14 Quality Principles
for the Value Stream
Q-Basics Value Stream
Version 1.2
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Q-Basics Value Stream
Principle 1
Customer complaints are communicated
within the production site and displayed at
the station in question. Using problemsolving techniques, they are processed in
a fast and systematic manner. IPN
production sites are promptly informed.
Q-Basics Value Stream
Principle 1
A STOP sign process with all of the 8D elements is
displayed on the shop floor. A standard review process
involving the production management and quality
management takes place. The decision to end the STOP
sign process is taken by production management after a
review of the measures’ effectiveness.
It is necessary to ensure that customer complaints are
communicated quickly within all IPN value streams.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
8.5.2
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.3.1, 6.5.3, 7.4
Q-Basics Value Stream
Principle 2
In the event of deviations in quality or if control limits are
exceeded in the value stream (source, make, deliver),
the employee needs to stop the process and escalate.
Q-Basics Value Stream
Principle 2
There is a system (e.g. Andon cord) in place that allows
the operator, if he notices deviations, to choose to stop
the process and notify his supervisor immediately.
Deviations can occur if control limits are exceeded, and
also based on subjective observations (for example, the
power 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.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
8.3
Process audit: Mapping to VDA 6.3 (2010)
6.3.1, 6.2.2
Q-Basics Value Stream
Principle 3
Security, health, production, and inspection
instructions are complied with. 5S standards
are put in place and observed.
Q-Basics Value Stream
Principle 3
The production and inspection instructions are clearly
visible at every station. A consistent set of symbols is
available, the right/left hand movement becomes evident
from the instruction. The error modes from the FMEA
and special characteristics from the control plan are
taken into account. Detailed photos support the process.
There is a feedback loop in place that ensures the
consistency of the control plan, FMEA, and directions.
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.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
For HSE and 5S: 6.4, 6.4.1, 6.4.2
For production and inspection instructions: 7.5.1, 7.5.1.2
Process audit: Mapping to VDA 6.3 (2010)
6.4.3, 7.4
Q-Basics Value Stream
Principle 4
The target values/tolerances for all stated process
parameters are observed.
Q-Basics Value Stream
Principle 4
All process parameters that affect product quality are
clearly defined and systematically checked on basis of
the control plan. All required inspection criteria are
implemented according to specification. Process
validations are performed to determine whether target
values/tolerances of the defined parameters have been
observed. Deviations are systematically recorded and
eliminated.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.1, 7.5.1.1, 7.5.1.3, 8.1, 8.2.4
Process audit: Mapping to VDA 6.3 (2010)
6.2.2
Q-Basics Value Stream
Principle 5
Measuring and test equipment is defined, and
monitoring intervals are observed.
Q-Basics Value Stream
Principle 5
The type of measuring and test equipment and its
uses is defined for all processes in the control plans.
All measuring and test equipment is calibrated and
only utilized with valid inspection certificate sticker.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.6, 7.5.1.1
Process audit: Mapping to VDA 6.3 (2010)
6.4.2
Q-Basics Value Stream
Principle 6
The “check the checker” principle
is applied, and the “checker’s”
suitability is ensured.
Q-Basics Value Stream
Principle 6
The suitability of processes used to prevent or detect
errors (e.g. camera-monitored 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, mistakeproofing is always preferable to error detection (e.g. Poka
Yoke).
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
8.2.3.1, 8.5.3, 7.6.1
Process audit: Mapping to VDA 6.3 (2010)
6.4.2, 4.7, 6.3.2
Q-Basics Value Stream
Principle 7
A maintenance standard is installed and
observed at every station.
Q-Basics Value Stream
Principle 7
The four-pillar TPM model, particularly the
autonomous and preventative maintenance,
is instituted at every station. This contains
both the roles and responsibilities for production
and the supporting areas. Systematic damage
and dirt built-up on machinery and device
components need to be consistently analyzed,
recognized, and remedied.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.1.4
Process audit: Mapping to VDA 6.3 (2010)
6.4.1
Q-Basics Value Stream
Principle 8
Each tool has a defined service life; the current
status must be recognizable. A quality evaluation
must be carried out during removal or disassembly.
Q-Basics Value Stream
Principle 8
The current service lives of all tools have been recorded.
