一家美资企业的内训资料.ppt

,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),-Provideadditionalpartsinlieuofdefectedqty.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,Customersrequirement.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,ProductionQty,DefectiveQty,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,OPERATORSNAME,SUPERVISORSNAME,No,Checkitems,Signaturebysupervisor,MON(/),TUE(/),WED(/),THU(/),FRI(/),SAT(/),09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,09:0011:00,11:0001:00,02:0004:00,04:0006:00,Specs,*TimeCheckProcessBoard,TIMECHECKPROCESS,550MM,145MM,TIMECHECKBOARD,TimeCheckSheet,09:0011:00,11:0001:00,02:0004:00,04:0006:00,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,-UnderstandcustomersneedsEstablishoutgoinginspectionparameters.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,(/)(/),ProdQty,RejQty,PPM,APCused,APCrej,PPMrej,2.Worst5items(Customer/Line),12345,Problem&Cause,Countermeasure,Date,Resp.,Sign,APC,SHOP,MONTH,12345678910111213141516171819202122232425262728293031,Total,ProductionQty,APCusedQty,RejectionQty,APCRej.Rate,Date,Rate,(Unit:PPM),50,100,150,200,300,APCrej.Qty,ShopRejectionRate,APCTARGET,MonthlyLineRejectionRate,2004,REJECTIONRATE,(PPM),JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC,50,100,150,200,ProdQty,APCused,Rej.Qty,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,1015%ofsalesisfailurecostHaving66,807defectsperMillionDependsonthedetectionofdefectsBelievesthathighQualityisexpensiveDoesntfollowsystematicapproachBenchmarkingagainstcompetingcompaniesBelieves99%isgoodenoughDefinesCTQsinternally,5%ofsalesisfailurecost3.4defectsperMillionFocusonprocessnottoproduceDefectsBelievesthathighQualitycreateslowcostUsesD-M-A-I-CKnowhowBenchmarkingtobetheBestintheWorldBelieves99%isunacceptable.DefinesCTQsfromcustomerpointofview,1-16SigmaConcept-II,3SigmaLevelCompany,6SigmaLevelCompany,54,000wrongdrugprescriptions/yearUnsafedrinkingwater2hrs/monthNotelephoneservicefor27min/week5Shortorlonglandingsattheheatheroai