š BLUF ā Bottom Line Up Front
Theme: 0 COP Compliance Issues at ASSB Format: SLIDE DECK (PPTX), TBP-step categorized
Current: Phase 3a "Develop Theme" (11-30 Jun '26) Ā· Days to Theme Confirmation Report: ā Ā· Days to Report-Out: ā
Critical risk THIS WEEK: Sir's #1 TBP failure mode = stopping 5-Whys at Q2-3. 5-Whys MUST land on system/process cause (QMS gate) ā not operator. Otherwise theme drops to score 2/3.
š¦ Current Stage at a Glance LIVE
šÆ Scoring Target
š Upcoming Milestones (next 90 days)
| When | Milestone | Days | Action needed | Trace |
|---|
Phase 3 ā Theme Confirmation (TBP BG-Step 1) CURRENT
š Theme Confirmation Report to Executive Panels (16-31 Jul '26)
| # | Sub-event | When | Status | Self-Score | Next action |
|---|---|---|---|---|---|
| 3a | Develop Theme (TBP BG-Step 1) | 11-30 Jun '26 | NOW | 2 ā 3 | Fill real ASSB data + 1 gemba walk + 5-Whys Q5 |
| 3b | Get approval (Sup + Approver sign) | 1-9 Jul '26 | PEND | ā | Pre-meet Sup + Approver for sign-off |
| 3c | HR Home final quality gate | 13 Jul '26 | PEND | ā | Submit by 12 Jul (1 day buffer) |
| 3d | TMA/ATL review & submit | 14-15 Jul '26 | PEND | ā | kenneth_ow@toyota-asia.com Ā· piya_cha@toyota-asia.com |
| 3e | REPORT THEME to Executive Panels | 16-31 Jul '26 | PEND | ā | 10 min + 10 min Q&A on MS Teams |
ā Checklist ā click to mark done (persists in browser)
š Evidence required for Theme Confirmation to score 3/3
| Evidence type | Specific item | Why needed | Status |
|---|---|---|---|
| Real ASSB data | QMS system name Ā· paper traveler % Ā· IATF 4 majors | Business Perspective ā without it, drops to 2 | PENDING |
| Gemba walk | 1 walk at paperless traveler station, ~30 min | POO evidence (sir's #2 failure mode) | PENDING |
| 5-Whys | Q1-Q5 landing on process/system cause | Sir's #1 failure mode | PENDING |
| Theme deck | 15-slide PPTX (TBP-step categorized) | Sub-day deliverable | DRAFT IN PROGRESS |
| Q&A prep | Why 0 COP? Why not other theme? What if pilot fails? | 10 min Q&A scoring | PENDING |
Phase 4 ā Develop Project (TBP BG-Step 6) UPCOMING
š Develop 20-30 slide PPTX project deck for Report-Out
| # | Sub-event | When | Status | Open items |
|---|---|---|---|---|
| 4a | Develop Project (20-30 slide PPTX) | 3 Aug - 30 Sep '26 | PEND | Full TBP A3 v3.0 Kalyan strengthened Ā· Lit Review by 15 Aug Ā· Pillars 1-3 by 30 Sep |
| 4b | Get approval (Sup + Approver sign) | 1-12 Oct '26 | PEND | Project draft to Supervisor 1 wk before |
| 4c | HR Home final quality gate | 13 Oct '26 | PEND | Submit by 12 Oct (1 day buffer) |
| 4d | TMA/ATL review & submit | 14-15 Oct '26 | PEND | TMA/ATL verifies and submits |
| 4e | REPORT-OUT PROJECT to Panels | 16-30 Oct '26 | PEND | 10 min + 10 min Q&A Ā· Final scoring |
ā Checklist
Phase 5 ā Final Submission + Certification (TBP Step 7-8) FUTURE
| # | Sub-event | When | Status | Open items |
|---|---|---|---|---|
