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6TOOLGUIDE21st.Feb.2004IndiaPvtLtd1.6TOOL?100PPMQUALITYPROCESSOS&D*SequentialInspectionMainProcessControlTimeCheckQualityAuditReviewMeeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D:Over,Shortage&Defect2.6TOOL-1/OS&DActivityAsystemtoimprovequalityofcomponentsfounddefectivebymonitoring,analyzing&actingonactualrealtimedata&materialsuppliedbysuppliers.OS&DImageEstablishfullinspectionsystemEstablishqualityinformationsystem-Realinformationsystem.Realdata.Realmaterial-ComputerizedOS&DmanagementEstablishvendorappraisalsystem-Qualitycontract(agreementoftargetquality)-I&PSystemInnovationFlow*I&P:Incentive&PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal&QuickInformationImprovedMaterialInnovationActivities•Attachtagafterfindingadefectontheline•Placecollectionboxfordefectivesintheline•Collectrejection&analysisofsamefromIQCmembers•Displayrejectionduetosupplier•Requestforurgentdeliveryinexchangeoftotalrejection.•Suppliermustreceiverealinformationandhaveimprovementmeeting(once/week)=Q-managerattend•Receiveimprovedmaterial&follow-up2.6TOOL-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&TransportationReturnDataReplacementfordefectivepartsSelf-inspectionCheck-listPreparedByCheckedByApprovedByMACHINE/MODELBUYERORIGINDATEREVISEDDATEPROCESSNAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTIONMETHODREVISIONNO*OS&DStickers1.SUPPLIERDEFECT2.WORKMANSHIPDEFECTOS&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-ing*SequentialinspectionGuideITEMPROCESSNAMECHECKPOINTSequentialinspectionguide*SequentialinspectionStickerIndividualresult-SequentialinspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy12345678910111213141516171819202122232425262728293031PtPtPtPtPtPtPtPtPtRepairRecordNOFaultSHOP/:DATE://PreparedByCheckedByApprovedByCauseActionTakenItemQtyConcernedOperationTOTALPROD.QTY%REPAIRRemarks4.6TOOL-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-Engineering*SignBoardMAJORPROCESSSPECIFICPROCESSCRITICALPROCESS550MM145MMMainProcessControlSheetProductionQ’tyDefectiveQ’tyDefectiveRateDate12345678910111213141516171819202122232425262728293031TotalDefectRate(ppm)1,0002,000DRAWINGCONTROLPOINTSHOPPROCESSNAMECATEGORYOPERATOROPENINGDATESUPERVISORTARGET5.6TOOL-4/TimeCheckToassurecomponentqualitywhichareprocessedinhouse,checkmaincontrolpointregularlyTimeCheckImageFlowChartActivity-Checkqualityperiodicallyandtakeaction-Initialinspection:.Assureinitialsettingcondition-Intermediateinspection:Check4Mvariation.Correctspecificationvariationof4Matmidofproductionday-Finalinspection:AssurethequalityoffinishedproductDecidecheckpointTakesampleCheckKeepsampleRecording•Initial•Intermediate•Final•EverytwohourOKNGStopproduction&checkearlyLotRecheckall(100%)Changeworkingcondition&repair-Isolaterejectedlot-Stopthedefectiveinputtothenextprocess-Decidelimitlevelandsegregate-Repairordisposal-Findoutdefectcause-Establishpermanentsolutionwithconcerneddept.TIMECHECKSHEETWEEKLYCHECKEDBY(SUPERVISOR):APPROVEDBY(MANAGER):LINEPROCESSNAMEDUR