一家美资企业的内训资料
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- 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
Sequential inspection image
Sequential inspection image
After checking pre-processed work, do own process activities
Start
Assembly Line
1st Process
Work -ing
*TDRE : Tear Down & Re- Engineering
* Sign Board
550MM
MAJOR PROCESS
145MM
SPECIFIC PROCESS
CRITICAL PROCESS
SHOP
Main Process Control Sheet
CATEGORY
PROCESS NAME
the cause of rejection. . Classify the reason their types like internal
. Sunrise M/T
work error or
- Display the defective parts - Organize the receipt/ issuing of alternated parts to the line
• Display rejection due to supplier
• Request for urgent delivery in exchange of total rejection.
FACTORY
Defect Found
• Supplier must receive real information and have improvement meeting (once/week) => Q-manager attend
OS&D Image
Innovation Flow
Innovation Activities
Establish full inspection system
Establish quality information system - Real information system
. Real data . Real material - Computerized OS&D management
Material
Work defect Replacement for defective parts
Vendor defect & Transportation
Return
Data
Self-inspection Check-list
Prepared By
Checked By
Approved By
OPERATOR OPENING DATE
SUPERVISOR
<DRAWING>
<CONTROL POINT>
(ppm) 2,000
1,000
Defect Rate
Date
1234
Production Q’ty
Defective Q’ty
Defective Rate
TARGET
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
Time Check Quality Audit Review Meeting
Implement 6TOOL
Cultivating Team Skill
2. 6TOOL-1 / OS&D Activity
A system to improve quality of components found defective by monitoring , analyzing & acting on actual real time data & material supplied by suppliers.
Prod. QC Prod.
QC
Total
Remarks
Supervisor Manager Q
C
3. 6TOOL-2 / Sequential inspection
To filter all the rejection on the line by inspecting pre-processed work totally (100%) at the next process.
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, Standard items
Individual result - Sequential inspection
Prepared By
Checked By
Approved By
LINE :
MONTH :
N O
Name
Pt 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
- Make countermeasures
Inspect 100% in assembly process
* Sequential inspection Guide
ITEM <CHECK POINT>
Sequential inspection guide
PROCESS NAME
* Sequential inspection Sticker
- 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 & appraisal system
transportation or vendor
- Record and manage
current defect status
and feed back
- Receive the defective parts - Analyze the reason - Hold improvement meeting .Daily meeting .Weekly innovation meeting (Q-manager attend) - Monthly evaluation meeting (Q-manager attend)
Improvement Activities
• Place collection box for defectives in the line
Improved Material
Real & Quick Information
• Collect rejection & analysis of same from IQC members
Pt
Pt
Pt
Pt
Pt
Pt
Pt
Pt
Repair Record
SHOP / : NO Item
DATE : / Fault
/ Qty
Cause
Prepared By
Checked By
Approved By
Action Taken
Concerned Operation
TOTAL PROD. QTY % REPAIR
6TOOL GUIDE
21st. Feb. 2004
India Pvt Ltd
1. 6TOOL ?
100 PPM QUALITY PROCESS
1
2
Perfect
Check
3
System
4
5
6
*OS&D : Over, Shortage & Defect
OS&D* Sequential Inspection Main Process Control
- Provide additional parts - Collect the defective
in lieu of defected q’ty parts (once/day)
. Emergency delivery - Analyze and evaluate
- Hold improvement M/T with supplier
Establish vendor appraisal system - Quality contract
(agreement of target quality) - I&P System
SUPPLIERS
• Attach tag after finding a defect on the line
MACHINE / MODEL PROCESS NAME
BUYER
ORIGIN DATE REVISED DATE REVISION NO
DRAWING
PART
SPECIFICATION
SELF-INSPECTION METHOD
* OS&D Stickers
1. SUPPLIER DEFECT
2. WORKMANSHIP DEFECT
ProInspection
2nd Process
PreInspec-
Work
ProInspec-
tion -ing tion
3rd Process
PreInspec-
Work
ProInspec-
tion -ing tion
- Setting sequential inspection points of each process
Remarks
4. 6TOOL-3 / Main Process Control
Establish visual management for main process (Heavy rejection, Customer complaints,critical etc.) and concentrate on improvement activity like Fool Proof.
• Receive improved material & follow-up
*I&P : Incentive & Penalty
2. 6TOOL-1 / OS&D Activity (RULE)
PRODUCTION
PURCHASE
IQC
MATERIAL
SUPPLIER
Activities
- Find defective parts -Attach tag . Supplier defect : Red . Transportation : Blue . Work defect : Yellow - Store defective parts - Issue OS&D NCR (once/day)
OS&D Report
Production Line :
DATE : /
/
S/No
Part Name
Part No
Vendor Name
Defect Description
Prepared
P
By
R
O
D
Checked By
Approved By
Defect Status
Vendor
Workmanship
5. 6TOOL-4 / Time Check
To assure component quality which are processed in house, check main control point regularly
Time Check Image
Flow Chart
- 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
Sequential inspection image
Sequential inspection image
After checking pre-processed work, do own process activities
Start
Assembly Line
1st Process
Work -ing
*TDRE : Tear Down & Re- Engineering
* Sign Board
550MM
MAJOR PROCESS
145MM
SPECIFIC PROCESS
CRITICAL PROCESS
SHOP
Main Process Control Sheet
CATEGORY
PROCESS NAME
the cause of rejection. . Classify the reason their types like internal
. Sunrise M/T
work error or
- Display the defective parts - Organize the receipt/ issuing of alternated parts to the line
• Display rejection due to supplier
• Request for urgent delivery in exchange of total rejection.
