22118440 5 quality maintenence
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1
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Hinshitsu HozenHinshitsu Hozen
oror
Quality MaintenanceQuality Maintenance
PILLAR
2
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
“Hinshitsu-Hozen”What is “Hinshitsu-Hozen?
To maintain integrity of quality (state of 100% non-defectives)
* Condition setting :Set conditions for zero defects aimed at equipment and processes that do not produce quality defects.
* Daily and periodical inspections :Inspect and measure conditions in time series.
* Quality preventive maintenance :Prevent quality defects by maintaining measured values within the standard
* Trend control and predictive maintenance :Predict possibilities of quality defects occurring by observing trends of measured values.
* Prior countermeasures:Take measures beforehand
© JIPM, 1994
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Producing materials and energy not to generate defects
Manufacturing equipment not to generate defect
Devising methods not to generate defects
Fostering operators proficient in equipment and job
Jishu-Hozen activities
Skill Education and Training
+
PM Analysis
Pursue relationship between quality characteristics and material and energy condition / equipment precision / method conditions
Maintenance and management ability training (Ability to find cause system troubles and to quickly and correctly take actions)
Set conditions of equipment not to generate defects
Management of conditions not to generate defects
(Hinshitsu – Hozen) Zero quality defects
Caused by raw material conditions
Caused by equipment precision
Caused by method conditions
Caused by conditions of people involved
Quality Defect Factors
Hinshitsu – Hozen Concept
© JIPM, 1987
Quality Assurance+
Equipment and environment management
Design checkMaterial Management
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Quality maintenance - Making of equipment which will not make poor quality products.
Setting of Conditions (Technical Aspect) Decide
properlyRestorationPursuit of the optimal ConditionElimination of Minor DefectsAdjustmentsClarification of Skill
Individual Improvement
Autonomous Maintenance
MP Design
Education and Training
PM Analysis
Basic Thinking of Improvement
7 Steps of Autonomous Maintenance
• Daily Inspection• Proper Operation
Preventive Maintenance Application of Equipment Diagnosing Technology
Feedback
Condition Control (Control Aspect) Observe precisely
Realization of Zero-Defect
Fostering of personnel who thoroughly understand the equipment
<Coping with the TPM 5 Principles>
Relation among 5 Principles of TPM Development and Quality Maintenance
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Concept of the Promotion of Quality Maintenance
To promote quality maintenance, it is necessary to satisfy the following two preconditions:• Forced machine deterioration has been thoroughly
removed.• Natural deterioration removal under is progresses.• Managers and operators have become skillful with
equipment, so that the functions and structure of equipment are well understood by them.
• Have Sufficient inspection skill. • Training of staff who handle equipment on skill.• Jishu-Hozen, Kobetsu-Kaizen, PM analysis training,
and skill education and training must be enforced
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Choosing time of quality maintenance.
• Total Jishu Hozen Implementation.
• Workshop is free from forced deterioration.
•"when failures cannot be reduced, defects cannot be
reduced.”
• Losses such as Equipment failure, Minor Stoppages,
Process failure are under control.
•All relevant data on Quality defects is available.
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Implementation Procedure for
Quality Maintenance
• Understanding quality defect phenomena.
• Setting of standard values for inspection items
and confirmation of results
• Concentration of inspection items and
shortening of inspection time
• Drafting of QM (Quality Maintenance) matrix
and reflection in standards
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Implementation Procedure for
Quality Maintenance (contd…)
• Master plan for QM
• 3M Analysis
• PM analysis for exposure and handling of
malfunctions
• Kaizens and Poka Yoke for eliminating defects
• Maintaining Zero Defect
• Process capability improvement plan
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Understanding quality defect phenomena
• Clarity on the definition of the defect
• Frequency of occurrence and effect of defects
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Defects classification
A - Type defect B - Type defect C - Type defect
OK
OK
NOT OK
Action taken by operator
OK
OK
NOT OK
No action by operator
LSL USLLSL USL
OK
OK
NOT OK
Action taken by operator
LSL USL
• The output is (OK) initially• Becomes (NG)• Corrective action is taken
by operator• Becomes (OK)• Uue Why – Why Analysis
• The output is (OK) initially• Becomes (NG)• No action taken by
operator• Becomes (OK)• Use PM Analysis
• The output is (NG) initially• Action taken by operator• Becomes (OK) (setting scrap)
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
A - Type defect : Examples
OK
OK
NOT OK
Action taken by operator
LSL USL
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status :
