美资企业内训资料(ppt 27页)(英文版).ppt

1、1. 6TOOL ?,100 PPM QUALITY PROCESS,Perfect Check System,Cultivating Team Skill,Implement 6TOOL,*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 & material supplied by suppl

2、iers.,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 : Incentive

3、 & Penalty,FACTORY,SUPPLIERS,Improvement Activities,Defect Found,Real & Quick Information,Improved Material,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

4、to supplier 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

5、defect : Red . Transportation : 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 t

6、he cause of rejection. . Classify the reason their 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

7、the reason - Hold improvement meeting .Daily meeting .Weekly 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,Prepared By,Checked By,Approve

8、d By,MACHINE / MODEL,BUYER,ORIGIN DATE,REVISED DATE,PROCESS NAME,DRAWING,PART,SPECIFICATION,SELF-INSPECTION METHOD,REVISION NO,* OS&D Stickers,1. SUPPLIER DEFECT,2. WORKMANSHIP DEFECT,OS&D Report,Prepared By,Checked By,Approved By,Production Line : DATE : / /,S/No,Part Name,Part No,Defect Descriptio

9、n,Vendor,Prod.,QC,Workmanship,Prod.,QC,Total,Defect Status,Vendor Name,Q C,Supervisor,Manager,P R O D,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,

10、After checking pre-processed work, do own process activities,Start,Assembly Line,1st Process,2nd 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 -

11、Feed back to the concerned operator - Record and manage repair history - Notify the defective contents to operators 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,PR

12、OCESS NAME,Sequential inspection guide,* Sequential inspection Sticker,Individual result - Sequential inspection,N O,Name,LINE : MONTH :,Prepared By,Checked By,Approved By,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,

13、Fault,SHOP / : DATE : / /,Prepared By,Checked By,Approved By,Cause,Action Taken,Item,Qty,Concerned Operation,TOTAL,PROD. QTY,% REPAIR,Remarks,4. 6TOOL-3 / Main Process Control,Establish visual management for main process (Heavy rejection, Customer complaints,critical etc.) and concentrate on improve

14、ment activity like Fool Proof.,Main Process Operation,- Install sign boards such as : . Major process : Customer Complain, Line Defect . Specific process : Time Check process, Customers requirement . Critical process : Critical items, Standard items - Register defective process : When defect occurs

15、- Withdraw main process : when no defect occurs - If rejection occurs establish countermeasure : attach the process - TDRE* activity when defect occurs continuously - Make a permanent countermeasure : Fool Proof - Establish check & appraisal system,*TDRE : Tear Down & Re- Engineering,* Sign Board,MA

16、JOR 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 25 26 27 28 29 30 31 Total,Defect Rate,(ppm),1,000,2,000,SHOP,PROCESS NAME,CATEGORY,OPERATOR,OPENING DA

17、TE,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 and take action - Initial inspection : . Assure initial setting condition - Intermediate inspect

18、ion : 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 Intermediate Final,Every two hour,OK,NG,Stop production & check early Lot,Recheck a

19、ll (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 concerned dept.,TIME CHECK SHEET,CHECKED BY(SUPERVISOR): APPROVED BY(M

20、ANAGER):,LINE,PROCESS NAME,DURATION,( / / ) ( / / ),CYCLE,EVERY ( ) HR,OPERATORS NAME,SUPERVISORS NAME,No,Check items,Signature by supervisor,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

21、: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,* Time Check Process Board,TIME CHECK PROCESS,550MM,145MM,TIME CHECK BOARD,Time Check Sheet,09:0011:00,1

22、1:0001:00,02:0004:00,04:0006:00,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,Manag

23、e till innovated,Process,Class,Step 1,Step 2,Step 3,Outgoing Audit,Step 1 +Line Audit,Step 2 + Process (Parts) Audit,M A I N F O C U S,Rem- arks,- Understand customers needs Establish outgoing inspection parameters. Do 100% inspection Find out weak point & improve.,Establish line process parameters.

24、 Do regular audit. Find out line problems & improve.,- Find out process or parts problem & solve them permanently,Regular Audit by QA along with production & sometimes from Customer.,Establish control Parameters.,7. 6TOOL-6 / Review Meeting,We must naturalize ourselves to prevent defect input & impr

25、ovement of such defects through systematic 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 - On

26、ce per week,- Review monthly target & result, establish next month plan - Supervisor & All Managers - Once per month,Quality Review Report,LINE,DATE,/ /,Prepared by,A P P R O V A L,Prepared by,Checked by,HOD,LQC Status,1. Rejection rate,( / ) ( / ),Prod Qty,Rej Qty,PPM,APC used,APC rej,PPM rej,2. Wo

27、rst 5 items ( Customer / Line),1 2 3 4 5,Problem & Cause,Countermeasure,Date,Resp.,Sign,A P C,S H O P,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,Production Qty,APC used Qty,Rejection Qty,APC Rej. Rate,Date,Rate,(Unit : PPM),50,100,150,200,300,APC

28、rej. Qty,Shop Rejection Rate,APC TARGET,Monthly Line Rejection Rate,2004,REJECTION RATE,(PPM),JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC,50,100,150,200,Prod Qty,APC used,Rej. Qty,APC Rej. Rate,APC rej.,Shop Rej. Rate,APC TARGET,1-1 6 Sigma Concept, level,PPM,6 3.4 5233 46210 366,807 2308,537 Pr

29、ocess Defects Capability Opportunity,Sweet Fruits ( Perfect Design),Bulk of fruits ( Optimization),Lower fruits ( 7 QC tools),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 o

30、n the detection of defects Believes that high Quality is expensive Doesnt follow systematic approach Benchmarking against competing 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

31、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. Defines 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.