Notes on the Project Dossier: Risk Evaluation Using the 8D Approach at YAZAKI

Context of the Project

  • University: Sidi Mohammed Ben Abdellah, Faculty of Science and Technology

  • Master's Thesis Title: Evaluation of Component Risks through the Adoption of the 8D Approach

  • Summary: Conducted at YAZAKI TANGER to identify and analyze potential risks associated with wiring components to minimize quality issues.

Introduction to YAZAKI and the Project

  • YAZAKI Corporation: Global leader in automotive wiring and components, established in Japan in 1929.

  • YAZAKI Morocco: Established a production unit in Tangier in 2000 focused on automotive wiring.

  • Project Objective: Evaluate risks associated with components to enhance product quality using the 8D methodology which addresses root causes of issues.

8D Methodology Overview

  • 8D Stages:

    • Action 1: Prepare the 8D Process - Form an interdisciplinary team.

    • Action 2: Describe the Problem - Clearly state the problem and its impact.

    • Action 3: Implement Immediate Actions - Contain the problem temporarily.

    • Action 4: Identify Root Causes - Utilize tools like the Ishikawa Diagram and AMDEC.

    • Action 5: Validate Permanent Solutions - Ensure solutions address the root causes effectively.

    • Action 6: Implement Corrective Actions - Develop a plan for execution.

    • Action 7: Prevent Recurrence - Standardize effective solutions.

    • Action 8: Recognize Team Efforts - Acknowledge contributions to motivate stakeholders.

Risk Evaluation Process

  • Diagnostic and Problematic Identification: Use historical data to classify observed anomalies in component risks, employing analysis tools such as Pareto diagrams for prioritization.

  • Root Cause Identification: Implement Ishikawa diagrams and AMDEC to analyze and validate different potential causes of components' issues.

Common Risks Identified

  1. Material Shortages: Caused by supplier errors or production misalignment.

  2. Excessive Material: Can be attributed to supplier issues as well, creating discrepancies in component quality.

  3. Deformation: Occurs from improper handling or faulty production processes.

  4. Non-Functional Relays: Cannot be detected until later stages and lead to significant quality issues.

  5. Missing Parts: Introduced mainly during the assembly phase under high-pressure environments.

AMDEC: Failure Mode and Effects Analysis

  • Purpose: Identify and evaluate potential failures in components, assessing their impact and detection chances to improve overall reliability.

  • Process:

    • Assess each mode of failure based on occurrence frequency, non-detection probability, and severity affecting production.

    • Create a risk priority number (RPN) by multiplying these three factors (RPN = Occurrence x Severity x Detection).

Corrective and preventive actions

  • Corrective Action Examples:

    • Improved inspections of components.

    • Enhanced storage procedures to prevent damage.

    • Continuous monitoring of supplier deliveries for critical components.

  • Preventive Measures:

    • Implement standardized operating procedures for all phases from storage to production.

    • Develop training programs focusing on quality checks and problem resolution techniques for operators and staff.

Conclusion

  • Expected Outcomes: The project aims to create a systematic approach to evaluate and mitigate risks in component quality that supports YAZAKI's mission to maintain high standards in their production.

  • Methodology Impact: The adoption of the 8D methodology has been instrumental in understanding and resolving issues comprehensively, thereby enhancing the overall operational quality.

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