＜Upper-Intermediate＞ Lesson No.12
Root Cause Analysis and Improvement Measures for Quality Issues / 品質問題発生時の原因究明と改善策提示
０．Greetings & Ice-break (2min.)｜挨拶と導入
0-1 Greetings
Let’s practice a short small talk that you can use to greet a business partner and start building a good relationship.
講師との挨拶を兼ねて、ビジネスパートナーと信頼関係を築くための短いスモールトークを練習してみましょう。
[Tips / 会話のヒント]
・Can you hear me clearly?
私の声はクリアに聞こえますか？
・How's your day going so far?
今日はどんな一日でしたか？
・Talk about one small topic (Work, Weather, News, Hometown, Sports event, etc.)
軽い話題について話しましょう（仕事、天気、ニュース、地元、スポーツイベントなど）
0-2 Introduction
In today’s lesson, we’ll learn about the following situation. Have you ever experienced something similar?
本日のレッスンでは以下のようなシチュエーションについて学びます。同様のシチュエーションを経験したことがありますか？
- If you have experience, please tell us what it was like, what was difficult, or what you learned.
経験があれば、どんな内容だったか、難しかったことや学んだことなどを教えて下さい。
- If you don’t have experience, try to imagine yourself handling that situation in English.
What do you think would be challenging?
経験がなければ、英語でその状況に対応しているところを想像してみましょう。どんなことが難しそうですか？
Situation / シチュエーション
Addressing quality variation issues in robot welding processes and proposing comprehensive improvement measures at a Mexican automotive parts manufacturer.
メキシコ自動車部品メーカーでのロボット溶接工程の品質ばらつき問題に対する包括的改善策を提案する場面です。
1. Read (2 min)｜型を学ぶ
Let's read the following key sentences aloud!
下記の文章や単語を順番に音読しましょう！
1-1 Basic phrases
１．I sincerely apologize for...（...を心よりお詫び申し上げます）
２．We take full responsibility and are committed to...（私どもは全責任を負い...をお約束いたします）
３．Based on preliminary assessment...（予備評価に基づくと...）
４．We will carry out a comprehensive inspection...（包括的な検査を実施いたします...）
５．Our recovery plan consists of...（回復計画は...で構成されます）
６．This means full resolution within...（つまり...以内に完全解決し...）
７．We will establish a preventive maintenance protocol...（予防保全プロトコルを確立いたします...）
1-2 Essential words
１．detected（検出した）
２．apologize（お詫びする）
３．assess（評価する）
４．carry out（実施する）
５．modify（修正する）
６．validate（検証する）
７．eliminate（排除する）
８．inconsistency（不安定さ）
９．calibration（校正）
１０．deviation（逸脱）
2. Try (3 min)｜ロールプレイ練習
Let’s practice the role-play.
ロールプレイの練習をしましょう！
Situation / シチュエーション（Reference again）
Addressing quality variation issues in robot welding processes and proposing comprehensive improvement measures at a Mexican automotive parts manufacturer.
メキシコ自動車部品メーカーでのロボット溶接工程の品質ばらつき問題に対する包括的改善策を提案する場面です。
👨💼【Teacher / Quality Manager】:
Thank you for coming on such short notice. We detected a serious quality issue in the welding process. The defect rate exceeded our acceptable limit, and we need your immediate support to resolve this.
（急なご連絡にもかかわらずお越しいただきありがとうございます。溶接工程で深刻な品質問題を検出しました。不良率が許容限度を超えており、これを解決するために早急なご支援が必要です。）
🧑🎓【Student / Sales Representative】:
I sincerely apologize for the inconvenience this has caused to your production. We take full responsibility and are committed to identifying the root cause immediately. Our technical team is ready to assist you.
（生産にご迷惑をおかけしたことを心よりお詫び申し上げます。私どもは全責任を負い、直ちに根本原因を特定することをお約束いたします。技術チームがご支援する準備ができております。）
👨💼【Teacher / Quality Manager】:
Can you explain what might be causing this inconsistency? We need to understand whether this is a programming issue or a mechanical problem with the robot itself.
