一家美資企業(yè)的內(nèi)訓(xùn)資料

1、,6TOOL GUIDE,India Pvt Ltd,1. 6TOOL ?,,100 PPM QUALITY PROCESS,PerfectCheckSystem,CultivatingTeamSkill,,Implement6TOOL,*OS&D : Over, Shortage & Defect,,,,2. 6TOOL-1 / OS&D Activity,,A system to improve

2、quality of components found defective by monitoring , analyzing &acting on actual real time data & material supplied by suppliers.,OS&D Image,,Establish full inspection system,,Establish quality information

3、 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 Flo

4、w,*I&P : Incentive & Penalty,FACTORY,SUPPLIERS,ImprovementActivities,DefectFound,,,Real & QuickInformation,ImprovedMaterial,Innovation Activities,Attach tag after finding a defect on the line Place co

5、llection 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 mu

6、st 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-Att

7、ach 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- H

8、old 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 tr

9、ansportation 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

10、- Analyze the reason- Hold improvement meeting .Daily meeting .Weekly innovation meeting (Q-manager attend) - Monthly evaluation meeting (Q-manager attend),,,Material,,,,,,,,,,,,,Work defect,Vendor de

11、fect &Transportation,Return,Data,,,,,,,,,,,,,Replacement for defective parts,,,,Self-inspection Check-list,,,,,PreparedBy,CheckedBy,ApprovedBy,,,,,,,MACHINE / MODEL,,BUYER,,ORIGIN DATE,,REVISED DATE,,PROCESS NAME

12、,,DRAWING,PART,SPECIFICATION,SELF-INSPECTION METHOD,REVISION NO,* OS&D Stickers,,,,1. SUPPLIER DEFECT,2. WORKMANSHIP DEFECT,,,,,,,,OS&D Report,,,,,PreparedBy,CheckedBy,ApprovedBy,Production Line :

13、 DATE : / /,,,,S/No,Part Name,,Part No,,,Defect Description,,Vendor,,Prod.,QC,,Workmanship,Prod.,QC,,Total,,Defect Status,,VendorName,,,,,,,,,,,QC,Supervisor,Manager,,PROD,Remarks,Pro- Ins

14、pec-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,After checking pre-processed work,

15、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

16、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 counterme

17、asures,Work-ing,Pro- Inspec-tion,,Pre-Inspec-tion,Work-ing,Pro- Inspec-tion,,Pre-Inspec-tion,Work-ing,* Sequential inspection Guide,,,,,,ITEM,,PROCESS NAME,,,Sequential inspection guide,,* Sequential

18、 inspection Sticker,,,,,,,,Individual result - Sequential inspection,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,NO,Name,LINE : MONTH :,,,,,PreparedBy,CheckedBy,ApprovedBy,1 2 3

19、 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,Fault,SHOP / : DAT

20、E : / /,,,,,PreparedBy,CheckedBy,ApprovedBy,Cause,Action Taken,,Item,Qty,,,,,ConcernedOperation,TOTAL,PROD. QTY,% REPAIR,Remarks,4. 6TOOL-3 / Main Process Control,,,Establish visual management for main

21、 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

22、Defect . Specific process : Time Check process, Customer’s requirement . Critical process : Critical items, Standard items- Register defective process : When defect occurs- Withdraw m

23、ain 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 &a

24、mp; appraisal system,*TDRE : Tear Down & Re- Engineering,* Sign Board,,,,,,MAJOR PROCESS,SPECIFIC PROCESS,CRITICAL PROCESS,,,,,,,550MM,145MM,,Main Process Control Sheet,,,,,,,,Production Q’ty,Defective Q’ty,Defective

25、 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,,,Defec

26、tRate,(ppm),,,,,,1,000,2,000,,,,,SHOP,,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 reg

27、ularly,Time Check Image,Flow Chart,Activity,- Check quality periodically and take action- Initial inspection : . Assure initial setting condition- Intermediate inspection : Check 4M variation . Correct s

28、pecification 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,E

29、very two hour,,,,,,OK,NG,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 an

30、d segregate- Repair or disposal- Find out defect cause- Establish permanent solution with concerned dept.,TIME CHECK SHEET,,,CHECKED BY(SUPERVISOR):APPROVED BY(MANAGER):,LINE,PROCESS NAME,DURATION,( / /