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
To eliminate process scrap due to Damage of M133551 Crank shaft
6
4
3
0
2
4
6
8
Nov'00 Dec'00 Jan'01
Reje
cti
on
Qty
Possibility of Wrong Loading
Prevent Possibility of Wrong Loading
Provide POKA YOKE
3
0
1
2
3
4
Jan'01 Feb'01
Re
jec
tio
n Q
ty
M . Karthikeyan
Scrap due to wrong loading
EMA
POKA YOKE
2000- 01CU
Component damage – Induction hardng
Inductor hitting the component
Component loaded in the wrong direction
Possibility of wrong loading
Why
Why
Why
1 EMA Mar’01 MK Compld.
CU 128
Before improvement:
Operation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
B CA
Eliminate process scrap due to Component pull out in M270081 Cylinder in machine 032505
4
1
2 2
0
1
2
3
4
5
June July Aug Sep
Rej
n Q
ty
Component damage during machining
component pulled out
Tennon broken
weaker section of the tennon
Reduced thickness
to avoid fouling with jaws
Tennon fouling with the jaws
Change the jaw design and tennon thickness
032507 Oct,00 NKN completed
4
1
2 2
000
1
2
3
4
5
June July Aug Sep Oct Nov
Rej
n Q
ty
N.Kothandaraman
Avoid tennon fouling with jaws
Why
Why
Why
Why
Why
032505
01
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated in
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM 2000- 01ACT AU 087
Eliminate process scrap due to damage in Un loader valve before Apr’00
Process scrap due to Damage
Wrong loading of component
Damage in body Why ?
Why ?
Provide stopper to avoid wrong loadingProvide Poka yoke pin
BDN / TSS
1
3
2
0
2
4
Jan'00 Feb Mar
Qty
Fixture accepting wrong loading
Poka Yoke pin
ULV Body Wrong Side on the top
No stopper arrangement to avoid wrong loading
Why ?
No stopper arrangement to avoid wrong loading
1
3
2
0 0 0 00
2
4
Jan'0
0Feb M
arApr
May Ju
nJu
l
Qty
V2 2000 -2001
0863031 Aug’00 BDN completed
082501
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
Not able to load
V2 025
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
B - Type defect : Examples
OK
OK
NOT OK
No action by operator
LSL USL
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
To reduce process scrap due to rough finish onBore dia inM 272291 Ty 20 Ram
2
1 1
0 0
3
0
1
2
3
4
5
Mar Apr May May June July
0 0 0 00
1
2
3
4
5
Aug Sep Oct Nov
Entrapment of Burr on bore duringfinish boring operation .
Rough finish on boreWhy ?
Why ?Burr generated during Rough boringoperation not fully flushed out
Why ?
Finish boring operation done immediatelyafter rough boring operation . .
Process sequencePresence of burr during boring operation
To eliminate burr presence
Change process sequence
Process sequence
Facing , OD Turning & grooving
Rough boring
Finish boring
Back facing
Facing , OD Turning & grooving
Rough boring
Back facing
Process sequence
Completed Finish boring
032302
01 032304 Nov ‘ 99 NKN
Aug ‘ 99
N.Kothandaraman
Act Au- 072
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
To avoid the rejection in crank shaft due to tool digging mark
High rejection ,while running thecrank shaft without the tailstocks Support
4
3
1
0
1
2
3
4
Dec'99 Jan'00 Feb'00
Reje
cti
on
Qty
High rejection in 120802
Tool digging
Excess Runout in the component
Why
Why
0 00
1
2
3
4
Mar'00 Apr'00
Rej
ect
ion
Qty
Provide limit switch
Before Mar’2000
WhyComponent not located properly
M .Karthikeyan
2000 - 2001
Tailstock not clamping
cu
WhyNo tailstock clamping
Eliminate tailstock not clamping
120802
CU -012
1 120801 Jul’00 MK Completed
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
C - Type defect : Examples
OK
OK
NOT OK
Action taken by operator
LSL USL
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
12.5
Setting MasterOil port Spot face height undersize
More material removed on face
Tool length set excess
Why?
Why?
How?No Setting facility
Tool length set excess
High process scrap due tooil port spot face height undersize in M 134561 TCL crankcase
To reduce rejection due to Oil port spot face height undersize in TCL Crank case Zero by Apr’2001
8
6
4
00
2
4
6
8
10
Jan'01 Feb'01 Mar'01 Apr'01
Rej
ecti
on
Qty
Before After
087803
2000-2001
Set the tool correctly
Why?
Provide Setting facility
Provide Setting Master
M .Karthikeyan
cu CU -185
1 086301 Jun’01 MK Compl.
Category:
KAIZEN - SHEET
Brakes Division JiPm -TPM
Kaizen Theme & Target :
Unit YearSub Comm SL. No.
Machine No :
Problem/Present Status : Before improvement:
Analysis :
Idea :
Scope & plan for Horizontal Deployment
Reversible Ir-reversible
If reversible updated inOperation Standard / QCPCJH Check SheetPM Check SheetEqpt / fixture Drawing
Poka Yoke type & Function
Prevention
Shut Down
Control
WarningDetection
SLNo. M/cNo. Status Target date Resp.
