1. Revamp Quality Inspection → Quality Promotion: QC as division cannot solely own the quality-gate mindset.
2. Centralise quality stories across shops & divisions to promote a shared quality mindset, linkable & accessible.
3. Digitalise the QC process end-to-end (capture → storage → tabulate → share) with an AI-tabulated shared database.
Three real ASSB cases that justify "now":
Plant direction alignment: digital transformation capability gap flagged for Plant Director track. AI firm 2027 launch requires a flagship case study.
Phase 1 (Apr–Dec 2026): VIS revamp & VRC paperless (Pillar 1 + 2). Yaris G pilot only
Phase 2 (Q1–Q2 2027): Real-time reporting & analytics live (Pillar 3). Full line rollout.
Phase 3 (H2 2027+): AI-vision add-on, cross-plant patterns, supplier scorecard.
Scope (locked): Yaris G 2026 line first, plant-wide in Phase 2. Sir to confirm pilot line.
New VIS (mobile/tablet platform):
Replaces: manual key-in to 2 separate VIS systems (CS Line + Scratch).
One digital record per unit (VIN-keyed):
Data migration: [sir/Razmair: legacy 10-yr VRC archive — scan? dual-record? consult legal on retention obligation?]
Tabulated real-time views: daily/weekly defect trends, COP risk, supplier scorecard, station Pareto.
AI-tabulated shared database (the "AI" in the title):
| Risk | Likelihood | Impact | Mitigation |
|---|---|---|---|
| ITSD cannot free infra owner in Q3 2026 | [L/M/H] | [L/M/H] | Escalate to GM Richie Week 1 post-approval; lock 0.5 FTE ITSD via service-level MoU before vendor shortlist |
| 10-yr legacy VRC migration (volume + retention obligation) | [L/M/H] | [L/M/H] | Legal review of 10-yr retention obligation; phased scan of high-COP units first; keep physical for 2 yr overlap |
| Shop-floor rejection of tablets (usability / culture) | [L/M/H] | [L/M/H] | 2-week operator pilot before Yaris G lock; Gemba walkthrough; Kazen team as change champions; tablet glove-mode test |
| Vendor lock-in (3-yr TCO exposure) | [L/M/H] | [L/M/H] | RFI requires open API + data-export clause; 1 backup vendor kept warm; standard data model (no proprietary schema) |
| IATF re-cert Q1 2027 deadline if Phase 1 slips | [L/M/H] | [L/M/H] | Decouple Pillar 1 milestone from Pillar 3; even Pillar 1 alone closes 3 of 4 majors — ship minimum-viable audit trail by Dec 2026 |
| No. | Item | Source / Owner | Phase |
|---|---|---|---|
| 1 | Vehicle defects & repair history | QC · QI Section | 1 |
| 2 | ICAR (Internal CAR) status & closure | QC · QI | 1 |
| 3 | Hot News (defect alert bulletins) | QC · QI | 1 |
| 4 | Asakai Graph (internal/external defects) | QC · QI | 2 |
| 5 | NCP (Non-Conforming Product) log | QC · QI | 1 |
| 6 | PFUS (Problem Follow-Up Sheet) | QC + cross-functional PICs | 2 |
| 7 | PDCS (Parts Defect Claim System) | Incoming QC | 2 |
| 8 | QAT Safety Torque Tightening Data | Incoming QC + Production | 2 |
| 9 | FVA defects & FVA Graphs | Incoming QC | 2 |
| 10 | Production line defects (cross-functional gap v1 missed) | Production + QC joint | 2–3 |
| 11 | Warranty claim cost (by defect type/station) | Customer Service + Finance | 3 |
| # | Benefit | → | Source / Assumption |
|---|---|---|---|
| 1 | Paper VRC: [N sheets/yr] → 0 | RM [X]K/yr saved | v1 estimate: 2.3M sheets · RM 230K/yr |
| 2 | QC analyst report time: 6 hr/wk × 4 staff → 0 | RM ~120K/yr | Re-deployed to value-add (Pareto/A3 work) |
| 3 | NC reporting latency: 5 days → <1 hr | RM ~80K/yr | Audit prep time reduction (IATF) |
| 4 | Avoid 1 stop-shipment/yr (probability-based) | RM 5–10M | Innova-scale event avoidance |
| 5 | IATF re-cert: 0 major NCs target | License to operate | Q1 2027 deadline · VCA auditor |
3-yr TCO: RM [sir to confirm]M (vendor licence + HW + integration). Payback target: <18 months on direct savings; positive Year-1 with avoided stop-shipment.