31、 ) ~ ( / / ),CYCLE,EVERY ( ) HR,OPERATOR’S NAME,SUPERVISOR’S NAME,,,,,,,,,No,Check items,Signature by supervisor,,,,,,,MON ( / ),TUE ( / ),WED ( / ),THU ( / ),FRI ( / ),SAT (

32、 / ),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

33、: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 CH

34、ECK BOARD,,,Time Check Sheet,09:00~11:00,11:00~01:00,02:00~04:00,04:00~06:00,,LINE : ________,ITEM : _________,OPERATOR,SUPERVISOR,,,6. 6TOOL-5 / Q-AUDIT,,,We will compare the required quality level & the quality lev

35、el of our products / processes and then narrow the gap.,Flow Chart,Select model,Find problems/Register task,Do Q-Audit,,Keep Record,Improvement,,Manage till innovated,,,,,,,,Process,,,,,,,Class,Step 1,Step 2,Step 3,Ou

36、tgoing Audit,Step 1 +Line Audit,Step 2 + Process (Parts) Audit,MAINFOCUS,,Rem-arks,- Understand customer’s needs Establish outgoing inspection parameters. Do 100% inspection Find out weak point

37、 & 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

38、 & sometimes from Customer.,,Establish controlParameters.,,7. 6TOOL-6 / Review Meeting,,,We must naturalize ourselves to prevent defect input & improvement of such defects through systematic review .,Daily Mee

39、ting,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 Re

40、jection)- Supervisor & Manager- Once per week,- Review monthly target & result, establish next month plan- Supervisor & All Managers- Once per month,Quality Review Report,,,,,,,,,LINE,,,DATE,,/

41、 /,,,Preparedby,APPROVAL,Preparedby,Checkedby,HOD,,,,,,,LQC Status,1. Rejection rate,,,,,,,( / ) ~ ( / ),ProdQ’ty,RejQ’ty,,,,PPM,APCused,APC rej,PPM rej,,2. Worst 5 items ( Customer /

42、 Line),,,,,,12345,Problem & Cause,Countermeasure,Date,Resp.,Sign,APC,SHOP,,MONTH,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

43、 20 21 22 23 24 25 26 27 28 29 30 31,Total,,,,,,ProductionQ’ty,APC usedQty,RejectionQ’ty,APC Rej.Rate,Date,,Rate,(Unit : PPM),,,,,,50,100,150,200,300,,,,,,APC rej.Qty,,Shop Rejection Rate,,,APC T

44、ARGET,,,,,Monthly Line Rejection Rate,2004,REJECTION RATE,,(PPM),,,,,,,,,JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC,,,,,50,100,150,200,,ProdQ’ty,APC used

45、,Rej.Q’ty,APC Rej.Rate,APC rej.,Shop Rej. Rate,,APC TARGET,1-1 6 Sigma Concept,,,,,,,,,,,,,,,,,,,σ level,PPM,6 3.45233 46210 366,807 2308,537 Process

46、 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 Compa

47、ny,6 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 Doesn’t follow systematic approach Benchmarkin

48、g against competing companies Believes 99% is good enough Defines CTQ’s internally,5% of sales is failure cost 3.4 defects per Million Focus on process not to produce Defects Believes that high Quality creates lo

49、w cost Uses D-M- A-I-C Know how Benchmarking to be the Best in the World Believes 99% is unacceptable. Defines CTQ’s from customer point of view,1-1 6 Sigma Concept-II,,,,3 Sigma Level Company,6 Sigma Level Compan

50、y,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 incorrect surgical operations / we

51、ek. 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 years 1 short or long landings at Heathero airport in 1

52、0 years. 1 incorrect surgical operation for 20 years. 35 lost articles of mail / year.,1-2 6 Sigma Concept ( Aspect of tools),,,,Steps,Tools,Definition,,,,,Measurement,Analysis,Improvement,Control,Process MappingLog

53、ic TreePareto AnalysisQFD , FMEA,Gage R&RRational subgroupingsProcess Capability,Hypothesis TestingRegressionGraph analysis,DOE( Design of ExperimentDirect Improvements,13)SPC,,1-3 Understanding Basic concep

54、ts of Statistics,“Z “ is the measure of process capability Z=3 Z=6,,,,,1σ,μ,,,,,,2σ,,3σ,LSL,USL,,,,,1σ,μ,,,,2σ,3σ,LSL,USL,,,,4σ,5σ,6σ,There are equal noOf S.D on both sidesSo for Z=3, the toleranceBand is