Kaizen type
Root Cause:
Providing Changing A B C
Counter measure :
Result / Benefit :
After improvement:
Team Members
QM
28
0 0
34
10
20
30
40
50
Nov Dec Jan’01 Feb
Multi rotational dial gauge
one rotational dial gauge
Month
10
20
30
40
50
28
0 0
34
Nov Dec Jan’01Feb’01Mar’01
0
Qty
Eliminate scrap due to Inner dia. O/S inR6 / RE6 top cover. Zero & Before March’01
Eliminate multi rotational gauge
Multi rotational dial gauge used for measurement
Dia 140.9 / 105.10 Bore over size
Wrong Setting by operator
Wrong reading of the dial
Multi rotational dial
VT / RBS
1 2
3
4
567
8
9
10
12
Small dial
Big dial
1
2
3 4 5
6
7
Change the bore dial to one rotation type.
032601
1 032504 Apr’01 NKN Compl.
2 032602 Apr’01 RBS Compl.
3 032201 Apr’01 NKN Compl.
2000-2001v1 v1 -168
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
If standard values are set for individual inspection items, and equipment
precision is maintained within the standard range, it is necessary to confirm
that all quality characteristics can be satisfied.
If they cannot, the cause is either that "there are omission in inspection items"
or "Standard values are not stringent enough." In either case, it is necessary to
return to PM analysis and carry out study.
Setting of standard values for inspection items and confirmation of results
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
If inspection items are many, inspection intervals are short, or inspection requires much time, maintenance and control will become difficult, and eventually achievement level will decline.
Elimination of forced deterioration and spots that are difficult to inspect depends greatly on Jishu-Hozen implementation.
Concentration of inspection items and shortening of inspection time
• Reducing inspection items by concentrating on the number of items for inspection
• Extending inspection interval by eliminating forced machine deterioration• Shortening inspection time by taking steps for 'difficult to inspect' spots
For orderly implementation of condition control, review inspection items themselves and satisfy the following conditions:
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
QA Matrix is prepared to establish the relationship
between defect / defect mode and the process which
causes it. It requires data collection for defects at various
process stages to prepare a QA Matrix.
Drafting of QM (Quality Maintenance) matrix and reflection in standards
24
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
25
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
26
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
3M condition analysis. Please follow following guidelines.
1 Based on QD matrix identify where the defect is generated
2 Draw a C & E diagram for the defect for each process/sub-process,
3 Identify inputs for each M (Man, Method, Machine and Material
4 Check each input whether Standard exists or not. If not then make a standard.
5 All standards are to be followed during Process.
6 If a standard is difficult to follow or if they are loose then standards are to be revised.
Status of Standard Symbol1 Loose Standard2 No Standard3As per standard and followed4 Difficult to follow5 Not followed
27
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
28
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
QM Master plan
Master Plan for quality maintenance is planning of various
activities in this pillar with respect to the time frame in
months and years. According to the stage of TPM
implementation it can start at various levels. In the
beginning it will start with data collection on defects to
improving conditions to sustaining zero defect conditions.
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Brakes India (Sholinghur)
31
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
TPM MASTER PLAN QM SUB COMMITTEE
32
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Activity Palnned Actual Plant. A Actual line A Actual line B Actual SlittingYear
QM-STEPS Details of activity Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3
9.Consolidation and confirmation of all check points.
*Use the results of step8 to summarize the inspection items. *Prepare quality check point list.
10.Preparation of a quality component control table and asurance of quality through
*Define standard in numerical / observable form.
7.Implementation of improvements.
8.Review of production input conditions.
*Review the production input conditions identified in step2. *Check whether production input conditions are appropriate and correct.
5. Usage of P-M analysis technique to track down causes of problems.
*Investigate using techniques such as P-M analysis and propose countermeasures.
6.Assesment of impact of proposed counter measures (FMEA2).
*Perform preliminary evaluation of the post improvement situation.
3.Preparation of problem chart
*Clearify production-input conditions for problems in each subprocess. *Act promptly against problems that can be tackled on the spot *Carefully work out countermeasures for complex problems. *Devise investigation techniques and plan 4.Evaluation of
seriousness of problems. (FMEA1)
*Priorities problems by assessing their impact on quality defects.
1. Preparation of QA Matrix:
*Check quality characteristics. *Investigate defect modes and subprocess where defect occures. *Assess seriousness of defect mode.
2. Preparation of Production-Input condition analysis table
*Check deficiency in production input conditions for each defect mode in each sub-process. *Check whether standards exists and are being followed.
MASTER PLAN FOR QUALITY MAINTENANCE ACTIVITIES.
2004-2005 2005-2006 2006-2007 2007-2008
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
3M analysis
This analysis is a set of conditions with respect to
machine, material and method for obtaining a good
products. It helps in identifying 3M standards and checking
is possible against these standards. Removing this
variability can some times eliminate Quality Defects in the
product.
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Identification of Operating Conditions with respect to Machine, Material & Method
Defect Sl.no Mode1 Blister 1) Unloading of baked linings 1) Temperature in the 1) Moisture in the material
from Thermal shock oven in Post curing oven as pera specified time. the specification. 2) Variation in resin
properties2) Variation in Setting of Vent 2) Curing pressure as perstroke. the specification.
3) Temperature in the curingmould as per specification.
