一家美资企业的内训资料

一家美资企业的内训资料2.6TOOL-1/OS&DActivityAsystemtoimprovequalityofcomponentsfounddefectivebymonitoring,analyzing&actingonactualrealtimedata&materialsuppliedbysuppliers.OS&DImageEstablishfullinspectionsystemEstablishqualityinformationsystem-Realinformationsystem.Realdata.Realmaterial-ComputerizedOS&DmanagementEstablishvendorappraisalsystem-Qualitycontract(agreementoftargetquality)-I&PSystemInnovationFlow*I&P:Incentive&PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal&QuickInformationImprovedMaterialInnovationActivitiesAttachtagafterfindingadefectonthelinePlacecollectionboxfordefectivesinthelineCollectrejection&analysisofsamefromIQCmembersDisplayrejectionduetosupplierRequestforurgentdeliveryinexchangeoftotalrejection.Suppliermustreceiverealinformationandhaveimprovementmeeting(once/week)=>Q-managerattendReceiveimprovedmaterial&follow-up100PPM2.6TOOL-1/OS&DActivity(RULE)PRODUCTIONPURCHASEIQCMATERIALSUPPLIERActivities-Finddefectiveparts-Attachtag.Supplierdefect:Red.Transportation:Blue.Workdefect:Yellow-Storedefectiveparts-IssueOS&DNCR(once/day)-Provideadditionalpartsinlieuofdefectedq’ty.Emergencydelivery-HoldimprovementM/Twithsupplier.SunriseM/T-Collectthedefectiveparts(once/day)-Analyzeandevaluatethecauseofrejection..Classifythereasontheirtypeslikeinternalworkerrorortransportationorvendor-Recordandmanagecurrentdefectstatusandfeedback-Displaythedefectiveparts-Organizethereceipt/issuingofalternatedpartstotheline-Receivethedefectiveparts-Analyzethereason-Holdimprovementmeeting.Dailymeeting.Weeklyinnovationmeeting(Q-managerattend)-Monthlyevaluationmeeting(Q-managerattend)MaterialWorkdefectVendordefect&TransportationReturnDataReplacementfordefectiveparts100PPMSelf-inspectionCheck-listPreparedByCheckedByApprovedByMACHINE/MODELBUYERORIGINDATEREVISEDDATEPROCESSNAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTIONMETHODREVISIONNO100PPM*OS&DStickers1.SUPPLIERDEFECT2.WORKMANSHIPDEFECT100PPMOS&DReportPreparedByCheckedByApprovedByProductionLine:DATE://S/NoPartNamePartNoDefectDescriptionVendorProd.QCWorkmanshipProd.QCTotalDefectStatusVendorNameQCSupervisorManagerPRODRemarksPro-Inspec-tion3.6TOOL-2/SequentialinspectionTofilteralltherejectiononthelinebyinspectingpre-processedworktotally(100%)atthenextprocess.SequentialinspectionimageAftercheckingpre-processedwork,doownprocessactivitiesStartAssemblyLine1stProcess2ndProcess3rdProcessInspect100%inassemblyprocessSequentialinspectionimage-Settingsequentialinspectionpointsofeachprocess-Checkpre-processwork-Attachatagonthedefectedposition-Feedbacktotheconcernedoperator-Recordandmanagerepairhistory-Notifythedefectivecontentstooperatorsinthereviewmeeting-MakecountermeasuresWork-ingPro-Inspec-tionPre-Inspec-tionWork-ingPro-Inspec-tionPre-Inspec-tionWork-ing100PPM*SequentialinspectionGuideITEMPROCESSNAME<CHECKPOINT>Sequentialinspectionguide100PPM*SequentialinspectionSticker100PPMIndividualresult-SequentialinspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy12345678910111213141516171819202122232425262728293031PtPtPtPtPtPtPtPtPtRepairRecordNOFaultSHOP/:DATE://PreparedByCheckedByApprovedByCauseActionTakenItemQtyConcernedOperationTOTALPROD.QTY%REPAIRRemarks100PPM4.6TOOL-3/MainProcessControlEstablishvisualmanagementformainprocess(Heavyrejection,Customercomplaints,criticaletc.)andconcentrateonimprovementactivitylikeFoolProof.MainProcessOperation-Installsignboardssuchas:.Majorprocess:CustomerComplain,LineDefect.Specificprocess:TimeCheckprocess,Customer’srequirement.Criticalprocess:Criticalitems,Standarditems-Registerdefectiveprocess:Whendefectoccurs-Withdrawmainprocess:whennodefectoccurs-Ifrejectionoccursestablishcountermeasure:attachtheprocess-TDRE*activitywhendefectoccurscontinuously-Makeapermanentcountermeasure:FoolProof-Establishcheck&appraisalsystem*TDRE:TearDown&Re-Engineering100PPM*SignBoardMAJORPROCESSSPECIFICPROCESSCRITICALPROCESS550MM145MM100PPMMainProcessControlSheetProductionQ’tyDefectiveQ’tyDefectiveRateDate12345678910111213141516171819202122232425262728293031TotalDefectRate(ppm)1,0002,000<DRAWING><CONTROLPOINT>SHOPPROCESSNAMECATEGORYOPERATOROPENINGDATESUPERVISORTARGET100PPM5.6TOOL-4/TimeCheckToassurecomponentqualitywhichareprocessedinhouse,checkmaincontrolpointregularlyTimeCheckImageFlowChartActivity-Checkqualityperiodicallyandtakeaction-Initialinspection:.Assureinitialsettingcondition-Intermediateinspection:Check4Mvariation.Correctspecificationvariationof4Matmidofproductionday-Finalinspection:AssurethequalityoffinishedproductDecidecheckpointTakesampleCheckKeepsampleRecordingInitialIntermediateFinalEverytwohourOKNGStopproduction&checkearlyLotRecheckall(100%)Changeworkingcondition&repair-Isolaterejectedlot-Stopthedefectiveinputtothenextprocess-Decidelimitlevelandsegregate-Repairordisposal-Findoutdefectcause-Establishpermanentsolutionwithconcerneddept.100PPMTIMECHECKSHEET<WEEKLY>CHECKEDBY(SUPERVISOR):APPROVEDBY(MANAGER):LINEPROCESSNAMEDURATION(//)~(//)CYCLEEVERY()HROPERATOR’SNAMESUPERVISOR’SNAMENoCheckitemsSignaturebysupervisorMON(/)TUE(/)WED(/)THU(/)FRI(/)SAT(/)09:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:00Specs100PPM*TimeCheckProcessBoardTIMECHECKPROCESS550MM145MMTIMECHECKBOARDTimeCheckSheet09:00~11:0011:00~01:0002:00~04:0004:00~06:00LINE:________ITEM:_________OPERATORSUPERVISOR100PPM6.6TOOL-5/Q-AUDITWewillcomparetherequiredqualitylevel&thequalitylevelofourproducts/processesandthennarrowthegap.FlowChartSelectmodelFindproblems/RegistertaskDoQ-AuditKeepRecordImprovementManagetillinnovatedProcessClassStep1Step2Step3OutgoingAuditStep1+LineAuditStep2+Process(Parts)AuditMAINFOCUSRem-arks-Understandcustomer’sneedsEstablishoutgoinginspectionparameters.Do100%inspectionFindoutweakpoint&improve.Establishlineprocessparameters.Doregularaudit.Findoutlineproblems&improve.-Findoutprocessorpartsproblem&solvethempermanentlyRegularAuditbyQAalongwithproduction&sometimesfromCustomer.100PPMEstablishcontrolParameters.7.6TOOL-6/ReviewMeetingWemustnaturalizeourselvestopreventdefectinput&improvementofsuchdefectsthroughsystematicreview.DailyMeetingWeeklyMeetingMonthlyMeeting-Describeprocess&partsdefectwithactualmaterial-Conductedbysupervisorwithalloperators-Dodaily-Weeklymeetingtomakecounter-measure(OS&D,LineRejection)-Supervisor&Manager-Onceperweek-Reviewmonthlytarget&result,establishnextmonthplan-Supervisor&AllManagers-Oncepermonth100PPMQualityReviewReport<Daily>LINEDATE//PreparedbyAPPROVALPreparedbyCheckedbyHODLQCStatus1.Rejectionrate(/)~(/)ProdQ’tyRejQ’tyPPMAPCusedAPCrejPPMrej2.Worst5items(Customer/Line)12345Problem&CauseCountermeasureDateResp.SignAPCSHOPREJECTIONSTATUSMONTH12345678910111213141516171819202122232425262728293031TotalProductionQ’tyAPCusedQtyRejectionQ’tyAPCRej.RateDateRate(Unit:PPM)50100150200300APCrej.QtyShopRejectionRate<DAILY>APCTARGETMonthlyLineRejectionRate2004REJECTIONRATE(PPM)JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC50100150200ProdQ’tyAPCusedRej.Q’tyAPCRej.RateAPCrej.ShopRej.RateAPCTARGET1-1 6SigmaConceptσlevelPPM63.45 233

4 6210

3 66,807

2 308,537ProcessDefectsCapabilityOpportunitySweetFruits(PerfectDesign)Bulkoffruits(Optimization)Lowerfruits(7QCtools)Groundfruits(Straightviewpt)1-1 6SigmaConcept-I3SigmaLevelCompany6SigmaLevelCompany10~15%ofsalesisfailurecostHaving66,807defectsperMillionDependsonthedetectionofdefectsBelievesthathighQualityisexpensiveDoesn’tfollowsystematicapproachBenchmarkingagainstcompetingcompaniesBelieves99%isgoodenoughDefinesCTQ’sinternally5%ofsalesisfailurecost3.4defectsperMillionFocusonprocessnottoproduceDefectsBelievesthathighQualitycreateslowcostUsesD-M-A-I-CKnowhowBenchmarkingtobetheBestintheWorldBelieves99%isunacceptable.DefinesCTQ’sfromcustomerpointofview1-1 6SigmaConcept-II3SigmaLevelCompany6SigmaLevelCompany54,000wrongdrugprescriptions/yearUnsafedrinkingwater2hrs/monthNotelephoneservicefor27