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1、,6TOOL GUIDE,21st.Feb.2004,India Pvt Ltd,1.6TOOL?,100 PPM QUALITY PROCESS,PerfectCheckSystem,CultivatingTeamSkill,Implement6TOOL,*OS&D:Over,Shortage&Defect,2.6TOOL-1/OS&D Activity,A system to improve quality of components found defective by monitoring,analyzing&acting on actual real time data&materi
2、al supplied by suppliers.,OS&D Image,Establish full inspection system,Establish quality information system-Real information system.Real data.Real material-Computerized OS&D management,Establish vendor appraisal system-Quality contract(agreement of target quality)-I&P System,Innovation Flow,*I&P:Ince
3、ntive&Penalty,FACTORY,SUPPLIERS,ImprovementActivities,DefectFound,Real&QuickInformation,ImprovedMaterial,Innovation Activities,Attach tag after finding a defect on the line Place collection box for defectives in the line Collect rejection&analysis of same from IQC members Display rejection due to su
4、pplier Request for urgent delivery in exchange of total rejection.Supplier must receive real information and have improvement meeting(once/week)=Q-manager attend Receive improved material&follow-up,2.6TOOL-1/OS&D Activity(RULE),Activities,-Find defective parts-Attach tag.Supplier defect:Red.Transpor
5、tation:Blue.Work defect:Yellow-Store defective parts-Issue OS&D NCR(once/day),-Provide additional parts in lieu of defected qty.Emergency delivery-Hold improvement M/T with supplier.Sunrise M/T,-Collect the defective parts(once/day)-Analyze and evaluate the cause of rejection.Classify the reason the
6、ir types like internal work error or transportation or vendor-Record and manage current defect status and feed back,-Display the defective parts-Organize the receipt/issuing of alternated parts to the line,-Receive the defective parts-Analyze the reason-Hold improvement meeting.Daily meeting.Weekly
7、innovation meeting(Q-manager attend)-Monthly evaluation meeting(Q-manager attend),Material,Work defect,Vendor defect&Transportation,Return,Data,Replacement for defective parts,Self-inspection Check-list,PreparedBy,CheckedBy,ApprovedBy,MACHINE/MODEL,BUYER,ORIGIN DATE,REVISED DATE,PROCESS NAME,DRAWING
8、,PART,SPECIFICATION,SELF-INSPECTION METHOD,REVISION NO,*OS&D Stickers,1.SUPPLIER DEFECT,2.WORKMANSHIP DEFECT,OS&D Report,PreparedBy,CheckedBy,ApprovedBy,Production Line:DATE:/,S/No,Part Name,Part No,Defect Description,Vendor,Prod.,QC,Workmanship,Prod.,QC,Total,Defect Status,VendorName,QC,Supervisor,
9、Manager,PROD,Remarks,Pro-Inspec-tion,3.6TOOL-2/Sequential inspection,To filter all the rejection on the line by inspecting pre-processed work totally(100%)at the next process.,Sequential inspection image,After checking pre-processed work,do own process activities,Start,Assembly Line,1st Process,2nd
10、Process,3rd Process,Inspect 100%in assembly process,Sequential inspection image,-Setting sequential inspection points of each process-Check pre-process work-Attach a tag on the defected position-Feed back to the concerned operator-Record and manage repair history-Notify the defective contents to ope
11、rators in the review meeting-Make countermeasures,Work-ing,Pro-Inspec-tion,Pre-Inspec-tion,Work-ing,Pro-Inspec-tion,Pre-Inspec-tion,Work-ing,*Sequential inspection Guide,ITEM,PROCESS NAME,Sequential inspection guide,*Sequential inspection Sticker,Individual result-Sequential inspection,NO,Name,LINE:
12、MONTH:,PreparedBy,CheckedBy,ApprovedBy,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Repair Record,NO,Fault,SHOP/:DATE:/,PreparedBy,CheckedBy,ApprovedBy,Cause,Action Taken,Item,Qty,ConcernedOperation,TOTAL,PROD.QTY,%REPAIR,Remarks,4.6T
13、OOL-3/Main Process Control,Establish visual management for main process(Heavy rejection,Customer complaints,critical etc.)and concentrate on improvement activity like Fool Proof.,Main Process Operation,-Install sign boards such as:.Major process:Customer Complain,Line Defect.Specific process:Time Ch
14、eck process,Customers requirement.Critical process:Critical items,Standard items-Register defective process:When defect occurs-Withdraw main process:when no defect occurs-If rejection occurs establish countermeasure:attach the process-TDRE*activity when defect occurs continuously-Make a permanent co
15、untermeasure:Fool Proof-Establish check&appraisal system,*TDRE:Tear Down&Re-Engineering,*Sign Board,MAJOR PROCESS,SPECIFIC PROCESS,CRITICAL PROCESS,550MM,145MM,Main Process Control Sheet,Production Qty,Defective Qty,Defective Rate,Date,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2
16、5 26 27 28 29 30 31 Total,DefectRate,(ppm),1,000,2,000,SHOP,PROCESS NAME,CATEGORY,OPERATOR,OPENING DATE,SUPERVISOR,TARGET,5.6TOOL-4/Time Check,To assure component quality which are processed in house,check main control point regularly,Time Check Image,Flow Chart,Activity,-Check quality periodically
