 W3/W6) every hour for four hours.
9
10
GL Sign Off for Release:

associates to start.
GL Sign Off for Release:
GL Sign Off for DTA Complete:

Release Signature
GL Sign Off for DTA Complete:
Instructions:
Check box beside item at the top to be done. Verification step to be done by appropriate person and initial. GL to
Instructions:
Check box beside item at the top to be done. Verification step to be done by appropriate person and initial. GL to

Restart
- Andon
turned off

45 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
10 Labeling

46 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
10 Labeling

Color-coded Tags

47 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
10 Labeling
 Requirement  Products are protected against environmental
influences (e.g. contamination) in line with
 Products and containers are labeled according regulations.
to the set standard.  Red boxes must be secured and inaccessible
 1) No rejected parts in the green box on the production line (either by locking them
 2) No good parts in the red box or placing them at the proper location at the
station; hint: red boxes may be sent unlocked
 3) Rejected parts in the red box from the machine to the analysis station);
 Consistent labeling concept at the production storage at the analysis station or in the
site: collective rejects container only in locked
 a) A white card with a red diagonal stripe boxes.
means: Product blocked;  Containers for rejects must be emptied in line
 b) a green card means: Product after additional with standards and the parts must be
test back in production flow and in good analyzed.
condition;  What we do?
 c) a yellow card means: Product for rework;
 Locked red containers are used to store NOK
 d) a red card means: Product is scrap; modules.
 e) a white card means: Product in good  NOK modules are electronically locked and
condition. cannot be used.
 Filled boxes must always be labeled.  Labeling standards are in place for OK, Scrap,
and Hold parts.
48 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
10 Labeling
 Components, WIPs
and FGs are labeled
Laser marked through out the
Part# process.
GREEN PAN/GOOD Molded Part#
from Supplier  Rejected
components and
WIPs are placed in
proper color coded
ORANGE PAN/HOLD pans.
 NOK parts are
electronically locked
and placed in
Locked Red Scrap
ORANGE PAN/
Container Locked red scrap
SPECAIAL HANDLING RED PAN/SCRAP
container.
49 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
11 Scrap / Rework

50 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
11 Scrap / Rework

Scrap Recode
Person
51 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
11 Scrap / Rework
 Requirement  What we do?
 The handling of rejected parts and those to be  Rework processes are generally not allowed.
reworked is clearly regulated. Those that are in the control plan.
 As a basic rule, rework has to be avoided and  NOK parts (Scraps) are held and coded in a
is only permissible if a respective procedure manner that prevents unintended usage.
exists.  If containment actions outside of normal
 If rework is permitted the following conditions processes are initiated, the concession
must be met: an FMEA and a control plan for process is used.
reassembly and reintroduction exist,  Risk is assessed for containment actions.
 rework takes place on the original assembly
line,
 rework is limited in time.
 If the rework process is permanently required,
this must be transferred to a standard process
that is approval by GB/QM.
 Scrap must be disposed of in line with the
standard and unauthorized further use of these
products must be prevented (for example, by
destroying them.)

52 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
11 Scrap / Rework
Scrap Transaction at GL desk  Scrap and Hold
parts rejected from
processes are
collected by SRP
and transferred to
GL desk which has
Scrap / Hold pan
system.
 Once SRP
completes scrap
transaction, scraps
are placed in
Locked red scrap
Locked Red Scrap Container
container.
53 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
12 Fallen Parts

54 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
12 Fallen Parts

Dropped Parts

55 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
12 Fallen Parts
 Requirement  What we do?
 Any products that fall on the floor, into the  All dropped parts are scrapped.
machine or cannot be classified must be  The number of dropped parts is tracked using
scrapped. the scrap system. This system can be
 Each individual employee must adhere to this systemically analyzed to determine
standard regardless of what part of the improvement activities.
organization he/she belongs to or his/her
position within the company.
 The shop floor management must be notified.
 The products must be scrapped according to
procedure.

56 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
12 Fallen Parts
 All parts dropped
past the working
surface are scrap!
No exceptions.
 Parts or
Working Surface components that are
on the floor are to
be placed in the red
scrap bins for GL or
SRP

57 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
13 Correct Product

58 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
13 Correct Product

Change-over
Blue Light
59 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
13 Correct Product
 Requirement  What we do?
 Only the correct product may be provided for  Components for multiple part types are not
removal and assembly. generally stored on the line at the same time.
 Only the correct product may be available to  Change over process is standardized to
the associate at the time of assembly. replace correct parts being presented to the
 All other variants or versions that are stored at affected stations.
the assembly station must not be accessible to  Change-Over Blue Light initiates and indicates
the employee. change over in progress.
 It is furthermore necessary to ensure, across  Incorrect components are blocked. Only
the entire logistics chain, that only the correct correct component is accessible by operators.
product is retrieved or available.  Incorrect components are also detected by
Poka-Yoke (Error Proof).

60 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
13 Correct Product
 Change-Over Blue
Light initiates and
Incorrect components are indicates change
blocked and not accessible over in progress.
 Incorrect
components are
blocked. Only
Change-Over Blue Light
correct component
is accessible by
operators.
 Incorrect
components are
Only correct component is also detected by
accessible
Poka-Yoke (Error
61 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
Proof).
TCM Value Stream
14 Remaining Items

62 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
14 Remaining Items

Change-over
Racks
63 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
14 Remaining Items
 Requirement  What we do?
 The handling of remaining items/ quantities is  Standards are in place to handle remaining
clearly regulated. items in accordance with these criteria.
 Remaining quantities must be clearly labeled  Remaining parts are labeled with Green Tag.
and stored securely (using the accompanying Lot/Date code and process information are
card/on the correct shelf). documented on the tag in order to sustain
 The “First In, First Out” principle must be FIFO.
observed.  Remaining parts are stored in Change-Over
 Close attention must be paid to ensure tidiness Racks designated by each line and process.
and cleanliness as the goods have yet to be  Change-Over Racks are designed to protect
placed in the final packaging. parts during handling and storage.
 Maximum storage times must not be  Part exceeded maximum storage time is
exceeded. processed according to standardized
 The quantity of remaining items must be taken procedure.
into consideration with regard to engineering
change requests.

64 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
14 Remaining Items
Remaining TCUs  Changeover (C/O)
racks are used to
store part types that
are not currently
running on line
Remaining TCMs  Remaining parts are
stored in Change-
Over Racks.
 Remaining parts are
labeled with Green
Tag.
 Part exceeded
Remaining HMs and EMs storage time follows
special tag process.
65 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
Display Board Printing Instruction
 ln order to maintain consistency, all slides must be printed with
following print options.

66 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016


© 2016 Robert Bosch LLC and affiliates. All rights reserved.
THANK
YOU

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