2 Soft 1) Even spreading of mix 1) Curing pressure as per 1) Inclined Plate Flow value in the moulds. the specification. of the powder resin as per
specification.2) Cleaning of mould edges 2) Temperature in the curingafter the application of Liquid mould as per specification. 2) Curetime of the resin as emulsion solution in the per specification.moulds.
3) Variation in the bulkdensity of the mix.
4) Concentration of the liquidemulsion solution as per specification.
According to standard Statndards needed
Standards not properly followed
Method (People) Machine Material3M Relation
35
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Identification of Operating Conditions with respect to Machine, Material & Method
Defect Sl.no Mode3 Dent 1) Cleaning of curing moulds 1) Chrome plating of the 1) Concentration of the liquid
after unloading the product. mould as per specification. emulsion solution as per specification.
2) Temperature in the curingmould as per specification.
4 Crack 1) Setting of Vent stroke as 1) Temperature in the curing 1) Variation in resin needed to the product. mould as per specification. properties
2) Curing pressure as perthe specification.
5 Flash 1) Cleaning of flashes in the 1) Clearance between the 1) Inclined Plate Flow of theDent edges of the box after mould and the spacers powder resin as per the
unloading the lining from the specificationcuring moulds. 2) Curing pressure as per
the specification.
6 Thickness 1) Weighment of mix as per 1) Curing pressure as per 1) Bulk density of the mix asUnclear the specification the specification per specification.
2) Flash removal below the 2) Error free weighing scalebottom mould. at common weighing.
3) Correct stock removal inOD grinding.
4) Correct stock removal inID grinding.
According to standard
Standards not properly followed Statndards needed
3M RelationMethod (People) Machine Material
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
3M CONDITION FOR NO BLISTER BUBBLES
How tocheck
Machine
Baffle plate Both sheet should be seated Hand Comp.sup. Daily
without gap
Dipper agitator Uniform Rotation Visual Prodn.sup Daily
Voltage 240±10 V Voltmeter Prodn.sup Daily
Track Chain No jerking Visual Prodn.sup Shift once
PROCESS
Dipper temperature 28±2 C Digitron Prod. Sup./operator Hourly
Latex circulation No repelling of bubbles from Visual Prod. Sup./Comp.sup Weekly
dipper agitator
Drying All teat end heaters should
Visual Prod.Sup. Dailybe switched off in I drier
Responsibility Frequency3M COndition Required value What to do
37
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
3M CONDITION FOR NO BLISTER BUBBLES
How to
check
No.1 product weight 0.75 - 0.80 Gms. Weighment Prodn.sup Hourly
Material(LATEX)
S.I.Value 2.0 - 2.4 S.I.check Comp.sup/Lab.sup Daily
Total alkalinity 0.35 - 0.50 % Titration Comp.sup/Lab.sup Daily
Sediments No sediments Hand Comp.sup/Lab.sup Weekly
3M Condition Required value Responsibility Frequency What to do
38
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
BILISTER BUBBLE -ANALYSIS
1 Latex Temperature Chiller failure Alarm providedabove 30°c
Solenoid failure Alarm provided (K)
2 Former temp Voltage variation Based on EB voltage
above 60°c. Tapping during II dipper in Sub Station.
3 Dipper latex Baffle plate Periodic check.agitation. misalignment.
4 Ammonia content High Total Alkalinity above 0.5% Total Alkalinity checked once in a day
and maintainedbelow 0.5%.
S No. Phenomenon Cause Countermeasure
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
GOOD IN NO GOOD -3 M CONDITIONHow to check
Loading Exactly on viton ring
Visual Supervisor Every shift
Solenoid wing gap
No gap Visual Operator Twice in a shift
Disc play No play Visual Operator Twice in a shift
stripping Uniform stripping Visual Operator Twice in a shift
Conductivity No worn out layers
Visual Operator Once in hourbrush
Voltage 1200/900V +100V Voltmeter Electrician Once in a shift
Carbon brush No powder Visual Fitter Once in a shift
Sensor LEDshould glow. Visual Electician Once in a shift
No product in helmet Visual Operator Twice in a shift
3M conditions Required valueResponsi-bility Frequency
What to do
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Execution of PM analysis for exposure and handling of malfunctions
PM Analysis is one of the most effective techniques to handle B
type of problems. PM denotes (P) Physical phenomena (M)
Mechanism. In this analysis we try to establish the relationship
between phenomena and the physical mechanism behind it
which explain the contributing conditions to cause such physical
mechanisms. These contributing conditions are then elaborated
in terms of relationship with primary (man, material, machine,
method) conditions. Usually these primary conditions are not
measurable so they are once again converted into secondary
conditions that can usually be physically inspected against a
standard.
41
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
Execution of PM analysis for exposure and handling of malfunctions (contd…)
After finding the standards, a survey is performed to see
the variability against these standards and all such
conditions are listed as (Not Good). It is advisable to take
countermeasures against all these conditions
simultaneously so as to eliminate most of the chance
causes in the system. This helps achieving zero defects in
the product.
