QRQC imlementation
Our team of experts supports your supplier in the implementation of quick response quality control (QRQC-Quick Response Quality Control), which is a simple method of continuous improvement for quality control used in companies that need to manage their processes and solve difficulties quickly.
Troubleshooting> QRQC implementation
WHY IMPLEMENT A QRQC SYSTEM AT YOUR SUPPLIER?
QRQC is an approach that aims to provide a rapid response to quality problems in manufacturing using a two-way scaling process.
It is based on taking the first step of solving quality problems to the point of occurrence, that is, to the production line.
The line operator together with the supervisor must try to solve the problem. If this is not possible, the problem is pushed “upstream” where a multidisciplinary team of engineers and managers analyze the problem in detail and determine the solution. For this reason, QRQC is usually proposed as an approach with at least two events:
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QRQC in real time
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QRQC Meetings
The objectives of the QRQC are:
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Prevent any defective or problematic items from moving down the production line.
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Achieve rapid resolution of problems (between 1 day and a week). Have accurate information and data about the problem that have been taken directly from the point of occurrence.
More than just a problem-solving method, it consists of a work system and a way of understanding how the organization should act in a comprehensive way.
As a consequence of this, QRQC has a philosophy and fundamental concepts on which it is based and which is interesting to keep in mind to internalize this approach and be able to put it into practice successfully.
HOW DOES QRQC WORK?
The method is based on a cycle similar to the PDCA Cycle (Plan, Do, Control and Act), where incidents are first detected, communicated and studied, then corrective measures are implemented and finally it is verified that there is no recurrence. The QRQC consists of 3 levels of monitoring:
First level: closest to the field; QRQC team/cell/line.
The cause of the problem is sought with “the field knowledge of those who do it.” It is not intended to apply elaborate problem-solving methods. The meeting should last 20 minutes maximum. If the problem is not eradicated within the allotted time the problem is escalated to the next level.
Second level: QRQC / UAP (Autonomous Production Unit) workshop / service.
At this level, support functions are associated (quality, process, etc.) to the second-level unit manager and a first-level team representative (coordinator/leader/supervisor, etc.). Problem solving tools such as 5 Why or 5W2H are used. If the problem is still not resolved, if it involves multiple areas, or requires additional resources that are not decided together, the problem is elevated to the next level.
Third level: factory/QRQC site.
The logic is the same as in level 2. A structured and dynamic management and training system.
The UAP workshop or supervisor is responsible for training field team leaders or supervisors (level 1) in a daily review.
The production manager is responsible for training shop floor managers (level 2) during a weekly review.
The plant manager is responsible for training the production manager during a weekly review.
WHICH ARE THE BENEFITS?
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Empowerment and development of team autonomy.
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Time savings for management: less meetings and actions implemented by teams autonomously.
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A development of a culture of continuous improvement.
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Fact-based management.
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Long-term monitoring through a formalized review process.
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ncreased reactivity by treating abnormalities as soon as they appear.