17、and take action-Initial inspection:.Assure initial setting condition-Intermediate inspection:Check 4M variation.Correct specification variation of 4M at mid of production day-Final inspection:Assure the quality of finished product,Decide check point,Take sample,Check,Keep sample,Recording,Initial In
18、termediate Final,Every two hour,OK,NG,Stop production&check early Lot,Recheck all(100%),Change working condition&repair,-Isolate rejected lot-Stop the defective input to the next process-Decide limit level and segregate-Repair or disposal-Find out defect cause-Establish permanent solution with conce
19、rned dept.,TIME CHECK SHEET,CHECKED BY(SUPERVISOR):APPROVED BY(MANAGER):,LINE,PROCESS NAME,DURATION,(/)(/),CYCLE,EVERY()HR,OPERATORS NAME,SUPERVISORS NAME,No,Check items,Signature by supervisor,MON(/),TUE(/),WED(/),THU(/),FRI(/),SAT(/),09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:0
20、0,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,Specs,*Time Check Process Board,TIME CHECK PROCESS,550MM,145MM,TIME CHECK BOARD,Time Check Sheet,09:
21、0011:00,11:0001:00,02:0004:00,04:0006:00,LINE:_,ITEM:_,OPERATOR,SUPERVISOR,6.6TOOL-5/Q-AUDIT,We will compare the required quality level&the quality level of our products/processes and then narrow the gap.,Flow Chart,Select model,Find problems/Register task,Do Q-Audit,Keep Record,Improvement,Manage t
22、ill innovated,Process,Class,Step 1,Step 2,Step 3,Outgoing Audit,Step 1+Line Audit,Step 2+Process(Parts)Audit,MAINFOCUS,Rem-arks,-Understand customers needs Establish outgoing inspection parameters.Do 100%inspection Find out weak point&improve.,Establish line process parameters.Do regular audit.Find
23、out line problems&improve.,-Find out process or parts problem&solve them permanently,Regular Audit by QA along with production&sometimes from Customer.,Establish controlParameters.,7.6TOOL-6/Review Meeting,We must naturalize ourselves to prevent defect input&improvement of such defects through syste
24、matic review.,Daily Meeting,Weekly Meeting,Monthly Meeting,-Describe process&parts defect with actual material-Conducted by supervisor with all operators-Do daily,-Weekly meeting to make counter-measure(OS&D,Line Rejection)-Supervisor&Manager-Once per week,-Review monthly target&result,establish nex
25、t month plan-Supervisor&All Managers-Once per month,Quality Review Report,LINE,DATE,/,Preparedby,APPROVAL,Preparedby,Checkedby,HOD,LQC Status,1.Rejection rate,(/)(/),ProdQty,RejQty,PPM,APCused,APC rej,PPM rej,2.Worst 5 items(Customer/Line),12345,Problem&Cause,Countermeasure,Date,Resp.,Sign,APC,SHOP,
26、MONTH,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31,Total,ProductionQty,APC usedQty,RejectionQty,APC Rej.Rate,Date,Rate,(Unit:PPM),50,100,150,200,300,APC rej.Qty,Shop Rejection Rate,APC TARGET,Monthly Line Rejection Rate,2004,REJECTION RATE,(PPM),JAN FEB MAR APR
27、 MAY JUN JUL AUG SEP OCT NOV DEC,50,100,150,200,ProdQty,APC used,Rej.Qty,APC Rej.Rate,APC rej.,Shop Rej.Rate,APC TARGET,1-1 6 Sigma Concept,level,PPM,6 3.45233 46210 366,807 2308,537 Process Defects Capability Opportunity,Sweet Fruits(Perfect Design),Bulk of fruits(Optimization),Lower fruits(7 QC to
28、ols),Ground fruits(Straight viewpt),1-1 6 Sigma Concept-I,3 Sigma Level Company,6 Sigma Level Company,10 15%of sales is failure cost Having 66,807 defects per Million Depends on the detection of defects Believes that high Quality is expensive Doesnt follow systematic approach Benchmarking against co
29、mpeting companies Believes 99%is good enough Defines CTQs internally,5%of sales is failure cost 3.4 defects per Million Focus on process not to produce Defects Believes that high Quality creates low cost Uses D-M-A-I-C Know how Benchmarking to be the Best in the World Believes 99%is unacceptable.Def
30、ines CTQs from customer point of view,1-1 6 Sigma Concept-II,3 Sigma Level Company,6 Sigma Level Company,54,000 wrong drug prescriptions/year Unsafe drinking water 2hrs/month No telephone service for 27 min/week 5 Short or long landings at the heathero airport in a day.1,350 incorrect surgical opera
31、tions/week.54,000 lost articles of mail loss/hr.,1 wrong drug prescription in 25 years.Unsafe drinking water for 16 years.No telephone service for 6 sec for 100 years 1 short or long landings at Heathero airport in 10 years.1 incorrect surgical operation for 20 years.35 lost articles of mail/year.,1
32、-2 6 Sigma Concept(Aspect of tools),Steps,Tools,Definition,Measurement,Analysis,Improvement,Control,Process MappingLogic TreePareto AnalysisQFD,FMEA,Gage R&RRational subgroupingsProcess Capability,Hypothesis TestingRegressionGraph analysis,DOE(Design of ExperimentDirect Improvements,13)SPC,1-3 Under
33、standing Basic concepts of Statistics,“Z“is the measure of process capability Z=3 Z=6,1,2,3,LSL,USL,1,2,3,LSL,USL,4,5,6,There are equal noOf S.D on both sidesSo for Z=3,the toleranceBand is divided into 6S.DFor Z=6,the tolerance Band isDivided into 12 S.DAs number of S.D increasesThe curve narrows down&soProcess capability increases&Thus defect decreases.,Cp 2.0Cpk 1.5,