42
TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
-
P.M. ANALYSIS ON ELIMINATION OF CURED PASSENGER TYRE SCRAP DUE TO TREAD BLOW
PHENOMENONCONTRIBUTING
CONDITIONRELEASING WITH
4M (PRIMARY)RELATION WITH 4M (SECONDARY)
1.1.1)Air Leakage from joints of Bellow.
1.2.1) Air leakage from pipe joints.
01) Thrust exerted by Stitcher Disc is less.
1.1) Air Leakage inside bellow. 1.1.2) Degraded Beloow
1.2) Required Air does not reach in bellow from air Hose.
1.3) Stitcher disc oblique transfer less thrust
1.2.2) Leakage from Pipe
1.3.1) Lever Bush Wear Out
1.3.2) Pin Bush Wear Out
1.3.3) Housing Bush Wear Out
1.3.4) Feed Nut Wear Out
1.3.5) Sprocket teeth Damage
1.3.6) Loose Coupling of Sprocket
1.4.1) Feed nut wear out1.4) Bottom Stitcher Play 1.4.2) Sprocket teeth damage
1.4.3) Loose coupling of Sprocket
1.5) Bottom Stitcher Height displacement
1.5.1) No locks of height adjustment square bar1.5.2) Worm gear thread damage
1.5.3) Cylinder thread damage1.5.4) Lead Screw thread damage
Air Entrapment between Nylon Carcass surface (A)and Rubber Tread bottom surface(B).
Force applied by Stitcher on Rubber Tread Surface is less than the resistance given by Rubber Tread.
PHYSICAL VIEW LOGICAL REASONING
02) Resistance given by tread is large.
2.1) Tread Swells out near joint.
2.1.1) Tread length more
2.1.2) Tread Splicing more
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TPM Club India Quality Maintenance Pillar
Confederation of Indian Industry
EVALUATION
CHECK PART DECISIONCHECK ITEM
01) Bellow -Air leakage from joint of bellow
MEASURING METHOD
-Visual / Hand
TOLERANCE
No leakage
MEASUREMENT VALUE
No leakage
TROUBLE SHOOTING
METHODRESULT
OKOKOK
-Degraded Bellow -Hardness 60-70 Shore-A 75 Not ok Bellow replaced
OK
OK
-Air leakage from pipe joints
02) Air Pressure
-Visual / Hand No leakage No leakage OK OK OK
-Air leakage from pipe .
-Visual / Hand No leakage No leakage OK OK
03) Bush -Lever Bush wear out.
Dimension Check(Vernier)
ID-50±0.5 mm.
OD-52±0.5 mm.
W- 2 mm.
ID-51 mm.
OD-50mm.
W- 2 mm.
To be Changed
Changed OK
-Pin Bush wear out.
Dimension Check(Vernier)
ID-70±0.5 mm. ID-71 mm.-OD-72±0.5 mm.
W- 2 mm.
OD-69mm.
W- 2 mm.
To be Changed
Changed OK
-Housing Bush wear out.
Dimension Check(Vernier)
ID-65±0.5 mm. ID-65 mm.-OD-68±0.5 mm.
W- 2 mm.
OD-68mm.
W- 2 mm.
OKOKOK
-Feed nut wear out04) Feed Nut & Gear
Pitch -10 TPI OK OK OK
-Sprocket teeth damage
-Visual No teeth damage
Not ok,To be changed
Changed OK
-Loose Coupling of Sprocket
-Visual No Looseness Loose Tightened OK
Dimension Check(Vernier)
10 TPI
Teeth damage
Tightened
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EVALUATION
CHECK PART DECISIONCHECK ITEM
05) Bottom Stitcher Height
-No locks of height adjustment square bar
MEASURING METHOD
-Visual
TOLERANCE
No looseness
MEASUREMENT VALUE
Loose
TROUBLE SHOOTING
METHODRESULT
OKLock to be provided
Lock provided
-Worm gear thread damage
06) WormGear
ID-76.2± 0.2mm. Not ok, to be changed
Changed OKDimension Check(Vernier) Depth : 2 mm.
ID-75mm.
Depth : 2 mm.
-Cylinder thread damage
07) Cylinder OD-80.4± 0.2mm. OKDimension Check(Vernier) Depth : 2 mm.
OD-80.3mm.
Depth : 2 mm.OKOK
-Lead screw thread damage
08)Lead Screw
OD-33.75± 0.2mm.OK
Dimension Check(Vernier)
OD-33.7mm. OKOK
-Tread length more
09)Tread 1750 ± 5 mm. OKMeasuring Tape 1752 OKOK
-Tread splicing more
Dimension Check(Vernier)
0 mm. ± 3 mm. - 3 mm. OK OK OK
12
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Identification of Operating Conditions with respect to Machine, Material & Method
3 M C O N D IT IO N S C H E C K L IS T
D e fe c t S l.n o M o d e1 N o tc h in g1 ) N o tc h in g o p e ra tio n to 1 ) R ig id c la m p in g o f th e
s ta rt a f te r c o rre c t b u tt in g o fp ro d u c t d u r in g n o tc h in gth e p ro d u c t o p e ra tio n .
