1、6TOOL GUIDE21st.Feb.2004India Pvt Ltd1.6TOOL?100 PPM QUALITY PROCESSOS&D*Sequential InspectionMain Process ControlTime CheckQuality AuditReview Meeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D:Over,Shortage&Defect2.6TOOL-1/OS&D ActivityA system to improve quality of components
2、found defective by monitoring,analyzing&acting on actual real time data&material supplied by suppliers.OS&D ImageEstablish full inspection systemEstablish quality information system-Real information system .Real data .Real material-Computerized OS&D managementEstablish vendor appraisal system-Qualit
3、y contract (agreement of target quality)-I&P System Innovation Flow*I&P:Incentive&PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal&QuickInformationImprovedMaterialInnovation Activities Attach tag after finding a defect on the line Place collection box for defectives in the line Collect re
4、jection&analysis of same 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-up2.6TOOL-1/OS&D Activity(RULE)PROD
5、UCTIONPURCHASEIQCMATERIALSUPPLIERActivities-Find 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 q ty .Emergency delivery-Hold improvement M/T with supplier .Sunrise M/T
6、-Collect the defective 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 t
7、o the line-Receive the defective parts-Analyze the reason-Hold improvement meeting .Daily meeting .Weekly innovation meeting (Q-manager attend)-Monthly evaluation meeting(Q-manager attend)MaterialWork defectVendor defect&TransportationReturnDataReplacement for defective partsSelf-inspection Check-li
8、stPreparedByCheckedByApprovedByMACHINE/MODEL BUYERORIGIN DATEREVISED DATEPROCESS NAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTION METHODREVISION NO*OS&D Stickers1.SUPPLIER DEFECT2.WORKMANSHIP DEFECTOS&D ReportPreparedByCheckedByApprovedByProduction Line:DATE:/S/NoPart NamePart NoDefect DescriptionVendorP
9、rod.QCWorkmanshipProd.QCTotalDefect StatusVendorNameQCSupervisorManagerPRODRemarksPro-Inspec-tion3.6TOOL-2/Sequential inspectionTo filter all the rejection on the line by inspecting pre-processed work totally(100%)at the next process.Sequential inspection imageAfter checking pre-processed work,do ow
10、n process activitiesStartAssembly Line1st Process2nd Process3rd ProcessInspect 100%in assembly processSequential 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 re
11、pair history-Notify the defective contents to operators in the review meeting-Make countermeasuresWork-ingPro-Inspec-tionPre-Inspec-tionWork-ingPro-Inspec-tionPre-Inspec-tionWork-ing*Sequential inspection GuideITEMPROCESS NAMESequential inspection guide*Sequential inspection StickerIndividual result
12、-Sequential inspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy1 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 31PtPtPtPtPtPtPtPtPtRepair RecordNOFault SHOP/:DATE :/PreparedByCheckedByApprovedByCauseAction TakenItemQty ConcernedOperationTOTAL PROD.QTY%REPAIR Rem
13、arks 4.6TOOL-3/Main Process ControlEstablish 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:
14、Time Check process,Customer s 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 per
15、manent countermeasure:Fool Proof-Establish check&appraisal system*TDRE:Tear Down&Re-Engineering*Sign BoardMAJOR PROCESSSPECIFIC PROCESSCRITICAL PROCESS550MM145MMMain Process Control SheetProduction Q tyDefective Q tyDefective RateDate1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
16、26 27 28 29 30 31 TotalDefectRate(ppm)1,0002,000SHOPPROCESS NAMECATEGORYOPERATOROPENING DATESUPERVISORTARGET5.6TOOL-4/Time CheckTo assure component quality which are processed in house,check main control point regularlyTime Check ImageFlow ChartActivity-Check quality periodically and take action-Ini
17、tial 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 productDecide check pointTake sampleCheckKeep sampleRecording Initial Intermediate Final Every
18、two hourOKNGStop production&check early LotRecheck 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 SHEETCHE
19、CKED BY(SUPERVISOR):APPROVED BY(MANAGER):LINEPROCESS NAMEDURATION(/)(/)CYCLEEVERY()HROPERATOR S NAMESUPERVISOR S NAMENoCheck itemsSignature by supervisorMON(/)TUE(/)WED(/)THU(/)FRI(/)SAT(/)09:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:000
20、4:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:00Specs*Time Check Process BoardTIME CHECK PROCESS550MM145MMTIME CHECK BOARDTime Check Sheet09:0011:0011:0001:0002:0004:0004:0006:00LINE:_ITEM:_OPERATORSUPERVISOR6.6TOOL-5/Q
21、-AUDITWe will compare the required quality level&the quality level of our products/processes and then narrow the gap.Flow ChartSelect modelFind problems/Register taskDo Q-AuditKeep RecordImprovementManage till innovatedProcessClassStep 1Step 2Step 3Outgoing AuditStep 1+Line AuditStep 2+Process(Parts
22、)AuditMAINFOCUSRem-arks-Understand customer s needs-Establish outgoing inspection parameters.-Do 100%inspection-Find out weak point&improve.-Establish line process parameters.-Do regular audit.-Find out line problems&improve.-Find out process or parts problem&solve them permanentlyRegular Audit by Q
23、A along with production&sometimes from Customer.Establish controlParameters.7.6TOOL-6/Review MeetingWe must naturalize ourselves to prevent defect input&improvement of such defects through systematic review.Daily MeetingWeekly MeetingMonthly Meeting-Describe process&parts defect with actual material
24、-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 next month plan-Supervisor&All Managers-Once per monthQuality Review ReportLINEDATE/PreparedbyAPPROVALPreparedbyChe
25、ckedbyHODLQC Status1.Rejection rate(/)(/)ProdQ tyRejQ tyPPMAPCusedAPC rejPPM rej2.Worst 5 items (Customer/Line)12345Problem&CauseCountermeasureDate Resp.SignAPCSHOPREJECTION STATUSMONTH 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 31TotalProductionQ tyAPC usedQtyR
26、ejectionQ tyAPC Rej.RateDateRate(Unit:PPM)50100150200300APC rej.QtyShop Rejection RateAPC TARGETMonthly Line Rejection Rate2004 REJECTION RATE(PPM)JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 50100150200ProdQ tyAPC usedRej.Q tyAPC Rej.RateAPC rej.Shop Rej.RateAPC TARGET1-1 6 Sigma Concept levelPP
27、M6 3.45233 46210 366,807 2308,537 Process Defects Capability OpportunitySweet Fruits(Perfect Design)Bulk of fruits(Optimization)Lower fruits(7 QC tools)Ground fruits(Straight viewpt)1-1 6 Sigma Concept-I3 Sigma Level Company6 Sigma Level Company 10 15%of sales is failure cost Having 66,807 defects p
28、er 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 process not to produce Defe
29、cts 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 view1-1 6 Sigma Concept-II3 Sigma Level Company6 Sigma Level Company 54,000 wrong drug prescriptions/year Unsafe drinking w
30、ater 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 operations/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
31、 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.1-2 6 Sigma Concept(Aspect of tools)StepsToolsDefinitionMeasurementAnalysisImprovementControl1)Process Mapping2)Logic Tree3)Pareto Analysis4)QFD,FMEA5)Gage R&R6)R
32、ational subgroupings7)Process Capability8)Hypothesis Testing9)Regression10)Graph analysis11)DOE(Design of Experiment12)Direct Improvements13)SPC1-3 Understanding Basic concepts of Statistics“Z“is the measure of process capability Z=3 Z=612 3LSLUSL123LSLUSL4 5 6There 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
