Anzen sengen Audit of
Honda
Anzen sengen is Japanese term, which stand for “We Are Ready”. Anzen is Japanese word, meaning safety. So this is safety stock verification audit of new model.
Audit is about mass production preparation check. In this
audit safety stock verification is done for initial mass production. This audit
is about overall review of project readiness before mass production.
Verification of Production preparation, BOP procurement, equipment readiness,
line run and quality check is done in this audit.
Audit is done as per Anzen sengen check sheet. But Honda
team also verifies supplier readiness for model, for which they usually review
through supplier PPT, actual Gemba check and Quality verification of part.
What is Purpose of
Anzen sengen audit?
Purpose of anzen sengen audit is “Mass production declaration”. Vendor top management (QA responsible
person) signed on Angen sengen check sheet. Joint signature with Honda team is
also done on evaluation sheet of Anzen sengen sheet after this audit.
Vendor declares to Honda Company that they are ready for
mass production of model XYZ.
Anzen Sengen Audit
Requirement
The following requirements have to be fulfilled for this
audit and the record of those requirements has to be shown in a Anzen sengen
audit PPT.
- Purpose
- Part Details in model
- Change w.r.t existing model
- Design changed summary
- Product details (With exploded views-New and common child
part details) - QAV step 2 ~ step 5 observation & closure status
- 200parts/2hrs status
- Tooling status (Tooled Up part details, Tooling P/A,
Preventive plan) - Equipment, Jig Fixture details
- Assy Line PPM plan & Capacity confirmation
- Fixture spare part list
- PRS, Jig Fixture maintenance Plan
- Control Documents (PQCT, PFMEA & OGS)
- Supply Plan- Packaging standard, Bin calculation, Supplier
PPAP - Line Layout and manpower requirement
- OTP, Operator Skill Level
- Kakotota
- Zenbara Observation Status
- Inspection standard
- Spec test status
- MQC
- Design change control summary
- Lot Control
- Event Status
- Event Wise Observation & Status
- Safety Declaration
- Mass Production planning
Let’s
understand each of the above mentioned points:-
Purpose is mass
production declaration. Safety stock verification and mass product readiness check.
Part details in model–
Here details like- Part no, part name, part photo, and design no has to
mention. Details like new or existing to be added. We can also add exploded
view of parts using hyperlink in PPT.
Change with respect to existing model:- Here change point to be mentioned. What child
part is change with respect to existing model has to be added in details.
Design change summary:-
Here all parts design no with latest revision has to be mention. Here not only
latest revision added but also previous revision including red pen drawing
number.
QAV step2~step5 Audit
observation and closure:- Here we have to add details of all QAV audits.
For QAV 2 step5 audit we have to show closure of audit observation. We can add backup closure pictures using
hyperlink in PPT.
200parts/2hrs trial
status:- Here we have to show audit check sheet of 200parts/2hrs trial.
Observation and closure report has to be added in details. Also result also to
be mention, what was output of the trial, was it successful?
Tooling status:- Here in tooling status we have to show
completion details of tooling –mold tool, sheet metal tools, jig fixture tools,
inspection tools. We also have to add details like- What is tool maturation
status or level of tool right now, Plan vs Actual status of tool preparation
and preventive maintenance plan of tool, jig fixture to be added in PPT.
Equipment and Jig
Fixture details:- Here we add details like- total no of equipment used in
new model, process wise equipment picture, equipment condition, jig fixture
picture to be added.
Assy. line PPM plan
and Capacity confirmation:- Here process wise capacity details to be added,
completed capacity plan to be inserted in PPT. Also assembly line PPM details
to be added in that Honda capacity sheet.
PRS and Jig fixture
maintenance plan:- PRS stand for process realization schedule. Here we add
details like-process maturation status, training status, jig fixture readiness
status, jig fixture accuracy status, line trial status, observation and closure
status and line maintenance status. In PRS we also add details of control
document readiness, documents like- PQCT, OGS, PCC, P chart and Q chart on
assembly line.
Supply Plan:- In
supply plan we add details like- route to supply to Honda, Bin and trolley
readiness, Packaging approval details, storage and transport details to be
added.
Line Layout and Manpower training plan:-
Here we add details of assembly line layout and manpower requirement as per
process. Training plan, manpower training status to be added. Operator skill
level to be added.
Kakotora:-
Kakotora meaning is past defect learning (Technical Know How). It is the sheet
in which previous defect faced in similar model are listed and countermeasure
for those defect is also mention. In anzen sengen kakotora sheet along with its
verification to be added in details.
Inspection Standards:-
Here we show inspection standards for part and child parts are prepared and on
part production and movement inspection will be done as per inspection
standards.
Spec Test status:-
Well here we show DV and PV lab test status. All durability and specification
testing is done as per plan.
Mass production
preparation:- Here we add material procurement plan. Imported procurement
plan. Ram-up production plan. Current status of child part and inventory of
child parts at their location.
Well these are details that are added in Anzen sengen audit.
After this Gemba audit is done just for verification of details. Later this
closure sharing and summary is prepared.
What industry should do
for smooth mass production of new model?
Here are few things that need to do for smooth mass
production of new model.
- Line trails should be completed
before customer mass production trail. - Line QAV audit should be completed
- 200parts/2hrs trial (LPVT) should
be completed. - Child parts PPAP should be
completed 2 month before customer mass production. - PPAP of all process (Paint,
printing, Mold, Tool PPAP) should also be completed & approved. - Now PPAP should be approved and
move to their location. Here location mean-PPAP file with its document No.
should move to its area, where it can be review if required. Example- Child
part PPAP will move to RQC area, because in mass production all child part will
come in RQC. Painting PPAP will move to Paint shop. - Parts storage area should be fixed
and location should be fixed in supermarket. - Bin & trolley should be available with tag
and Number on assembly line
This all about mass production declaration of new model.
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