3 M R e la tio nM e th o d (P e o p le ) M a c h in e M a te ria l
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Identification of Operating Conditions with respect to Machine, Material & Method
3 M FUGUAI IDENTIFICATION & RECTIFICATION
Production Machine Problem Defect Mode
Survey Survey Countermeasure In
inputs (3M) Method Result charge
Method NOTCHING
1) Notching operation starts before correct butting of the product
Wrong Visual Limit switch fixing To check the limit switch fixing condition once in a week
QM /
Location of
screw found looseproducer
Notchingand corrected
Machine NOTCHING
1) Clamping of the product is not rigid
Wrong Check air pressure
Air leak noticed Hose replaced & to ensure the hose condition during machine start.
Producer
Locationin the gauge
at the pushing
Notching cylinder inlet due todamaged hose
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PM Analysis
Wrong Location Product is shifted from 1) Product is located 1-1) Pusher cylinder 1-1-1) Air pressure Low
notching in it's Location during without butting with stroke length variation 1-1-2) Leak in the Cylinder seal
TATA SCAM Notching operation. the butting reference 1-1-3) Disturbance to the
Products limit switch setting
1-1-4) Dust accumulation in
the guide bushes
1-1-5) Scoring marks in the
A = Feeding Unit guide rod
B = Holding Unit 1-1-6) Leak in the air hose
1-1-7) Scoring marks in the
ID surface of the guide bush.
1-1-8) Leak in the ferrule
1-1-9) Wear in the piston seal
Notching
OK Lining 1-2) Premature clamping 1-2-1) Limit switch malfunction
1-2-2) Limit switch locking
screw loose
1-2-3) Less Clearance between
the product and clamping band
Not OK Lining
2) Product location change 2-1) Variation in clamping 2-1-1) Band length is more
After clamping. force 2-1-2) Air pressure low
2-1-3) Band locking screw
got loosened
2-1-4) Burr between band and
Notch cutters the product
NOT OK 2-1-5) Band Damage
OK Condition Condition
(Logical reasoning) (Primary) (Secondary)
Phenomenon Physically view Contributing Condition Relation with 4M Relation with 4M
Butting
Reference
Product
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PM Analysis
Wrong Location 2-1-6) Band elongation
notching in 2-1-7) Band fixing hole
TATA SCAM elongataion
Products 2-1-8) Burr in the ID surface
of the product
2-1-9) Clamping cylinder
fixing screw got loosened
2-1-10) Thickness of the
product is less
2-1-11) Clamping cylinder
fixing screw damage
(Logical reasoning) (Primary) (Secondary)
Phenomenon Physically view Relation with 4M Relation with 4MContributing Condition
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Review of Survey resultsPhenomena : Wrong Location Notching Machine : Notching Machine, U-Line I
Check Check Item Measurement Standard Measured Evaluation Restoration / ResultSite Method Value Value ImprovementPushing 1.Air Pressure Pressure gauge 4 - 7 bar 6 bar OKCyclinder2.Cylinder seal condition Visual No damage No damage OK -
3.Air hose leak Visual No Leak No Leak OK -4.Leak in the ferrule Visual No Leak No Leak OK -5.Piston seal wear Visual No damage No damage OK -6.Dust accumulation in the guide bushVisual Free from dustFree from dustOK -7.Scoring marks in the ID of the guideVisual No scoring No scoring OK -bush8.Scoring marks in the guide rod Visual No scoring No scoring OK -
Limit 9.Limit switch function Visual No Error No Error OK -switch 10.Locking screw loose Visual Rigid Tight Rigid Tight OK -
11.Locking screw damage Visual No damage No damage OK -Clamping 12.Air pressure Pressure gauge 4 - 7 bar 6 bar OK -Cylinder 13.Band Length Scale 380 +/- 3 mm 386 mm Not ok To replace band
14.Band Locking screw loose Visual No loose No loose OK -15.Burr in the band Visual No burr No burr OK - Clamping16.Band damage Visual No damage No damage OK - method 17.Clearance between the product andVernier 4 - 6 mm 9 mm Not ok To correct the modifiedthe band bend in the band18.Band elongation Scale No elongation No elongation OK -19.Band Fixing Hole elongation Vernier caliper No elongation Elongated Not ok To relocate the hole20.Cylinder fixing screw loose Visual No Loose No Loose OK -21.Cylinder fixing screw damage Visual No damage No damage OK -
Product 22.Thickness Micrometer 16.72/17.12 16.93 OK -23.Burr in the ID surface Radius gauge 0.127 proof 0.100 proof OK -
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Countermeasure for the causes identifiedPlant : TSK Plant II SUNDARAM BRAKE LININGS LIMITED
Kaizen Theme : Idea :
To eliminate wrong location Notching Scrap in U Line I To Improve the clamping grip of the lining. "B" TYPEPHENOMENA
Problem / Present status Current Status 14 nos / Week
Clamping method modified Target Zero
Notching area wrongly located in the Kaizen started on 07.01.2001product during notching operation. Kaizen finished on 08.01.2001
Before After Team MembersN. Sridhar
OK Lining R.Rajaambikeswaran
Clamping band Clamping Pad K.Venkatasubramanian
Notching Product K.NambiappanProduct G.K.Rajkumar
Fixture Benefits :Not OK Lining
Wrong Location Notching scrap eliminated in U Line I Nothcing Machine
Clamping Cylinders
Analysis : Results: Scope & Plan for Horizontal DeploymentWrong location notching scrap in U-Line I
PM Analysis S.No Machine Target Resp Status1 Chamfering 30.01.01 UM Completed
Machine
Counter Measure
KAIZEN IDEA - SHEET
28
915
0 0 0 0 0 0 0 0 005
1015202530
Nov
'200
0
Jan-
2001
Mar
-20
01
May
-20
01
Jul-2
001
Sep
-20
01
Month
Scr
ap in
no
s.