（この不安定さの原因は何だと考えられますか？これがプログラムの問題なのか、ロボット本体の機械的な問題なのかを理解する必要があります。）
🧑🎓【Student / Sales Representative】:
Based on preliminary assessment, there are three possible factors. First, the welding parameters may need adjustment for your specific material thickness. Second, the robot calibration might have drifted over time. Third, environmental conditions such as temperature fluctuations could affect consistency. We will carry out a comprehensive inspection today to determine the exact cause.
（予備評価に基づくと、3つの要因が考えられます。第一に、溶接パラメータがお客様の材料厚に合わせた調整が必要な可能性があります。第二に、ロボットの校正が時間とともにずれた可能性があります。第三に、温度変動などの環境条件が一貫性に影響を与えている可能性があります。本日、正確な原因を特定するため包括的な検査を実施いたします。）
👨💼【Teacher / Quality Manager】:
How long will it take to implement the corrective actions? Our production schedule is very tight, and we cannot afford extended downtime.
（是正措置の実施にはどのくらい時間がかかりますか？生産スケジュールが非常にタイトで、長時間の停止は許容できません。）
🧑🎓【Student / Sales Representative】:
We understand the urgency. Our recovery plan consists of three phases. First, we will complete the diagnostic inspection within 4 hours today. Second, we will modify the program and recalibrate the robot within 24 hours. Third, we will monitor the process for 48 hours to validate the improvements. This means full resolution within 3 days, with minimal impact on your production.
（緊急性は理解しております。回復計画は3段階で構成されます。第一に、本日4時間以内に診断検査を完了いたします。第二に、24時間以内にプログラムを修正しロボットを再校正いたします。第三に、48時間プロセスを監視し改善を検証いたします。つまり3日以内に完全解決し、生産への影響は最小限となります。）
👨💼【Teacher / Quality Manager】:
What guarantee can you provide that this issue will not recur? We need a long-term solution, not just a temporary fix.
（この問題が再発しないという保証は何ですか？一時的な修正ではなく、長期的な解決策が必要です。）
🧑🎓【Student / Sales Representative】:
We will establish a preventive maintenance protocol specifically for your facility. This includes monthly calibration checks, quarterly parameter reviews, and real-time monitoring software that will detect any deviation before it affects quality. Additionally, we will train your maintenance team to identify early warning signs. These measures will eliminate the risk of recurrence.
（お客様の施設専用の予防保全プロトコルを確立いたします。これには月次の校正チェック、四半期ごとのパラメータレビュー、品質に影響する前に逸脱を検出するリアルタイム監視ソフトウェアが含まれます。さらに、保守チームが早期警告サインを識別できるよう訓練いたします。これらの措置により再発リスクを排除いたします。）
👨💼【Teacher / Quality Manager】:
I appreciate your comprehensive approach. Please proceed with the inspection immediately, and keep me updated on the progress every 4 hours. We are counting on your team to resolve this quickly.
（包括的なアプローチに感謝いたします。直ちに検査を進めてください。そして4時間ごとに進捗状況を報告してください。迅速な解決を貴社チームに期待しております。）
3. Use (4 min)｜ロールプレイ & 実践（空欄補完）
Let's perform the role-play and fill in the blanks by translating the Japanese into English!
空欄の日本語を英語に訳しながら、ロールプレイを実践してみましょう！
Situation / シチュエーション（Reference again）
Addressing quality variation issues in robot welding processes and proposing comprehensive improvement measures at a Mexican automotive parts manufacturer.
メキシコ自動車部品メーカーでのロボット溶接工程の品質ばらつき問題に対する包括的改善策を提案する場面です。
👨💼【Teacher / Quality Manager】:
Thank you for coming on such short notice. We detected a serious quality issue in the welding process. The defect rate exceeded our acceptable limit, and we need your immediate support to resolve this.
