taehwa 6 tool motor audit english
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8/7/2019 Taehwa 6 Tool Motor Audit ENGLISH
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C&M Go
2010. 7.28
CONTENTS
3
2
Process audit overall1
Q-System audit result
5
Process audit list : 6 Tool
Process audit list :Condition control
Process audit list : T5S
Auditor : Gu, Jin-Mok
4Process Audit List :
Outgoing assurance /CTQ Control
6 NC point of Process Audit
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1 / 7
Vendor) Q-System audit result approvalIn charge approval
C&M Biz. Team
Gu, Jin-Mok
27 th J u ly 10
Vendor Motor line, Taehwa Ent. India Pvt.
Ltd.
Audit dt. 27 th July 10 Obtained
mark
Grade
Auditor Gu, Jin-Mok Attended byfrom Taehwa
QA manager /Koreansupport team
55 A, B, C, D
category Item Allottedmark
Obtainedmark
6-tools
Qualitymeeting
9 2.4
OS&D control 8 3.8
Seq uentialinspection
8 1.9
Key processcontrol
8 1.6
T/Check 9 5.4
Q-a ud it 8 1.6
Total 50 16.7
4 M control
Man 5 1.8
Machine /tools 5 1.3Materials 5 3.0
Metho d 10 6.2
Information of 4 M changes
5 1.3
Total 30 13.6
Outgoing qualityassurance /CTQ control
20 4.7
T5S 50 20
Opinion aboutoverall audit
result
[Good points]-M/C 5S ( du e to no work time increases)
[Major problems]-Pro du ction is carrie d ou t witho u t basic 6 tool con d ition control
in Q-system.- No q u ality training to workers an d QA personal does not have
concept abo u t qu ality.- No q u ality ass u rance du ring pro du ct o u tgoing.
(No OQC control.)
Audit historyAudit dt. Mark Grade Audit dt. Mark Grade
27 th July10
55 D
Grade (Grade A : 150~131 points, Grade B : 130~111 marks,Grade C : 110~91 mark, Grade D : lower than 90)F/up of result (Higher than Grade B : Pass, to publish NCR report,Lower than Grade C : re-audit and to link to biz wrap up???)
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A udit check list 6 tools
2 / 7Profitable Market Share Growth
ItemDetaile d a ud it item
Excellent -- Ba d calc u lation
Obtaine d mark Opinion from a ud itor
5 4 3 2 1
1) Q u alitymeeting
(9 points)
1) Is d aily q u ality meeting being hel d? z
2.4
1) Q u ality meeting not being calle d .2) Weekly an d monthly q u alitymeeting not being hel d .
Qu ality meeting itself is notbeing hel d .
2) Is d aily q u ality meeting recor d being maintaine d properly ?
z
3) Is Q u ality in d ex being recor d e d in the q u alitystat u s boar d?
- Part RTN d efect rate (monthly) , process d efect rate ( d aily , monthly)
z
4) Is weekly q u ality improvement meeting being hel d? z
5) Is monthly review meeting being d one ? z
6) Is F/Up for the d eci d e d item being d one z
2) OS&Dcontrol(8 points)
- Ret u rn setcontrol
1) Is RTN , IQC reject , an d claim receive d set beingrecovere d imme d iately ?
z
3.84
1) RTN sample not being ret u rne d imme d iately. : 1 no. of d ispatche d Q member to L G .2) Q u ality training to operator nil.3) N G set d isplaye d d ie notavailable.4) Except NC report an d co u ntermeas u re against L G qu ality meeting , no d oc u mentavailable.
2) Is N G set being d isplaye d for a specifie d perio d? z
3) Is d efect phenomena being ta u ght to operator ? (Isoperator aware abo u t NG? )
z
4) Is co u ntermeas u re for the NC item being replie d in time ? z
5) Is the d etail regar d ing 2 nd ven d or being F/B an d isits co u ntermeas u re being followe d?
z
3)Seq u entialinspection
1) Is self/seq u ential inspection item being set an d followe d? z
1.9
1) Overall , seq u ential inspectionactivity is lacking.2) No training recor d abo u tseq u ential inspection for operator.
2) Is N G set being recognize d by p u tting tag or marking with marker ?
z
3) Is N G set being kept in d efect box ? z
4) Is operator wise recor d being maintaine d? z
5) Is co u ntermeas u re for the d efect been set ? z
6) Is prize being awar d e d as per the achievement of eachoperator ?
z
|x in
1.8
|x in
1. 6
|x in
1.9
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A udit C/List 6 Tools
3 / 7Profitable Market Share Growth
Item Detaile d a ud it item
Excellent -- Ba d calc u latio
n
Obtaine d
mark Opinion from a ud itor 5 4 3 2 1
4) Keyprocesscontrol(8 points)
1) Has key process sign boar d been attache d on theproblem process ?
z
1.6
1) There is no signboar d operationr u le.
2) Is check sheet being ma d e an d is s u pervisor checkingthe performance ?
z
3) Is key process control like d with history control an d improvement activity ?
z
5) T/Check
1) Is T/Check being carrie d ou t time wise (initial , mid, final) ? z
5.4
2) T/Check of resistance checkitem only being d one2) Has s u rface plate , meas u ring eq u ipment , jig, an d check
sheet etc. been d isplaye d?z
3) Is act u al set being kept as first set , mid pro du ction set , an d final set wise ?
z
4) Is line lea d er , pro du ction hea d checking whether T/Checkis being d one ?
z
5) Is N G imme d iately correcte d an d its improvement activitybeing carrie d ou t?
z
3)Sequentialinspection
1) Is Q-a ud it system been assigne d? z
1.6
3) No a ud it assessment is beingma d e.
