ACTS System Management - ACE

1 1 AchievingCompetitiveExcellenceThe ACTS Operating SystemQuality Manager: Willis Huang2 Non - Visible5-8 % of SalesVisible2-3 % of SalesHidden?The Cost of Poor Quality Iceberg Engineering Changes Recurring Service Bulletins Recurring Engineering Notices Extra Set-ups Long Cycle Times Non-Contractual Warranty Expediting Costs Late Delivery Charges Excess Inventory Supplier QualityLost CredibilityLost SalesWarranty, Scrap,Escapes, Rework,Repair, Extra InspectionLost Customer LoyaltyACE Fosters a Quality Mindset3 Achieving Competitive Excellence to: provide products and services that are 100% defect-free. do work that adds value to the company. partner with customers and execute flawlessly, so they are delighted andkeep coming back. be a great place to work! Financial PerformanceQuality Processes & Products Employee FulfillmentCustomer FocusACE is the UTC operating System well adopted in ACTS 4 What is an operating System ?.. defines our daily Management has three elementsculture ( humanware )set of tools ( hardware )competencyAchieving Competitive Excellence has,a Culture;a set of Tools; andthe Competency to implement the culture and the tools in everything that we do.

2 5 CustomerACE - CultureIdentify gaps & execute RRCAD efine MetricsEstablish vision, Strategy & goals Powered by the disciplined application of ACE toolsfor Process improvement and waste elimination Problem solving Decision making Powered by the disciplined application of ACE toolsfor Process improvement and waste elimination Problem solving Decision makingMonitor ProgressCustomers define our QualityDrives relentlessly to close gaps between actual results and ACE Culture we Identifying opportunities to improve Solving problems Sustaining continuous improvement7 ACE The HardwareProcess Improvement and Waste EliminationNew 5S (visual workplace) + Safety (6S)Value Stream Management Process Control & CertificationStandard WorkProduction Preparation Process (3P)Total Productive MaintenanceSet-up ReductionProblem Solving (DIVE process)Market Feedback AnalysisQCPC (Quality Clinic Process Charts)Relentless Root Cause AnalysisMistake ProofingDecision MakingPassport ProcessThe 12 ACE tools8 The Quality Model9 Description of 6S (UTC s New 5S)6S1.

3 SafetyPrevent / control hazards2. SortEliminate what is not needed3. StraightenOrganize what remains4. ShineClean work area5. StandardizeSchedule cleaning and maintaining6. SustainMake 6S a way of lifeCreating workplace efficiencyImproving morale10 Drawer UnitAttached ToMachineItems RequiredFor NormalOperation6S Establishes the Foundation forWorkplace OrganizationPoint-of-useTooling11A roadmap to quality products and processesDefinition of Quality Clinic Process Charts(QCPC)QCPC encompasses a simpletool used to continuously analyze a process for quality improvement opportunities and process inefficiencies, called turnbacks .12 What Are QCPC Turnbacks?Any situation that hinders the flow of work. Turnbacks include any inefficiency in the example: Priority and plan changes Re-design / Re-work / Re-do Miscommunication Incorrect data and information Equipment and computer problems Software discrepanciesReporting turnbacks gives all employeesa voicein process improvement13 Determine yourgreatest opportunityMap process andidentify turnback pointsApply an ACEP roblem Solving Strategy to investigate andeliminate root causePPDP(Detail Level Map)PMT / IPTE ngineeringConfigurationManagementProduce rAssy & TestQualityCollect and summarizeturnback data atestablished intervalsHow QCPC WorksTotalStep 1 Step 2 Step 3 Step 4 Step 5 Step 6 Week 1 Week 2 Week 314 Definition of Relentless Root Cause Analysis (RRCA)The rapid and persistent pursuit of the fundamental breakdown or failure of the process that, when resolved, prevents a recurrence of the RRCA WorksUtilizes a variety of strategies and tools to.

4 Define the problem, Investigate probable root causes, Verify what is the actual cause, and Ensure a mistake-proof of Mistake ProofingUsing wisdom and ingenuity to provide methods and devices that allow you to do your job 100% defect-free, 100% of the for Effective Mistake Proofing Minimal cost Simple to use Easy to install Durable Easy to maintain Does not hinder operator / user Foolproof18 ACE - CompetencyCompetency is built throughEducation - Ito University - ACE training - Operations Transformation Leader curriculum - High-impact ACE teams - Doing: experience in many improvement activitiesSharing of best practices - Benchmark19 Levels of ACE CompetencyImproved PerformanceStep-change in Business PerformanceBaseline Customer expectations quantified Performance baselines and gaps identified Savings demonstrated from waste eliminations Measurable improvements in key customer deliverables achieved Business results positively impacted Significant business performance improvement targets set for Silver Business performance targets for Silver sustained Stretch business performance goals set for GoldDelighted Stakeholders Best-in-class customersatisfaction and businessperformanceACE SilverACE GoldACE BronzeACE Qualifying20 ACTS Performance Trend Performance05101520252003200420052006200 72008 PlanYear02004006008001000120014001600 SalesEscape PPM21 Summary ACE is a continuing journey The ACE Elements are the foundation ACE provides powerful strategies and

5 Tools to improve business results ACE uses achievement levels to recognize quality improvements and business results ACE can involve and empower every employee22 Thank You!Quality Manager: Willis Huang