After kaizen
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Poka Yoke for eliminating defects
To err is Human. Human Beings are very forgetful and tend to make mistakes. Many times we end up saying “Operator Carelessness / Negligence” or “Operator Inattentiveness”. If we carefully look at such processes, we can reason out that these are a combination of many factors rather than just “Operator Carelessness”.
Monotonous, mechanical and long tense working environment tend to make people commit mistakes. If we bracket these mistakes as “carelessness”, the people get demotivated and discouraged. Poka-Yoke is a technique for avoiding simple human errors at work.
Poka is a Japanese word meaning “inadvertent errors” and Yoke comes from Japanese word Yokerie meaning “to avoid”. This has also been termed as “Mistake / Fool Proofing” or “Fail Safing”. The idea behind poka-yoke is to free a person’s mind from maintaining repetitive vigil which may be practically infeasible. By doing so a person without the fear of making mistake can constructively do more value added activities.
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People always make mistakes. These can be reduced or
even eliminated. Some of the Poke-Yoke devices,
which can help avoid defects, are ;
• Guide Pins / Locators of different sizes.
• Error Detection Buzzers and Alarms
• Limit Switches, Proximity and Photosensors.
• Counters
• Checklists
ERRORS ARE INEVITABLE BUT CAN BE ELIMINATED
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BASIC CLASSIFICATIONS OF POKA-YOKE
• PREDICTION v/s DETECTION
• ALARM v/s SHUTDOWN v/s CONTROL
• CONTACT v/s FIXED VALUE v/s MOTION READING
METHODS
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When a Poka-Yoke is designed in a way that it helps the operator to recognise the defect before it is about to occur, it is called a Prevention or Prediction type Poka-Yoke.
When a Poka-yoke helps the operator to know immediately on the occurrence of the defect then it is called Detection type Poka-Yoke. Detection is “after’ the defect is produced. The merit of this type of poka-yoke is based on the stage at which the defect is detected. In simple language “Earlier the better”.
PREDICTION v/s DETECTION
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The figure 1-A shows that holes are wrongly drilled due to incorrect
positioning of plate.
Figure 1-B shows that incorrect positioning of the plate is prevented by
locating 4 reference pins. The cause of Incorrect Drilling (incorrect
positioning) is prevented.
Pins
Pins
1 (A) 1 (B)
Example : Prevention
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Example : Detection
Figure 2-A shows that plate with four holes drilled is to be despatched to
the Customer. Customer complaints show many plates with 3 holes
drilled.
Figure 2-B shows the mistake of less drilled holes is detected through a
check by using four locator pins on a gauge.
Pins
2 (A) 2 (B)
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ALARM v/s SHUTDOWN v/s CONTROL
ALARMSignals in form of buzzers, blinking lights are used to warn when an abnormality, has occurred (detect) / about to occur (predict).
SHUTDOWNNormal function of machine or process is stopped when defect predicted/detected.
CONTROLIn Prevention type Poka-Yoke , Control means that even intentional errors are impossible or methods by which the cause of a defect if starts happening, it is automatically prevented from happening (feedback mechanism).In Detection type Poka-Yoke , Control means that the process is not stopped but the defective items are automatically separated out and are not allowed to pass on to next stage
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CONTACT v/s FIXED VALUE v/s
MOTION READING METHODS
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CONTACT METHOD
These use the principle of physical or energy contact with the product using sensing devices. They range from guide pins, limit switches, photo electric beams, etc. Contact methods often take advantage of parts that are designed with an uneven shape. We can use guide pins or blocks that don’t allow the product to be seated in a machines jig in the wrong position.
product
JIG3 (B)
product product
JIG
PRESS PRESS
3 (A)
JIG
CORRECT INCORRECT
BeforeIn figure 3A the Sheet Metal Part could be placed incorrectly during forming operation
AfterA limit switch turns the machine on only whenthe protruding neck is positioned where it is supposed to be .
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FIXED VALUE METHOD
Fixed Value Methods are used when a fixed number of parts must be attached to the product or when fixed repeats of operations needs to be done at some process station. Counting devices count the number of times something is done and signals or releases the product from its clamping when the required number is reached.
