Valeo 5000, what is "quality auto-matrix"

I recently received a question from a Cover as to what is "quality auto-matrix".
It appears that it comes from the Valeo 5000 standard.
Help any one?

Yes Howard,
I am former qualiticien of Valeo and I can help you:
the auto-quality matrix is a system to trace along the production process where the defect is caused and where the defect is detected.

The scope is clear: the defect must not be passed to the following steps of the process.

The control chart is the following:
1. List both on the columns and rows the process phases and/ or workstations
2. Colour the "union cells" in which the same phase on the column and on the row meets
3. You will have a diagonal that separate the graph in two parts. The lower one is of course useless.
4. Record on this chart all the non-conformities generated along the process in this way:
choose the phase where the defect is caused on the X-axe and the phase where it's detected on the Y-axe and record in the corresponding cell a very brief description of the non-conformity (5W2H or something shorter, or even a code, if defects are classified).
5. After a while, you will be able to see in just a glance how many defects are on the diagonal cells (so they are stopped where they are born) and how many are over it (so they are discovered later).
6. It's important to show the evolution over time: i.e. by using the same panel and changing ink colour each week or month, or showing the previous and the current panel side by side.

The implementation method is the same of the other V5K quality tools:
1. Choose a line or a production unit (P)
2. Open a "workshop" on it by training and motivating people to use the tool. (D)
3. Put a big panel with the over mentioned chart in the "5' meeting area" of the line. (D)
4. Check the correct usage of the tool and if the situation improves (C)
5. Involve people from other lines/ P.U. in order to convince them it's a tool worth using. (A)

It must be admitted that this method has been developed 100% by Valeo quality people.

Hope this helps
Gianfranco

Thanks a lot.

Is it an effective tool?

To be honest, I never had the chance to test it, I have only seen a workshop running in a Valeo Italian plant.
Furthermore, people from that line were in training at the time and no result had been achieved yet.

Generally speaking, I think that tool could be useful in long and complicated processes, in which several units are involved (subcontractors, different lines or plants etc.)

Former Valeo manufacturing engineer here.

In my opinion, the AQM was an extremely effective tool for new product lines or new workcells/assembly lines where you’re still working out the buts. It really helped us to figure out where additional error proofing was needed, and showed the harmful effects of letting bad product get too far downstream.

Part of the key here is that when you mark a reject on the AQM chart, you also place a reject tag on the part with a number (i.e. 10-30 means defect caused at station 10, found at station 30) and collect all the rejects in one location. This allows the engineers to go back and see what kinds of defects are being produced.

Once the product/cell has matured, the AQM is basically useless. You’re getting only a few defects a day; they’re ones you’ve known about for months now, and it’s not telling you anything new.

If you need any more info, I’d be glad to help.

a example wanted

dear everyone:
thank you for all of your answers!!
I am very interesting in AQM and I am going to start my new job in a Valeo plant in China,would you show me a detailed example if itis convenient to you?

thanks Howard to post the topic here

Here's a quick example of an AQM. What you see in China might be a slightly different format, but the basics are the same. The grey boxes reflect the fact that you can't find a defect before it happens. Each time an operator finds a no good part, they will put a tick mark in the appropriate box. For example, if the bearing press created a bad part, and it was discovered at the packing station, the tick goes in the top right box.

As a note, while the primary objective is to eliminate manufacturing defects altogether, the second goal is to get all the tick marks in the boxes with bold outlines - this means that each defect is found at the station where it was created, preventing the bad part from getting further downstream and causing more waste.

Our example tells us the following: We really need to fix station 20 because it builds a lot of rejects. We also need to increase defect detection at station 20, because the defects are moving downstream and having more parts added before the bad part is scrapped. The same holds true for station 10, to a lesser extent.

Please note, as I said before, it's important to have the operators label the bad parts so the engineers can see WHAT rejects are being generated. I've seen this done using an AQM cart, which is a cart with compartments set up just like the matrix. The operator just drops the bad part into the appropriate compartment. That works really well for building small components but if you were making something large, like a dashboard, it becomes impractical - the cart would have to be huge!

Valeo 5000, what is "quality auto-matrix- Examples

Can anyone forward some good examples of this tools. It seems very effective document.

thanks a lot

thank you jmp4429:
your reply really helpful and is much appreciated
i think it works

Hello,

Could you please share with the V5000 check list audit ?

Thank you