美资企业的內训资料英文版

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 im

2、prove quality of components 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&am

3、p;D managementEstablish vendor appraisal system- Quality contract (agreement of target quality)- I&P System Innovation Flow*I&P : Incentive & PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal & QuickInformationImprovedMaterialInnovation Activities Attach tag after finding a

4、 defect on the line Place collection box for defectives in the line Collect rejection & 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)

5、= Q-manager attend Receive improved material & follow-up2. 6TOOL-1 / OS&D Activity (RULE)PRODUCTIONPURCHASEIQCMATERIALSUPPLIERActivities- Find defective parts-Attach tag . Supplier defect : Red . Transportation : Blue . Work defect : Yellow- Store defective parts- Issue OS&D NCR (once/da

6、y)- Provide additional parts in lieu of defected q ty . Emergency delivery- Hold improvement M/T with supplier . Sunrise M/T - 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-

7、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 the reason- Hold improvement meeting .Daily meeting .Weekly innovation meeting (Q-manager attend) - Monthly evaluati

8、on meeting (Q-manager attend)MaterialWork defectVendor defect &TransportationReturnDataReplacement for defective partsSelf-inspection Check-listPreparedByCheckedByApprovedByMACHINE / MODEL BUYERORIGIN DATEREVISED DATEPROCESS NAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTION METHODREVISION NO* OS&D

9、 Stickers1. SUPPLIER DEFECT2. WORKMANSHIP DEFECTOS&D ReportPreparedByCheckedByApprovedByProduction Line : DATE : / / S/NoPart NamePart NoDefect DescriptionVendorProd.QCWorkmanshipProd.QCTotalDefect StatusVendorNameQCSupervisorManagerPRODRemarksPro- Inspec-tion3. 6TOOL-2 / Sequential inspectionTo

10、 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 own process activitiesStartAssembly Line1st Process2nd Process3rd ProcessInspect 100% in assembly processSequential inspection im

11、age- 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 repair history- Notify the defective contents to operators in the review meeting- Make countermeasuresWork-ingPro- Inspec-t

12、ionPre-Inspec-tionWork-ingPro- Inspec-tionPre-Inspec-tionWork-ing* Sequential inspection GuideITEMPROCESS NAMESequential inspection guide* Sequential inspection StickerIndividual result - Sequential inspectionNONameLINE : MONTH : PreparedByCheckedByApprovedBy1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

13、 18 19 20 21 22 23 24 25 26 27 28 29 30 31PtPtPtPtPtPtPtPtPtRepair RecordNOFault SHOP / : DATE : / / PreparedByCheckedByApprovedByCauseAction TakenItemQty ConcernedOperationTOTAL PROD. QTY % REPAIR Remarks 4. 6TOOL-3 / Main Process ControlEstablish visual management for main process (Heavy rejection

14、, 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 : Time Check process, Customer s requirement . Critical process : Critical items, Sta

15、ndard 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 permanent countermeasure : Fool Proof- Establish check & appraisa

16、l 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 26 27 28 29 30 31 TotalDefectRate(ppm)1,0002,00

17、0SHOPPROCESS 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- Initial inspection : . Assure initial settin

18、g 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 two hourOKNGStop production&

19、; 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 SHEETCHECKED BY(SUPERV

20、ISOR):APPROVED BY(MANAGER):LINEPROCESS NAMEDURATION( / / ) ( / / )CYCLEEVERY ( ) HROPERATOR S NAMESUPERVISOR S NAMENoCheck itemsSignature by supervisorMON ( / )TUE ( / )WED ( / )THU ( / )FRI ( / )SAT ( / )09:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:00

21、01:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:0009:0011:0011:0001:0002:0004:0004:0006:00Specs* Time Check Process BoardTIME CHECK PROCESS550MM145MMTIME CHECK BOARDTime Check Sheet09:0011:0011:0001:0002:0004:0004:0006:00LINE : _ITEM : _OPERATOR

22、SUPERVISOR6. 6TOOL-5 / Q-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

23、1 +Line AuditStep 2 + Process (Parts) 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

24、 parts problem & solve them permanentlyRegular Audit by QA 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 MeetingWe

25、ekly MeetingMonthly 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- Once per week- Review monthly target & result, establish next

26、 month plan- Supervisor & All Managers- Once per monthQuality Review ReportLINEDATE/ /PreparedbyAPPROVALPreparedbyCheckedbyHODLQC Status1. Rejection rate( / ) ( / )ProdQ tyRejQ tyPPMAPCusedAPC rejPPM rej2. Worst 5 items ( Customer / Line)12345Problem & CauseCountermeasureDate Resp.SignAPCSHO

27、PREJECTION 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 usedQtyRejectionQ tyAPC Rej.RateDateRate(Unit : PPM)50100150200300APC rej.QtyShop Rejection RateAPC TARGETMonthly Line Rejection Rate2004 REJECTION RATE(PPM)JAN FEB MAR AP

28、R MAY JUN JUL AUG SEP OCT NOV DEC 50100150200ProdQ tyAPC usedRej.Q tyAPC Rej.RateAPC rej.Shop Rej. RateAPC TARGET1-1 6 Sigma Concept levelPPM6 3.45233 46210 366,807 2308,537 Process Defects Capability OpportunitySweet Fruits( Perfect Design) Bulk of fruits( Optimization)Lower fruits( 7 QC tools)Grou

29、nd 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 per Million Depends on the detection of defects Believes that high Quality is expensive Doesnt follow systematic approach Benchmarking against competing co

30、mpanies 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 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 water 2hrs/ month No telephone service for 27 min / week 5 Short or long landings at the heathero airport in a day. 1,350 in