企业培训_某家美资企业的培训资料

6TOOLGUIDE 21st Feb 2004 IndiaPvtLtd 1 6TOOL 100PPMQUALITYPROCESS PerfectCheckSystem CultivatingTeamSkill Implement6TOOL OS D Over Shortage Defect 2 6TOOL 1 OS DActivity Asystemtoimprovequalityofcomponentsfounddefectivebymonitoring analyzing actingonactualrealtimedata materialsuppliedbysuppliers OS DImage Establishfullinspectionsystem Establishqualityinformationsystem Realinformationsystem Realdata Realmaterial ComputerizedOS Dmanagement Establishvendorappraisalsystem Qualitycontract agreementoftargetquality I PSystem InnovationFlow I P Incentive Penalty FACTORY SUPPLIERS ImprovementActivities DefectFound Real QuickInformation ImprovedMaterial InnovationActivities AttachtagafterfindingadefectonthelinePlacecollectionboxfordefectivesinthelineCollectrejection analysisofsamefromIQCmembersDisplayrejectionduetosupplierRequestforurgentdeliveryinexchangeoftotalrejection Suppliermustreceiverealinformationandhaveimprovementmeeting once week Q managerattendReceiveimprovedmaterial follow up 2 6TOOL 1 OS DActivity RULE Activities Finddefectiveparts Attachtag Supplierdefect Red Transportation Blue Workdefect Yellow Storedefectiveparts IssueOS DNCR once day Provideadditionalpartsinlieuofdefectedq ty Emergencydelivery HoldimprovementM Twithsupplier SunriseM T Collectthedefectiveparts once day Analyzeandevaluatethecauseofrejection Classifythereasontheirtypeslikeinternalworkerrorortransportationorvendor Recordandmanagecurrentdefectstatusandfeedback Displaythedefectiveparts Organizethereceipt issuingofalternatedpartstotheline Receivethedefectiveparts Analyzethereason Holdimprovementmeeting Dailymeeting Weeklyinnovationmeeting Q managerattend Monthlyevaluationmeeting Q managerattend Material Workdefect Vendordefect Transportation Return Data Replacementfordefectiveparts Self inspectionCheck list PreparedBy CheckedBy ApprovedBy MACHINE MODEL BUYER ORIGINDATE REVISEDDATE PROCESSNAME DRAWING PART SPECIFICATION SELF INSPECTIONMETHOD REVISIONNO OS DStickers 1 SUPPLIERDEFECT 2 WORKMANSHIPDEFECT OS DReport PreparedBy CheckedBy ApprovedBy ProductionLine DATE S No PartName PartNo DefectDescription Vendor Prod QC Workmanship Prod QC Total DefectStatus VendorName QC Supervisor Manager PROD Remarks Pro Inspec tion 3 6TOOL 2 Sequentialinspection Tofilteralltherejectiononthelinebyinspectingpre processedworktotally 100 atthenextprocess Sequentialinspectionimage Aftercheckingpre processedwork doownprocessactivities Start AssemblyLine 1stProcess 2ndProcess 3rdProcess Inspect100 inassemblyprocess Sequentialinspectionimage Settingsequentialinspectionpointsofeachprocess Checkpre processwork Attachatagonthedefectedposition Feedbacktotheconcernedoperator Recordandmanagerepairhistory Notifythedefectivecontentstooperatorsinthereviewmeeting Makecountermeasures Work ing Pro Inspec tion Pre Inspec tion Work ing Pro Inspec tion Pre Inspec tion Work ing SequentialinspectionGuide ITEM PROCESSNAME Sequentialinspectionguide SequentialinspectionSticker Individualresult Sequentialinspection NO Name LINE MONTH PreparedBy CheckedBy ApprovedBy 12345678910111213141516171819202122232425262728293031 Pt Pt Pt Pt Pt Pt Pt Pt Pt RepairRecord NO Fault SHOP DATE PreparedBy CheckedBy ApprovedBy Cause ActionTaken Item Qty ConcernedOperation TOTAL PROD QTY REPAIR Remarks 4 6TOOL 3 MainProcessControl Establishvisualmanagementformainprocess Heavyrejection Customercomplaints criticaletc andconcentrateonimprovementactivitylikeFoolProof MainProcessOperation Installsignboardssuchas Majorprocess CustomerComplain LineDefect Specificprocess TimeCheckprocess Customer srequirement Criticalprocess Criticalitems Standarditems Registerdefectiveprocess Whendefectoccurs Withdrawmainprocess whennodefectoccurs Ifrejectionoccursestablishcountermeasure attachtheprocess TDRE activitywhendefectoccurscontinuously Makeapermanentcountermeasure FoolProof Establishcheck appraisalsystem TDRE TearDown Re Engineering SignBoard MAJORPROCESS