| 5a | Submit progress + results to TMA(TH) | By 11 Dec '26 | PEND | Pilot dQMS results Ā· Step 7 monitor Ā· Step 8 standardize Ā· Yokoten w/ failure modes |
| 5b | Top Participants ā Asia Top Executives | (if applicable) | PEND | Auto if 3/3/3 |
| 5c | Award certification | Within Jan '27 | PEND | Cert to qualified (ā„2/3) participants |
3-Criteria Self-Assessment ā Target 3/3/3 (9/9)
| # | Criterion | What scores 3 (Exceed) | 0 COP evidence | Self | What to add for 3/3 |
|---|---|---|---|---|---|
| 1 | Business Perspective | Fact-based TBP, region-wide impact, breakthrough value across value stream | Quantified COPQ savings Ā· recall traceability 5dā30min Ā· parent plant daily metrics Ā· IATF re-cert pass Ā· cross-A3 leverage | 3 | COPQ $$ baseline + projected Ā· Parent plant TMC quote Ā· 5-yr strategic fit (AI firm 2027) |
| 2 | People Development | Team capability via coaching, feedback, learning env, maximize potential | Operator training on dQMS Ā· certification Ā· gemba culture shift Ā· kaizen self-sustaining | 3 | Training matrix (roles/tools/cert) Ā· # operators trained + certified Ā· Kaizen owner after impl |
| 3 | Attitude | Ownership, urgency, agility, networks, communication | TBP/Jidoka/Andon embedded Ā· gemba frequency Ā· 5-Whys Q5 depth Ā· yokoten w/ failure modes Ā· reflection in TBP voice Ā· cross-stakeholder work | 3 | 4-part Reflection in TBP voice Ā· Gemba frequency metric Ā· Yokoten w/ failure modes |
Pass criteria: ā„ 2/3 per criterion (ā„ 6/9 total). Target 9/9 = Asia Top Executives nomination path.
Critical-Path Items for 3/3 ā Kalyan R1-R5 + Sir's 3 Failure Modes
Click any row to mark done. The badge in the "Trace" column shows which deliverable holds the evidence.
| # | Item | Why it matters for 3/3 | Status | Trace (where the proof lives) |
|---|---|---|---|---|
| R1 | State problem type (Setting/Reaching/Trouble) | Panel checks first | DONE | |
| R2 | Label CMs Defensive / BR / BR-momentum | Mix tells the story | PEND | |
| R3 | Owner name + Q-by date (no "team"/"TBD") | "Team"=2, named=3 | PEND | |
| R4 | Pilot study + 26APF input connection | Report vs plan | PEND | |
| R5 | Reflection in TBP voice (not consultant) | Attitude criterion | PEND | |
| FM-1 | 5-Whys reaches Q5 (process/system cause) | Sir's #1 failure mode | PEND | |
| FM-2 | POO explicit w/ gemba evidence (date+names) | Sir's #2 failure mode | PEND | |
| FM-3 | Target #+date+"why challenging" | Sir's #3 failure mode (vague=BAU) | PEND | |
| NEW | Cross-A3 leverage (1 fix closes 4 findings) | Unique system-thinking | DONE | |
| NEW | Yokoten w/ FAILURE MODES (not slogan) | What to AVOID shared | PEND |
ā This-Week Critical Actions (19-25 Jun '26) CLICK TO TOGGLE
Your checklist state is saved in this browser. Clear via sidebar "Reset Checklist".
š Evidence Map ā Where Every Claim Lives
Traceability: every TBP claim ā underlying evidence (deck slide, gemba photo, plant data, Kalyan citation).