FACTORY
Defect Found
• Supplier must receive real information and have improvement meeting (once/week) => Q-manager attend
OS&D Image
Innovation Flow
Innovation Activities
Establish full inspection system
Establish quality information system - Real information system
. Real data . Real material - Computerized OS&D management
Material
Work defect Replacement for defective parts
Vendor defect & Transportation
Return
Data
Self-inspection Check-list
Prepared By
Checked By
Approved By
OPERATOR OPENING DATE
SUPERVISOR
<DRAWING>
<CONTROL POINT>
(ppm) 2,000
1,000
Defect Rate
Date
1234
Production Q’ty
Defective Q’ty
Defective Rate
TARGET
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
Time Check Quality Audit Review Meeting
Implement 6TOOL
Cultivating Team Skill
2. 6TOOL-1 / OS&D Activity
A system to improve quality of components found defective by monitoring , analyzing & acting on actual real time data & material supplied by suppliers.
Prod. QC Prod.
QC
Total
Remarks
Supervisor Manager Q
C
3. 6TOOL-2 / Sequential inspection
To filter all the rejection on the line by inspecting pre-processed work totally (100%) at the next process.
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, Standard items
Individual result - Sequential inspection
Prepared By
Checked By
Approved By
LINE :
MONTH :
N O
Name
Pt 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
- Make countermeasures
Inspect 100% in assembly process
* Sequential inspection Guide
ITEM <CHECK POINT>
Sequential inspection guide
PROCESS NAME
* Sequential inspection Sticker
- 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 & appraisal system
transportation or vendor
- Record and manage
current defect status
and feed back
- Receive the defective parts - Analyze the reason - Hold improvement meeting .Daily meeting .Weekly innovation meeting (Q-manager attend) - Monthly evaluation meeting (Q-manager attend)
Improvement Activities
• Place collection box for defectives in the line
Improved Material
Real & Quick Information
• Collect rejection & analysis of same from IQC members
Pt
Pt
Pt
Pt
Pt
Pt
Pt
Pt
Repair Record
SHOP / : NO Item
DATE : / Fault
/ Qty
Cause
Prepared By
Checked By
Approved By
Action Taken
Concerned Operation
TOTAL PROD. QTY % REPAIR
6TOOL GUIDE
21st. Feb. 2004
India Pvt Ltd
1. 6TOOL ?
100 PPM QUALITY PROCESS
1
2
Perfect
Check
3
System
4
5
6
*OS&D : Over, Shortage & Defect
OS&D* Sequential Inspection Main Process Control
- Provide additional parts - Collect the defective
in lieu of defected q’ty parts (once/day)
. Emergency delivery - Analyze and evaluate
- Hold improvement M/T with supplier
Establish vendor appraisal system - Quality contract
(agreement of target quality) - I&P System
SUPPLIERS
• Attach tag after finding a defect on the line
MACHINE / MODEL PROCESS NAME
BUYER
ORIGIN DATE REVISED DATE REVISION NO
DRAWING
PART
SPECIFICATION
SELF-INSPECTION METHOD
* OS&D Stickers
1. SUPPLIER DEFECT
2. WORKMANSHIP DEFECT
ProInspection
2nd Process
PreInspec-
Work
ProInspec-
tion -ing tion
3rd Process
PreInspec-
Work
ProInspec-
tion -ing tion
- Setting sequential inspection points of each process
Remarks
4. 6TOOL-3 / Main Process Control
Establish visual management for main process (Heavy rejection, Customer complaints,critical etc.) and concentrate on improvement activity like Fool Proof.
• Receive improved material & follow-up
*I&P : Incentive & Penalty
2. 6TOOL-1 / OS&D Activity (RULE)
PRODUCTION
PURCHASE
IQC
MATERIAL
SUPPLIER
Activities
- Find defective parts -Attach tag . Supplier defect : Red . Transportation : Blue . Work defect : Yellow - Store defective parts - Issue OS&D NCR (once/day)
OS&D Report
Production Line :
DATE : /
/
S/No
Part Name
Part No
Vendor Name
Defect Description
Prepared
P
By
R
O
D
Checked By
Approved By
Defect Status
Vendor
Workmanship
5. 6TOOL-4 / Time Check
To assure component quality which are processed in house, check main control point regularly
Time Check Image
Flow Chart