CDQ0519, Edition 2.

14 Quality Principles for the Value Stream Attachment 1

Value Stream
Q-Basics

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Value Stream Q-Basics

We want
our customers
to be satisfied!

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Value Stream Q-Basics

Capable production processes and operations through out

the entire value stream are decisive for the delivery quality of
our products.
We can only achieve zero defects if we identify and eliminate
failure modes in every work step, define standards and
consistently adhere to them.
Derived from main errors of the past, the 14 Q-Basics for the
value stream describe fundamental standards which will help
us to achieve best quality.
It is important that all associates are involved in the
implementation of these standards and in the continuous
improvement process. Only then we shall have failure-free
processes and permanently satisfied customers.

Sincerely Rolf Bulander

Member of the Board of Management Robert Bosch GmbH

Chairman Business Sector Mobility Solutions

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Principle 1
Stop Sign

Customer complaints are communicated

within the production site and, if possible,
displayed directly at the station in question.
Using problem-solving techniques, they are
processed in a fast and systematic manner.
The supply chain is promptly informed.

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Principle 1
Stop Sign
A STOP sign process with all of the 8D elements is
displayed on the shop floor.

A standard review process involving the

production/logistics management and quality
management takes place.

The decision to end the STOP sign process is taken

by production/logistics management after a review of the
measures’ effectiveness.

It is necessary to ensure that customer complaints are

communicated quickly over the entire supply chain from
supplier to customer.

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Best Practice: Stop Sign

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Best Practice: Stop Sign

Resource: CP/PUQ-IN
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Best Practice:

Resource: RBAC AE-CN

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Best Practice: Stop Sign

Resource: supplier
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Best Practice: Stop Sign

Resource: RBCD
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Best Practice:
Stop Sign

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Best Practice: Stop Sign

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Principle 2
Andon Cord

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 or escalate.

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Principle 2
Andon Cord
There is a systematics (e.g. Andon cord, blocking/
escalation process, reaction plan) in place that allows
the operator, if he notices deviations, to choose to
prevent the passing-on / further processing of parts (by
stopping/blocking) and to escalate 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, label badly
readable or incomplete).
After stopping the system there needs to be a well-
defined process governing the restarting and release of
the system by shop floor management.

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Best Practice: Andon Cord

*e.g. restart process, readjust

process, block parts, …

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Best Practice: Andon Cord

Resource: CP/PUQ-IN
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Best Practice: Andon Cord

Resource: RBAC AE-CN

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Best Practice: Andon Cord

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Best Practice: Andon Cord

alarm

Andon button

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Best Practice: Early Warning System

Resource: RBCD
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Best Practice: Andon Cord

Resource: CP/TSC1-AP
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Best Practice: Andon Cord

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Principle 3
Instructions

Safety, health, production, and inspection

instructions are complied with.
5S standards are put in place and observed.

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Principle 3
Instructions
The work, production and inspection instructions are
clearly visible at every work place. A consistent set of
symbols is available. If appropriate, the right/left hand
movement becomes evident from the instruction. The
failure 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 regarding safety, work, production and
inspection instructions or safety and health briefings
shall be resolved using the 8D method.

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Best Practice: Instructions

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Best Practice: Instructions

Resource: CP/PUQ-IN
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Best Practice: Instructions (1/2)

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Best Practice: Instructions (2/2)

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Best Practice:

Resource: RBAC AE-CN

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Principle 4
Process Parameters

The target values/tolerances for all

stated process parameters are observed.

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Principle 4
Process Parameters
All process parameters (e.g. press-in force, maximum
storage time) 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 permanently.

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Best Practice: Process Parameters

Resource: CP/PUQ-IN
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 Best Practice: Process Parameters (1/3)

*e.g. temperatures, flow rates, feed

rates, welding collapse distance, …
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 Best Practice: Process Parameters (2/3)

*e.g. temperatures, flow rates, feed

rates, welding collapse distance, …
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 Best Practice: Process Parameters (3/3)

*e.g. temperatures, flow rates, feed

rates, welding collapse distance, …
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Best Practice:

Resource: RBAC AE-CN

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Best Practice: Process Parameters

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Principle 5
Measurement/Test Equipment

Measuring and test equipment is defined,

and monitoring intervals are observed.

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Principle 5
Measurement/Test Equipment
The type of measuring and test equipment (e.g.
gages, scanners) incl. auxiliary means and its uses is
defined for all processes in the control plans.
All measuring and test equipment is calibrated and
only utilized within the permissible inspection interval.
The inspection status of the measuring and test
equipment is recognizable at its place of usage (e.g.
marked by inspection certificate sticker, tag).
In case of suspected malfunctions/damages this has
to be notified.

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Best Practice: Measurement/Test Equipment

Resource: CP/PUQ-IN
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Best Practice: Measurement/Test Equipment

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Best Practice: Measurement/Test Equipment

Resource: RBAC AE-CN

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Best Practice: Measurement/Test Equipment

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Principle 6
Check the Checker

The “check the checker” principle is applied,

and the “checker’s” suitability is ensured.