🧑🎓【Student / Sales Representative】:
I sincerely ［お詫びする］ for the inconvenience this has caused to your production. We take full responsibility and are committed to identifying the root cause immediately. Our technical team is ready to assist you.
👨💼【Teacher / Quality Manager】:
Can you explain what might be causing this inconsistency? We need to understand whether this is a programming issue or a mechanical problem with the robot itself.
🧑🎓【Student / Sales Representative】:
Based on preliminary ［評価する］ment, there are three possible factors. First, the welding parameters may need adjustment for your specific material thickness. Second, the robot ［校正］ might have drifted over time. Third, environmental conditions such as temperature fluctuations could affect consistency. We will ［実施する］ a comprehensive inspection today to determine the exact cause.
👨💼【Teacher / Quality Manager】:
How long will it take to implement the corrective actions? Our production schedule is very tight, and we cannot afford extended downtime.
🧑🎓【Student / Sales Representative】:
We understand the urgency. Our recovery plan consists of three phases. First, we will complete the diagnostic inspection within 4 hours today. Second, we will ［修正する］ the program and recalibrate the robot within 24 hours. Third, we will monitor the process for 48 hours to ［検証する］ the improvements. This means full resolution within 3 days, with minimal impact on your production.
👨💼【Teacher / Quality Manager】:
What guarantee can you provide that this issue will not recur? We need a long-term solution, not just a temporary fix.
🧑🎓【Student / Sales Representative】:
We will establish a preventive maintenance protocol specifically for your facility. This includes monthly ［校正］ checks, quarterly parameter reviews, and real-time monitoring software that will ［検出した］ any ［逸脱］ before it affects quality. Additionally, we will train your maintenance team to identify early warning signs. These measures will ［排除する］ the risk of recurrence.
👨💼【Teacher / Quality Manager】:
I appreciate your comprehensive approach. Please proceed with the inspection immediately, and keep me updated on the progress every 4 hours. We are counting on your team to resolve this quickly.
4. Challenge (7 min)｜応用実践
Let's perform the role-play and fill in the blanks by translating the Japanese into English!
空欄の日本語を英語に訳しながら、ロールプレイを実践してみましょう！
*Let's practice this part repeatedly until we can speak it smoothly.
このパートはスムーズにスピーキングできるようになるまで繰り返し練習しましょう。
Situation / シチュエーション（Reference again）
Addressing quality variation issues in robot welding processes and proposing comprehensive improvement measures at a Mexican automotive parts manufacturer.
メキシコ自動車部品メーカーでのロボット溶接工程の品質ばらつき問題に対する包括的改善策を提案する場面です。
👨💼【Teacher / Quality Manager】:
Thank you for coming on such short notice. We detected a serious quality issue in the welding process. The defect rate exceeded our acceptable limit, and we need your immediate support to resolve this.
🧑🎓【Student / Sales Representative】:
［生産にご迷惑をおかけしたことを心よりお詫び申し上げます。］ ［私どもは全責任を負い、直ちに根本原因を特定することをお約束いたします。］ Our technical team is ready to assist you.
👨💼【Teacher / Quality Manager】:
Can you explain what might be causing this inconsistency? We need to understand whether this is a programming issue or a mechanical problem with the robot itself.
🧑🎓【Student / Sales Representative】:
［予備評価に基づくと、3つの要因が考えられます。］ First, the welding parameters may need adjustment for your specific material thickness. Second, the robot calibration might have drifted over time. Third, environmental conditions such as temperature fluctuations could affect consistency. ［本日、正確な原因を特定するため包括的な検査を実施いたします。］
👨💼【Teacher / Quality Manager】:
How long will it take to implement the corrective actions? Our production schedule is very tight, and we cannot afford extended downtime.
