The Complete Guide to the QRQC Method

Introduction

The QRQC method, or Quick Response Quality Control , is a systematic and proactive approach to quality management, developed to quickly identify and resolve problems in production. It is distinguished by its speed of execution, its ability to involve all levels of a company and its focus on immediate action. Used in many industries, this method aims to reduce non-conformities, improve overall performance, and strengthen responsiveness to malfunctions. Faced with changing quality requirements, QRQC has become an essential tool for any organization wishing to maintain a high level of competitiveness.

The principles of QRQC

The QRQC method is based on several key principles that make it unique and effective in managing quality issues:

Speed ​​and responsiveness:

QRQC requires an immediate reaction as soon as a problem is detected. This means not letting defects accumulate, but dealing with them in real time to minimize their impact.

Collaborative work:

The method mobilizes multidisciplinary teams. All stakeholders, from operators to managers, are involved in identifying and solving problems, thus strengthening cohesion and collective responsibility.

Immediate problem solving:

Unlike traditional quality control methods, which can be reactive and slow, QRQC focuses on quickly correcting defects at their source.

Continuous improvement:

The QRQC not only corrects current problems, it also seeks to prevent their recurrence through an in-depth analysis of root causes and the implementation of sustainable solutions.

The steps of the QRQC process with the 8D method

The 8D (8 Disciplines) method is often integrated into the QRQC process to structure the resolution of complex problems. This eight-step approach allows for a deep analysis of a defect and the implementation of effective corrective solutions. Here is how it is structured within the framework of QRQC:

• D1: Team formation
  A multidisciplinary team is quickly formed to deal with the problem. It brings together all the skills necessary for effective analysis and resolution.

• D2: Description of the problem
  The team identifies and documents the problem precisely, including details about the nature of the defect, its impact, and the circumstances in which it occurred.

• D3: Immediate actions (contain the problem)
  Temporary actions are being implemented immediately to isolate the problem and limit its impact on production. These measures allow operations to continue while minimizing risks.

• D4: Identification of root causes
  This step focuses on deep analysis of the problem to determine the root cause. Tools like 5 Why or Ishikawa diagram are used to explore all potential sources of the defect.

• D5: Definition of permanent corrective actions
  Once the root cause is identified, the team defines lasting corrective actions to permanently eliminate the problem.

• D6: Implementation of corrective actions
  Corrective actions are put in place, involving operators and changing processes if necessary. This ensures that the problem will not happen again.

• D7: Prevention and continuous improvement
  The team evaluates the actions implemented and ensures that they work in the long term. This step also includes documenting lessons learned to prevent similar problems in the future.

• D8: Celebration of results
  Once the problem is solved and validated, it is important to recognize the team's efforts and celebrate the results. This reinforces motivation and commitment to continuous improvement processes.

Tools used in QRQC

To ensure the effectiveness of the QRQC process, several tools are used to structure the analysis and resolution of problems. Here are the main ones:

5 Why (5 Pourquoi) :

This simple but powerful tool allows you to get to the root causes of a problem by successively asking the question "Why" until you identify the root of the defect. It allows you to go beyond the visible symptoms to treat the real causes.

Ishikawa diagram (or cause and effect diagram) :

Also called a fishbone diagram, it helps organize the possible causes of a problem into categories (material, method, labor, etc.), making analysis easier.

Gemba Walk :

This is an approach that involves going into the field (Gemba) to directly observe operations and understand the problem in real conditions. This is a key principle in QRQC, which emphasizes a practical understanding of the problems.

Checklists and analysis sheets:

These tools help standardize the information collection process and ensure that all steps of the QRQC process are followed.

These tools, used together, facilitate the identification of root causes and the development of lasting corrective solutions.

Advantages of QRQC

Adopting the QRQC method brings several benefits for industrial and manufacturing companies:

Reduction of non-conformities :

Immediate response to defects helps limit losses and prevent the recurrence of the same problems. By addressing defects as soon as they appear, non-conformity rates are significantly reduced.

Save time and increase efficiency :

With the QRQC method, problems are resolved faster, reducing production downtime and optimizing resource utilization.

Improved productivity :

By removing the root causes of defects, production becomes smoother and more reliable, thereby increasing overall efficiency.

Team commitment :

QRQC involves all stakeholders in problem solving. This strengthens employees’ sense of ownership and fosters a culture of continuous improvement.

Continuous improvement :

By systematically documenting and analyzing each problem encountered, the company engages in a process of continuous improvement which makes it possible to increase quality in the long term.

Example of application of QRQC

The QRQC method is widely used in various industrial sectors, including automotive, aerospace, and electronics manufacturing. Here is a real example of QRQC application in the automotive industry:

Example: Automobile production plant in Japan (Nissan)

At a Nissan plant, a recurring problem was detected with misaligned parts on an assembly line. This defect was leading to increased returns of defective products and loss of productivity as vehicles had to be manually readjusted after assembly.

• D1: Team Formation : Nissan quickly established a QRQC team consisting of production engineers, maintenance technicians, and assembly line operators.

• D2: Problem Description : The team accurately described the problem: misalignment of parts was causing excessive friction and misfits during the assembly process.

• D3: Immediate actions : As an emergency, shims were used to manually adjust misaligned parts, in order to limit production delays while waiting for a definitive solution.

• D4: Root Cause Analysis : Through in-depth analysis with an Ishikawa diagram and observations via Gemba Walks, the team discovered that the problem was caused by premature wear of the assembly jigs used to position the parts.

• D5: Corrective actions : Worn jigs were replaced with more robust models and adjusted to better match the new manufacturing tolerances. A jig inspection process was also put in place.

• D6: Implementation of corrective actions : The new jigs were immediately installed, and additional quality checks were added to verify alignment in real time.

• D7: Effectiveness monitoring : Results were monitored for several weeks. Misalignment defects were completely eliminated, and plant productivity increased by 5%.

• D8: Celebration of results : The team was congratulated for their work and training was organized to share this experience with other production teams in other Nissan plants.

Conclusion

The QRQC method, incorporating the rigorous structure of the 8Ds, is an essential tool for companies wishing to improve their responsiveness to quality issues and increase their productivity. It allows for rapid resolution of defects in production while ensuring continuous improvement of processes. By involving all teams and capitalizing on lessons learned, QRQC not only corrects errors, it also prevents their recurrence.

If you are looking to implement this method in your business, using a QRQC Excel template can be a great starting point to structure and track your actions effectively.

👉 Download the QRQC Excel template here : QRQC Excel Template