A warning system promptly displays when tools need to
be serviced or replaced. Each tool needs to be inspected
when removed or disassembled to check for damage/
wear and tear. In case of deviations, it is necessary to
follow measures to ensure product quality is maintained.
Restart is performed according to clearly defined rules
(see Principle 9); the standard is regularly reviewed.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.1.5
Process audit: Mapping to VDA 6.3 (2010)
6.4.1
Q-Basics Value Stream
Principle 9
Restart after disruptions is clearly regulated
for all machinery and equipment.
Q-Basics Value Stream
Principle 9
Each disruption to the continuous production process (set-up,
break, shift change, maintenance, power failure, upgrade)
presents a potential risk to quality. Downtimes can alter process
parameters, workflow sequences may change, and the
consistency of material and supplies can change. A predefined
standard for post-restart is therefore necessary. This should
detail how to deal with products in the process after a
disruption. All devices have been inspected according to a
defined standard for quality risks in connection with disruptions
(for example, an unplanned disruption to the welding process,
the injection molding process stops unexpectedly, a product
remains in thermal treatment for too long, the silicone bead is
exposed to the air for too long). The standard also includes the
analysis of critical wear parts (for example, drill bits or welding
electrodes). Following longer disruptions (e.g. station upgrade),
it is necessary to newly release the process and carry out a
process audit.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.2, 7.5.1.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.2
Q-Basics Value Stream
Principle 10
Products and containers are labeled
according to the set standard.
Q-Basics Value Stream
Principle 10
The following criteria must always be adhered to:
- No rejected parts in the green box
- No good parts in the red box
- Rejected parts in the red box
- Consistent labeling concept at the production site:
A white card with a red diagonal stripe means: Product blocked;
a green card means: Product after additional test back in
production flow and in good condition; a yellow card means:
Product for rework; a red card means: Product is scrap;
a white card means: Product in good condition.
- Filled boxes must always be labeled.
- Products are protected against environmental influences
(e.g. contamination) in line with regulations.
- Red boxes must be secured and inaccessible on the
production line (either by locking them or placing them
at the proper location at the station; hint: red boxes may be sent
unlocked from the machine to the analysis station);
storage at the analysis station or in the collective rejects
container only in locked boxes.
- Containers for rejects must be emptied in line
with standards and the parts must be analyzed.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.3
Process audit: Mapping to VDA 6.3 (2010)
6.1.4, 6.2.5
Q-Basics Value Stream
Principle 11
The handling of rejected parts and those
to be reworked is clearly regulated.
Q-Basics Value Stream
Principle 11
As a basic rule, rework has to be avoided and is only
permissible if a respective procedure exists. If rework
is permitted the following conditions must be met:
- an FMEA and a control plan for reassembly
and reintroduction exist,
- 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;
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.)
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
8.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5
Q-Basics Value Stream
Principle 12
Any products that fall on the floor,
into the machine or cannot be classified
must be scrapped.
Q-Basics Value Stream
Principle 12
Each individual employee must adhere to this standard
regardless of what part of the 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.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
8.3.1
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5
Q-Basics Value Stream
Principle 13
Only the correct product may be provided
for removal and assembly.
Q-Basics Value Stream
Principle 13
Only the correct product may be available to the
associate at the time of assembly. All other variants
or versions that are stored at the assembly station
must not be accessible to the employee.
It is furthermore necessary to ensure, across the
entire logistics chain, that only the correct product
is retrieved or available.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.3
Process audit: Mapping to VDA 6.3 (2010)
6.2.1, 6.2.5
Q-Basics Value Stream
Principle 14
The handling of remaining items/
quantities is clearly regulated.
Q-Basics Value Stream
Principle 14
Remaining quantities must be clearly labeled and
stored securely (using the accompanying card/on the
correct shelf). The “First In, First Out” principle must be
observed. Close attention must be paid to ensure
tidiness and cleanliness as the goods have yet to be
placed in the final packaging. Maximum storage times
must not be exceeded. The quantity of remaining items
must be taken into consideration with regard to
engineering change requests.
System audit: Mapping to ISO/TS 16949:2009 (ISO 9001:2008)
7.5.5.1
Process audit: Mapping to VDA 6.3 (2010)
6.1.2
Q-Basics Value Stream
14 Quality Principles
for the Value Stream
Q-Basics Value Stream
Responsible for the content: C/QM