| Claim in theme | Evidence required | Where it lives | Status |
|---|---|---|---|
| Theme = "0 COP Compliance Issues at ASSB" | Theme brief, locked scope | tbp_theme_cop_compliance_v2.html | DONE |
| Real historical Case 1 (R101 Emission NG) | Lab testing root cause analysis | /PERMANENT/TBP/cop_real_cases/ (4 XLSM test data) | FLESH OUT |
| Real historical Case 2 (Innova stop lamp label NG) | Drawing vs ECE Application gap | /PERMANENT/TBP/cop_real_cases/ | FLESH OUT |
| Cross-cutting root cause (Drawing vs ECE drift) | 5-Whys Q5 system cause | Deck v2 (slide 8-9) ā in progress | PEND |
| ASSB COP Recertification Audit (15-16 Jun '26) | VCA audit (Keiko Matsuura) | 3 audit PDFs on Drive | DONE |
| MDP 2026 program structure + dates | Program outline PDF | mdp_2026_program_context.md | DONE |
| Kalyan R1-R5 critique framework | TMA-SG practice paper + critique table | extracted_text/MDP26_MDP_Practice_Paper.txt | DONE |
| 13-cron R-job milestone pattern | Cron job IDs (silent-when-OK) | TBP v3.7 skill + cron framework | ARMED |
š Real COP Cases @ ASSB ā Anchor Evidence for Theme
Case 1 ā R101 Emission NG [YEAR/STATUS TBD]
What happened: Yaris G 2026 NG on UN R101 Euro 3/4/5a Gasoline emission standard. Engine 2NR-FE 1.5L. VIN PN154SYF103586272/4/5/6.
Operator / Driver: Amierul / Syukur
Impact: Potential stop shipment
Suspected Q5 (process/system): Method of lab testing itself, not the vehicle. Test method = the COP gate.
To flesh out: [year] Ā· [resolution + current status] Ā· [affected unit count] Ā· [was 5-Whys done to Q5?] Ā· [yokoten to other plants]
Case 2 ā Innova Stop Lamp Label NG [YEAR/STATUS TBD]
What happened: Plant confirmed Part vs Drawing (passed internal check). Actual COP requirement = Part vs ECE Application document (regulatory reference).
Impact: COP NC at customer acceptance
Suspected Q5 (process/system): System doesn't enforce "check against ECE application" ā only "check against drawing". Drawing doesn't capture all regulatory requirements.
Yokoten-with-failure-modes potential: Don't check Part vs Drawing. Check Part vs ECE Application document.
To flesh out: [year] Ā· [resolution + current status] Ā· [affected unit count] Ā· [was 5-Whys done to Q5?] Ā· [yokoten to other plants]
š Cross-cutting insight (the 0 COP thesis)
Both cases share the same root-cause pattern: the COP verification process assumes internal reference (Drawing / test method) is equivalent to external regulatory reference (ECE Application / R101). The two drift apart because there's no forced cross-check at the COP gate. This is the system-level fix the 0 COP project must address.
šÆ Theme Brief ā 0 COP Compliance Issues at ASSB
Why this theme (sir's reasoning, 2026-06-16): "Regulation is global issue surrounding Toyota lately, want to prep ASSB for 0 COP."
| Dimension | Content |
|---|---|
| Customer | Parent plant (TMC) Ā· IATF auditors Ā· JPJ homologation Ā· Dealers Ā· End-customer (brand impact) |
| External | UN Regulations applicable to Malaysia (25) Ā· Non-Regulation Rules (150) Ā· VCA recertification audit (15-16 Jun) Ā· Global Toyota COP regulatory pressure |
| Internal | Hybrid paper+QMS+spreadsheet Ā· 2 historical COP NCs (R101 + Innova) Ā· COP verification gate assumes Drawing = ECE Application |
| Type of problem | Trouble-type ā 2 confirmed COP incidents (R101 + Innova), root cause at process/system level |
| Why now | VCA recertification audit just held (15-16 Jun) Ā· IATF Q1 2027 re-cert Ā· Parent plant daily metrics Ā· AI firm 2027 anchor |
| Strategic target | 0 COP NCs at customer acceptance by 31 Dec 2026 Ā· Sub-target: 100% COP verification enforced against ECE Application (not just Drawing) Ā· Sub-target: 100% lab test method audited against R101 standard |
Full brief: tbp_theme_cop_compliance_v2.html (local server)