E.g. Before
A tip of spot welding machine wears with use and should be replaced after certain number of welds. Operator used to forget changing the tip, resulting in defective product.
E.g. After
A counter, tracking the number of welds, stops the machine and flashes a light as a signal to change the tip.
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MOTION STEP METHODThis method senses whether a motion or step in the process has been carried out within a certain expected time ( of the machine cycle time)
This method uses sensors & devices like photoelectric switch connected to a timer.
E.g. A label dispensing machine uses a photoelectric switch to stop the line if it does not detect removal of label from the backing tape.
An example of the Motion Step Method for using Poka-Yoke
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TYPES OF SENSING DEVICES
We have many sensing devices:
• Limit switches, Micro-switches• Proximity Switches• Photoelectric Switches• Beam Sensors
• Sensor to detect changes in Physical condition like temperature, pressure etc. (Pressure switches, thermostats etc.)
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8 TYPES OF ERRORS
• Processing Errors including Safety Errors
• Assembly Errors
• Inspection Errors
• Processing Omissions
• Assembly Omissions
• Packing / Pasting / Labeling Errors
• Mis-orientation, Mis-alignment & Dimensional Errors
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Processing Errors including Safety Errors
Processing Error Section consists of examples where due to operators mistake some process step is partially or incorrectly done
For Example :
Sometimes the drill is raised back before drilling the required depth (through) . A Proximity Switch has been provided to sense the coming through of drill to indicate completion of drill operation
Fixture
Job
Fixture
Job
Proximity
JOB WITHOUT THRU’ HOLE JOB WITH DRILLED THRU’ HOLE
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Assembly Errors
This Section consists of examples where operator by mistake does partial or incorrect assembly.
For Example :
During Assembly of a gear on the shaft for two similar models, Gear ‘B” is assembled on the Shaft ‘a’ instead of Gear ‘A’. Gear A & B are similar looking gears differing only in the number of teeth.
To eliminate this error a Mating part is installed on the Assembly fixture corresponding to ‘A’ to ensure that only gear ‘A’ is loaded
Mating Part for A
Shaft ‘a’
Before After
Gear ‘B’ Installed Wrongly Only Gear ‘A’ Can Be Installed
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Inspection ErrorsSection on Inspection error consists of examples which are related to rejected components going down the line or to the customer. These errors are due to monotony and fatigue faced by the inspector.
The operator is not sure of the completion of leakage test and passes them to the bin meant for keeping jobs that have passed leakage test.
Seam welded jobs waiting for leakage testing
Leakage Testing Done
Beforekept
Jobs without Leakage Test is kept in the OK tray on the left.
Operator sometimes not sure of leakage testing test completion and keeps OK/Not OK products in the OK bin.
Head that stamps part numberAdvances when it senses no leakage
AfterNow Head for stamping added at leakage testing station. Only after leakage has been tested OK, job will be stamped by the Head for stamping
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Processing Omissions
This section consists of examples where due to mistake, the operator misses out few steps of the process
Example:
Four holes to be drilled Three holes drilled because of mistake
Now the drilling operation has been provided with counter and the job will not be unclamped unless, the counter with drilling machine reads four.
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Assembly Omissions
The section on Assembly Omissions consists of examples where an assembly part is not assembled by the operator by mistake and the assembly goes to next station.
For Example :
In an assembly operation washer were missed before providing nut. To remove this problem washer picking was sensed to give a start to nut runner.
Proximity which senses picking of washer gives signal to Nut Runner
Picking
Washer Sometimes missed
NutRunner
NutPICKING OF WASHER WILL BE SENSED TO
ALLOW THE START OF NUT RUNNER
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Packing / Pasting / Labeling Errors
As the name suggest this section includes examples on Errors in Packing / Pasting / Labeling.
For example:
On the cover page of this book an example of carton going without the medicine bottle inside is shown wherein due to mistake the packer missed to fill a bottle in the carton.
Now a draft of fan has been provided below the conveyor, carrying cartons with bottle, which is strong enough only to blow an empty carton.
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Mis-orientation, Mis-alignment & Dimensional Errors
This section consists of errors because of mis-aligned / mis-oriented job loaded on a process leading to slightly offset operations.
Example: Before
Movement of notch milling Movement of notch milling
RIGHT WRONG
Notch to be made on the side with one hole
Notch made on the side opposite to one hole
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Example: After
Now at notching operation the fixture has been made with 3 pins as shown. Job with wrong orientation cannot be loaded for Notch operation.
Fixture for Notch operation
Not possible to load
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There are lot of activities required to be done for
maintaining zero defects. It starts with following JH
checklist, preparing Quality Maintenance matrix,
preparing checklists for inspection of zero defect
conditions and also audits for monitoring activities related
to zero defects. This involves preparing correct operating
standards and other standards for maintenance.
Maintaining Zero Defect
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Process Capability Improvement Plan
Sometimes capability of a process needs to be enhanced
to obtain high Cp value for critical characteristics. This plant
again follows the analysis for variation in the characteristics
and taking countermeasure against all the sources.
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