一家美资企业的内训资料.ppt

1、,6TOOL GUIDE,21st. Feb. 2004,India Pvt Ltd,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

2、real time data & material 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) -

3、I&P System,Innovation Flow,*I&P : Incentive & 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 s

4、ame from IQC members Display rejection due 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,- F

5、ind defective parts -Attach tag . Supplier 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 defectiv

6、e parts (once/day) - Analyze and evaluate the 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 li

7、ne,- Receive the defective parts - Analyze 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-inspectio

8、n Check-list,Prepared By,Checked By,Approved 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 : /

9、 /,S/No,Part Name,Part No,Defect Description,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

10、 next process.,Sequential inspection image,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

11、 - Attach a tag on the defected position - 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

12、 -ing,* Sequential inspection Guide,ITEM,PROCESS 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,P

13、t,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Repair Record,NO,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 complaint

14、s,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 Check process, Customers requirement . Critical process : Critical items, Standard items - Regis

15、ter 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 countermeasure : Fool Proof - Establish check & appraisal system,*TDRE :

16、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 25 26 27 28 29 30 31 Total,Defect Rate,(ppm),1,000,2,000,SHO

17、P,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 and take action - Initial inspection : . Assure initi

18、al 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 Intermediate Final,Every two hour,OK,NG,

19、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 concerned dept.,TIME CHECK

20、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 ( / ),09:00 11:00,11:00 01:00,02:00 04:00,04:00 06:00,09:00 1

21、1:00,11:00 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,* Time Check Process Board,TIME CHECK PROCESS,550MM,145MM,TIM

22、E CHECK BOARD,Time Check Sheet,09:0011:00,11:0001:00,02:0004:00,04:0006:00,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 ta

23、sk,Do Q-Audit,Keep Record,Improvement,Manage 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 &

24、improve.,Establish line process parameters. 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 naturali

25、ze ourselves to prevent defect input & improvement 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,

26、Line Rejection) - Supervisor & Manager - Once 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

27、,Rej Qty,PPM,APC used,APC rej,PPM rej,2. Worst 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,Dat

28、e,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 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, lev

29、el,PPM,6 3.4 5233 46210 366,807 2308,537 Process 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

30、Having 66,807 defects per Million Depends on 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 pr

31、ocess 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. 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