🧑🎓【Student / Sales Representative】:
We understand the urgency. Our recovery plan consists of three phases. First, we will complete the diagnostic inspection within 4 hours today. Second, we will modify the program and recalibrate the robot within 24 hours. Third, we will monitor the process for 48 hours to validate the improvements. This means full resolution within 3 days, with minimal impact on your production.
👨💼【Teacher / Quality Manager】:
What guarantee can you provide that this issue will not recur? We need a long-term solution, not just a temporary fix.
🧑🎓【Student / Sales Representative】:
We will establish a preventive maintenance protocol specifically for your facility. This includes monthly calibration checks, quarterly parameter reviews, and real-time monitoring software that will detect any deviation before it affects quality. Additionally, we will train your maintenance team to identify early warning signs. These measures will eliminate the risk of recurrence.
👨💼【Teacher / Quality Manager】:
I appreciate your comprehensive approach. Please proceed with the inspection immediately, and keep me updated on the progress every 4 hours. We are counting on your team to resolve this quickly.
\ If you have some extra capacity, give it a try（余力があればやってみましょう）/
5. Real-world application (5 min)｜実務応用
Let's speak freely with the phrases and flow we learned today. If you can, imagine your real job—it makes practice more effective.
本日学習した単語やフレーズ、会話の流れを思い出しながら、自由に話してみましょう。可能であれば、自身の実務を想像しながら話すと効果的です。
Situation / シチュエーション
A quality issue has occurred in the welding process at an automotive parts manufacturing facility in Mexico, and the defect rate has exceeded acceptable limits.
The customer requires immediate corrective actions and a long-term preventive solution to avoid production disruptions.
メキシコの自動車部品製造施設で溶接工程に品質問題が発生し、不良率が許容限度を超えました。
顧客は生産中断を避けるため、即座の是正措置と長期的な予防策を求めています。
👨💼【Teacher / Quality Manager】:
We need you to explain the root cause of this quality problem and present a concrete action plan to prevent recurrence. How will you address this situation?
（この品質問題の根本原因を説明し、再発防止のための具体的な行動計画を提示していただく必要があります。この状況にどう対処されますか？）
🧑🎓【Student / Your Role】:
(Free Speaking based on today's lesson)
Hints / ヒント
１． Apologize and take responsibility
２． Explain possible causes systematically
３． Present a phased recovery plan
４． Propose preventive measures
※This is not a role-play. Please speak until you finish your thoughts.
このパートはロールプレイ形式ではありません。最後まで通して話してみましょう。
6. Wrap-up (2 min) ｜レッスンの振り返り
Let's review today's lesson with your teacher!
今日のレッスンについて講師と振り返ってみましょう！
6-1 Comments from student
・Good points / 良かったところ・上手くできたところ
・Things to work on / 今後強化したいところ
6-2 Feedback from teacher
・Good points / 良かった点
・Things to work on / 今後の強化ポイント
・What to review / 復習ポイント
*6-3 Questions from student (if any)
Japanese translation（日本語訳）
1. Read (2min)（型を学ぶ）｜基本フレーズ
2. Try (4min)（ロールプレイ練習）｜型を使った練習
Let’s practice the role-play.
ロールプレイの練習をしましょう！
3. Use (7min)｜応用
Let’s perform the role-play and filling in the missing English!
英語を補完しながら、ロールプレイを実践してみましょう！
4. Challenge (7min)｜実践
Let’s perform the role-play and filling in the missing English!
英語を補完しながら、ロールプレイを実践してみましょう！
5. Wrap-up (3min) – レッスンの振り返り
"Let’s review today’s lesson with your teacher!”
「今日のレッスンについて講師と振り返ってみましょう！」
5-1. Comments from Student
- Good points / 良かったところ・上手くできたところ
- Things to work on / 今後強化したいところ
5-2. Feedback from Teacher
- Good points / 良かった点
- Things to work on / 今後の強化ポイント
- What to review / 復習ポイント
5-3. Question from Students (If any)