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Principle 6
Check the Checker
The suitability of processes used to prevent or detect
errors (e.g. camera-monitored processes, sensor-based
measurements, inspection processes, scanning of
labels) needs to be checked according to a predefined
standard.
Possible errors, such as loading the incorrect camera
software/testing program or incorrect MAE software
versions/updates, entry of wrong inspection parameters,
or improper sensor calibration, need to be prevented by
carrying out the inspection. These inspection processes,
need to be evaluated using appropriate methods (e.g.
FMEA).
Check-the-Checker-parts are included in the control of
inspection measurement and test equipment.
Generally speaking, mistake-proofing is always
preferable to error detection (e.g. Poka Yoke).

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Best Practice: Check the Checker

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Best Practice: Check the Checker

Resource: CP/PUQ-IN
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Best Practice: Poka-Yoke

Resource: RBCD
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Best Practice: Check the Checker

Resource: CP/TSC1-AP
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Best Practice:

Internal | CP/TSC-AP | 13/06/2016 Resource: RBAC AE-CN

50 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Check the Checker

Resource: supplier
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Principle 7
Total Productive Maintenance

A maintenance standard is installed and

observed at every station.

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Principle 7
Total Productive Maintenance
The four-pillar TPM model, particularly the
autonomous and preventative maintenance, is instituted
at every machine, device, facility. This contains both the
roles and responsibilities for production and the
supporting areas.
Systematic damage and dirt built-up on machinery and
device components (e.g. workpiece carriers, storage
facilities, stackers) need to be consistently analyzed,
recognized, and remedied.
The restart after maintenance (see principle 9), has to
consider potential influences on product quality.

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Best Practice: TPM

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Best Practice: TPM

Resource: CP/PUQ-IN
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Best Practice: PS for MAE deviation

Resource: RBCD
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Best Practice: TPM

Resource: CP/TSC1-AP
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Best Practice:

Resource: RBAC AE-CN

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Best Practice: TPM

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Principle 8
Tools

Each tool has a defined service life; the

current status must be recognizable.
A quality evaluation must be carried out
during installation, removal or disassembly.

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Principle 8
Tools
Wear-prone tools with influence on product quality
(e.g. processing, assembly, molding tools, workpiece
fixtures/carriers) have been recorded and are controlled
(e.g. defined service lives, control on basis of product
characteristics, inspection during maintenance).
A warning system promptly displays when tools need
to be replaced or serviced.
Each tool needs to be inspected when installed,
removed or disassembled to check for recognizable
abnormalities (e.g. damage/wear and tear). In case of
deviations, it is necessary to follow measures to ensure
product quality is maintained.

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Best Practice: Tools

Resource: CP/PUQ-IN
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Best Practice: Tools

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Best Practice: Monitoring of tool life

Resource: RBCD
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Best Practice:

Resource: RBAC AE-CN

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Best Practice: Tools (1/2)

Resource: supplier
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Best Practice: Tools (2/2)

Resource: supplier
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Principle 9
Restart

Restart after disruptions is clearly regulated

for all machinery and equipment.

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Principle 9
Restart
Each disruption to the continuous production process
(tool change, set-up, break, shift change, maintenance,
power failure, upgrade, MAE software update,
parameter changes) presents a potential risk to quality.
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,
control software update), it is necessary to newly
release the process.
Set-up processes, need to be evaluated using
appropriate methods (e.g. FMEA).
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Best Practice: Restart

*e.g. due to shift change,

change over,
weekend, break-
down, repair)
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Best Practice: Restart

Resource: CP/PUQ-IN
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Best Practice:
Restart (1/2)

长时间及非正常
停机记录针对设备

Internal | CP/TSC-AP | 13/06/2016 Resource: CP/TSC1-AP

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Best Practice: Restart (2/2)

Internal | CP/TSC-AP | 13/06/2016 Resource: CP/TSC1-AP

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Best Practice:

Resource: RBAC AE-CN

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Best Practice: Restart (1/2)

Resource: supplier
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Best Practice: Restart (2/2)

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Principle 10
Labeling

Products and containers are labeled

according to the set standard.

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Principle 10
Labeling
 Outside the production flow:
 White card with a red diagonal stripe: Product blocked;
 Green card: Product after additional test back in
production flow and in good condition;
 Yellow card: Product for rework;
 Red card: Product is scrap;
 White card: Product in good condition.
 Rejected parts in the red box (scrap container).
 Red boxes must be secured against unintended access
(e.g. by locking them, covering, spatial separation,
covering during transport).
 Containers for rejects must be emptied in line with
In the entire value stream products must always standards and the parts must be analyzed.
have a clear status. Therefore, a consistent identi-  Parts at the analysis station are spatially separated from
fication/labeling concept at the production site and the production flow and clearly identified.
adherence to the following rules are necessary.  Only parts with the same status in the same container
Within the production flow:  No good parts in the red box.
 Filled boxes must always be labeled  A blocking process for production and logistics is defined.
 (e.g. card, sticker, RFID).  Products are protected against environmental influences
(e.g. contamination) in line with regulations.
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Best Practice: Labeling (1/2)

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Best Practice: Labeling (2/2)

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Best Practice: Labeling

Resource: CP/PUQ-IN
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Best Practice:

Resource: RBAC AE-CN

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Best Practice: Labeling (1/2)

83 Internal | CP/TSC-AP | 13/06/2016 Resource: supplier

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Best Practice: Labeling (2/2)

84 Internal | CP/TSC-AP | 13/06/2016 Resource: supplier

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Best Practice:
Labeling &
Remaining Items

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85 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 11
Rework / Scrap

The handling of rejected parts and those

to be reworked is clearly regulated.