SPECIFICPROCESS CRITICALPROCESS 550MM 145MM MainProcessControlSheet ProductionQ ty DefectiveQ ty DefectiveRate Date 12345678910111213141516171819202122232425262728293031Total DefectRate ppm 1 000 2 000 SHOP PROCESSNAME CATEGORY OPERATOR OPENINGDATE SUPERVISOR TARGET 5 6TOOL 4 TimeCheck Toassurecomponentqualitywhichareprocessedinhouse checkmaincontrolpointregularly TimeCheckImage FlowChart Activity Checkqualityperiodicallyandtakeaction Initialinspection Assureinitialsettingcondition Intermediateinspection Check4Mvariation Correctspecificationvariationof4Matmidofproductionday Finalinspection Assurethequalityoffinishedproduct Decidecheckpoint Takesample Check Keepsample Recording InitialIntermediateFinal Everytwohour OK NG Stopproduction checkearlyLot Recheckall 100 Changeworkingcondition repair Isolaterejectedlot Stopthedefectiveinputtothenextprocess Decidelimitlevelandsegregate Repairordisposal Findoutdefectcause Establishpermanentsolutionwithconcerneddept TIMECHECKSHEET CHECKEDBY SUPERVISOR APPROVEDBY MANAGER LINE PROCESSNAME DURATION CYCLE EVERY HR OPERATOR SNAME SUPERVISOR SNAME No Checkitems Signaturebysupervisor MON TUE WED THU FRI SAT 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 Specs TimeCheckProcessBoard TIMECHECKPROCESS 550MM 145MM TIMECHECKBOARD TimeCheckSheet 09 00 11 00 11 00 01 00 02 00 04 00 04 00 06 00 LINE ITEM OPERATOR SUPERVISOR 6 6TOOL 5 Q AUDIT Wewillcomparetherequiredqualitylevel thequalitylevelofourproducts processesandthennarrowthegap FlowChart Selectmodel Findproblems Registertask DoQ Audit KeepRecord Improvement Managetillinnovated Process Class Step1 Step2 Step3 OutgoingAudit Step1 LineAudit Step2 Process Parts Audit MAINFOCUS Rem arks Understandcustomer sneedsEstablishoutgoinginspectionparameters Do100 inspectionFindoutweakpoint improve Establishlineprocessparameters Doregularaudit Findoutlineproblems improve Findoutprocessorpartsproblem solvethempermanently RegularAuditbyQAalongwithproduction sometimesfromCustomer EstablishcontrolParameters 7 6TOOL 6 ReviewMeeting Wemustnaturalizeourselvestopreventdefectinput improvementofsuchdefectsthroughsystematicreview DailyMeeting WeeklyMeeting MonthlyMeeting Describeprocess partsdefectwithactualmaterial Conductedbysupervisorwithalloperators Dodaily Weeklymeetingtomakecounter measure OS D LineRejection Supervisor Manager Onceperweek Reviewmonthlytarget result establishnextmonthplan Supervisor AllManagers Oncepermonth QualityReviewReport LINE DATE Preparedby APPROVAL Preparedby Checkedby HOD LQCStatus 1 Rejectionrate ProdQ ty RejQ ty PPM APCused APCrej PPMrej 2 Worst5items Customer Line 12345 Problem Cause Countermeasure Date Resp Sign APC SHOP MONTH 12345678910111213141516171819202122232425262728293031 Total ProductionQ ty APCusedQty RejectionQ ty APCRej Rate Date Rate Unit PPM 50 100 150 200 300 APCrej Qty ShopRejectionRate APCTARGET MonthlyLineRejectionRate 2004 REJECTIONRATE PPM JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC 50 100 150 200 ProdQ ty APCused Rej Q ty APCRej Rate APCrej ShopRej Rate APCTARGET 1 16SigmaConcept level PPM 63 4523346210366 8072308 537ProcessDefectsCapabilityOpportunity SweetFruits PerfectDesign Bulkoffruits Optimization Lowerfruits 7QCtools Groundfruits Straightviewpt 1 16SigmaConcept I 3SigmaLevelCompany 6SigmaLevelCompany 10 15 ofsalesisfailurecostHaving66 807defectsperMillionDependsonthedetectionofdefectsBelievesthathighQualityisexpensiveDoesn tfollowsystematicapproachBenchmarkingagainstcompetingcompaniesBelieves99 isgoodenoughDefinesCTQ sinternally 5 ofsalesisfailurecost3 4defectsperMillionFocusonprocessnottoproduceDefectsBelievesthathighQualitycreateslowcostUsesD M A I CKnowhowBenchmarkingtobetheBestintheWorldBelieves99 isunacceptable DefinesCTQ sfromcustomerpointofview 1 16SigmaConcept II 3SigmaLevelCompany 6SigmaLevelCompany 54 000wrongdrugprescriptions yearUnsafedrinkingwater2hrs monthNotelephoneservicefor27min week5Shortorlonglandingsattheheatheroairpo