| # | Metric | Baseline (today) | Target | By When |
|---|---|---|---|---|
| 1 | NC reporting latency | 3–5 days | < 1 hour | Q2 2027 |
| 2 | Defect capture rate (manual → digital) | ~60% | > 95% | Q4 2026 (post-pilot) |
| 3 | Per-VIN record coverage | 0% (paper only) | 100% of pilot line | Q1 2027 |
| 4 | Audit prep time (IATF) | 3 days | < 8 hours | Q1 2027 |
| 5 | COP incidents (per-unit record retroactive) | 2–3/month | 0 surprise audits | Q2 2027+ |
| 6 | AI-tabulated monthly report | 0 (manual) | Auto-generated PDF | Q2 2027 |
| Workstream | Apr–Jun 2026 | Jul–Sep 2026 | Oct–Dec 2026 | Jan–Mar 2027 | Apr–Jun 2027 | H2 2027+ |
|---|---|---|---|---|---|---|
| Discussion with ITSD | ████ | |||||
| A3 Paper (this doc) | ████ v1 · v2 | approval | ||||
| Procurement (RFI → vendor) | ████ | award | ||||
| Detail requirements + infra setup | ████ | ████ | ||||
| Software development (Pillar 1+2) | ████ | |||||
| Yaris G pilot UAT + go-live | UAT | ████ go-live | ||||
| Pillar 3 (Reporting + AI) live | ████ | ████ live | ||||
| Full ASSB rollout (Hilux/Fortuner/Vios) | ████ | ████ | ||||
| AI-vision add-on (Phase 3) | ████████ |
Gate criteria per phase: vendor shortlist decision (Sep 2026) · Yaris G go-live (Mar 2027) · IATF re-cert evidence ready (Q1 2027) · Full ASSB Pillar 3 live (Jun 2027).
| # | Dimension | Current (v1) | Proposal (v2) |
|---|---|---|---|
| 1 | QC items digitalised | QC-internal only (9 items) | EXPANDED QC + Production + CS + Supplier read-only (11 items) |
| 2 | Approach | Reactive (defect → response) | EXPANDED Proactive quality mgmt (drift + AI alert) |
| 3 | Traceability | No per-unit record | EXPANDED Per-VIN digital record, 10-yr retention |
| 4 | Data architecture | Decentralised (2 VIS, paper) | EXPANDED Centralised DB + AI-tabulated shared layer |
| 5 | Reporting | Manual retrieve + plot | EXPANDED Auto-Pareto + AI-generated insights |
| 6 | Storage | Paper 10 yr, overflow risk | EXPANDED Server + retention + backup + audit trail |
Out of scope (v1 → v2 unchanged): ERP replacement · MES replacement · supplier portal replacement · customer-facing product (until AI firm 2027) · AI-vision as primary product · PUSPAKOM/JPJ VRC integration.
1. Approve the VIS Revamp & VRC Paperless Project (3-pillar, 14-month delivery).
2. Approve the 3-yr TCO budget envelope of RM [sir to confirm]M for reflection in Budget Year 2027 & 2028.
3. Approve cross-functional team: QC (lead) + ITSD + Production + Engineering + Finance liaison.
4. Approve Yaris G 2026 as pilot line, full ASSB rollout in Phase 2 (FY2027).
5. Lock IATF 16949 re-cert Q1 2027 as the regulatory anchor deadline.
Decision unlocks: vendor shortlist Q3 2026 · pilot Q4 2026 · full rollout FY2027 · AI firm 2027 flagship case study.