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86 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 11
Rework / Scrap
Basic rule: Inspection or processing of a part that,
contrary to the control plan, is removed from the
standard process, is rework.
If rework is unavoidable it takes place on an approved
device and is limited in time or quantity. A concession is
necessary.
A rework process that is permanently required must
be transferred to a standard process.
Sorting inspections require a
 risk assessment,
 description of the workplace,
 work / inspection instruction.
They are approved by the responsible for production
and the responsible for quality.
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).

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87 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Rework / Scrap

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88 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Rework / Scrap

Resource: CP/PUQ-IN
Internal | CP/TSC-AP | 13/06/2016
89 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice:

Resource: RBAC AE-CN

Internal | CP/TSC-AP | 13/06/2016
90 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Rework / Scrap (1/2)

91 Internal | CP/TSC-AP | 13/06/2016 Resource: supplier

© Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Rework / Scrap (2/2)

92 Internal | CP/TSC-AP | 13/06/2016 Resource: supplier

© Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 12
Dropped Parts

Any products that fall on the floor,

into the machine or cannot be classified
must be scrapped.

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93 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 12
Dropped Parts
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.
In case of repeated occurrence the shop floor
management must be notified by the employee.
Repeat events are analyzed regarding systematic
causes and improvement measures are implemented.
Nonconforming products or products that cannot be
classified must be scrapped according to procedure.

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94 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Dropped Parts (2/2)

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95 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Dropped Parts

Resource: CP/PUQ-IN
Internal | CP/TSC-AP | 13/06/2016
96 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice:

Resource: RBAC AE-CN

Internal | CP/TSC-AP | 13/06/2016
97 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Dropped Parts

Resource: supplier
Internal | CP/TSC-AP | 13/06/2016
98 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 13
Correct Product

Only the correct product may be

provided for removal and assembly.

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99 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 13
Correct Product
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/workplace must not be accessible to
the employee (e.g. closed/covered containers).
If several variants need to be available (e.g. mating of
parts), an inspection takes place after the handling
operation.

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100 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Correct Product

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101 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Correct Product

Resource: CP/PUQ-IN
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102 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice:

Resource: RBAC AE-CN

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103 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Correct Product

Resource: supplier
Internal | CP/TSC-AP | 13/06/2016
104 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice:
Correct Product

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105 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 14
Remaining Items

The handling of remaining items/

quantities is clearly regulated.

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106 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Principle 14
Remaining Items
Remaining quantities must be clearly labeled (e.g.
white card with part number, number of units, date,
name, remaining quantity in the comments field) and
stored securely (e.g. shelf for remaining items).
The “First In, First Out” principle must be observed.
Maximum storage times must not be exceeded.
Close attention must be paid to ensure tidiness and
cleanliness as the goods have yet to be placed in the
final packaging.
The quantity of remaining items must be taken into
consideration with regard to engineering change
requests.

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107 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Remaining Items

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108 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Remaining Items (1/2)

Resource: CP/PUQ-IN
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109 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Remaining Items (2/2)

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110 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice:

Resource: RBAC AE-CN

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111 © Robert Bosch GmbH 2016. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Best Practice: Remaining Items

Resource: supplier
Internal | CP/TSC-AP | 13/06/2016
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Terms and Abbreviations
(for information only)
5S: Approach for improvement of order and cleanliness at the MAE: Machinery and Equipment
workplace described by 5 Japanese words all beginning with S 
 Poka Yoke (from Japanese): Method to avoid human
8D: Method for structured problem solving in 8 steps mistakes, resulting defects and passing on of nonconforming

parts
Andon Cord: Term derived from Japanese for a system (e.g. 
rip cord, switch, systematics) enabling an employee to stop a RFID (radio-frequency identification): transmitter-receiver
device.
 system for contact-free identification of objects using
Audit (lat. hearing): systematic and independent investigation electromagnetic waves

of the actual state e.g. of a quality management system,
production process or product in comparison to the requirements source, make, deliver: short descriptions for the main
 sections of the value stream (purchase, production, delivery)
FMEA (Failure Mode and Effects Analysis): Analytical method 

to identify failure modes of systems, products or processes and TPM: Total Productive Maintenance

to avoid them by appropriate measures
 VDA: German Association of the Automotive Industry
IPN: International Production Network 
 GB/QM: Division / Head of Quality Management
ISO (International Organization for Standardization): worldwide 
union of national standardization institutes for the development of HSE: Health, Safety, Environment
international standards

ISO/TS 16949: Summarizing technical specification of the
worldwide existing requirements of the automotive industry for
management systems, developed by the ISO

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14 Quality Principles for the Value Stream

Value Stream
Q-Basics

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