2) Is A-a ud it being carrie d ou t on a monthly basis ? z
3) Is checking being carrie d ou t as per Check stan d ar d? z
4) Is Q-A ud it eval u ation sheet being ma d e ? z
5) Is improvement activity being carrie d ou t for the NC item ? z
6) Is a ud it res u lt (mark , NC point) being d isplaye d an d share d?
z
|x i
n2 .3
|x i
n 1.8
|x in
1. 6
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5 / 7
A udit C/List - 4 M control
Profitable Market Share Growth
Item Detaile d a ud it itemExcellent -- Ba d
Calc u lationObtain
e d mark
Opinion from a ud itor 5 4 3 2 1
4) Method(10 marks)
1) Is QC , 4M control chart been ma d e ? z
6.2
1) Operator d o not u nd erstan d thecontent of work stan d ar d
2) There is no working metho d revisionhistory.
3) There is no a ud it report for the 2 nd
ven d or.4) History for the Calibration of
meas u ring instr u ment omitte d .
2) Is working stan d ar d been d isplaye d in the process ? (more than 80%)
z
3) Is working st d . an d work matching an d is workingcon d ition being complie d (to check key process)
z
4) Is change d contents of working metho d an d inspectionmetho d been revise d an d controlle d (process chart , stan d ar d ) in chase working metho d an d inspectionmetho d are change d?
z
5) Is d rawing from c u stomer been entere d in d rawing log
book an d is its history being controlle d an d is its latestversion being marke d?
z
6)Is specification log book being recor d e d an d is its contentsbeing arrange d in d rawing an d is it being fee d /back torelate d d ept ?
z
7) Is process a ud it an d ven d or a ud it report for 2 nd ven d or been prepare d an d is perio d ical a ud it being carrie d ou t?
z
8) Is incoming q u ality inspection an d history control for the2nd ven d or being carrie d ou t?
z
9) Is necessary meas u ring instr u ment available an d
calibration being carrie d ou t perio d ically ? (Meas u ringeq u ipment history car d )
z
3)Materials(5 marks)
1) Is raw materials report (st d .) available ? z
1.3
1) Lacking in d oc u ment.
2) Is incoming low wise materials report (mill sheet) beenobtaine d an d controlle d?
z
3) Is materials incoming an d ou tgoing log book beingcontrolle d?
z
4) Is tracing system available in case there is problem in rawmaterials ?
z
|x i
n2 .0
|x i
n 1
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A udit C/List Outgoing quality assurance/CTQ control
6 / 7Profitable Market Share Growth
Item Detaile d a ud it itemExcellent -- Ba d
Calc u lationObtain
e d mark
Opinion from a ud itor 5 4 3 2 1
Outgoingqualityassurance(20 marks)
1) Is separate OQC inspector been assigne d in QCorganization chart an d is it being operate d?
z
4.7
1) No OQC system is available.
2) Is item wise OQC inspection item been assigne d an d isinspection history car d available ?
z
3) Is OQC inspection history being controlle d per every lot ? (Control with inspection report & system)
z
4) Is OQC inspector controlling the q u ality problem an d spec.changes history ?
z
5) Is Lot tracing possible by classifying o u tgoing lot wisepro du ction d ate ?
z
6) Is i d entification car d attaching for the inspection rea d y/inspection completion/ N G item been classifie d?
z
7) Is meas u rement an d item wise possible meas u ringinstr u ment been eq u ippe d as per o u tgoing inspectionitem ?
z
8) Is perio d ical gage R&R being carrie d ou t with c u stomer for the o u tgoing item ?
z
9) Is important q u ality been selecte d as CTQ item an d isCTQ item a d ju stment history been controlle d on amonthly basis ?
z
10) Is CTP control item been selecte d for the satisfaction of cu stomer ?
z
11) Is improvement activity being carrie d ou t du ring processcapa. analysis an d when target val u e (Z) is notachieve d?
z
|x in
4
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C/List T5S
7 / 7Profitable Market Share Growth
Aud it item G ra de E G ra de D G ra de C G ra de B G ra de A Obtaine d mark
Opinion from A ud itor
5S Arrangementan d organization
10
Unnecessary item , NG item , left over from pro du ction areleft at site witho u tmarking
2
Unnecessary itembeing han d led witho u tany plan
Part mixe d stacke d .4
Temporaryd isposal placeassigne d, perio d icallyd ispose d
Depot area control6
Whenever unnecessary item isfound, it is d ispose d asper r u le
Stan d ar d inventory/stock q uantity is beingcomplie d
8
Basic system toprevent defectrec u rrence isavailable
Linke d todecreases ininventory/ stock
10
4 points
OK pro du ct , NG pro du ctidentification not proper.Model of inventory can notbe i dentifie d .
Cleaning an d cleanness
10
Floor , wall notcleane d an d d irty.
2
Cleaning toolscontrol , d rinking water control , d ressing placecontrol OK
Floor , wall , an d ceiling is clean
4
Cleaning area , incharge freq uencyclear.
Corner , d rinkingwater , d ressing area
6
Eq u ipment cleaningis being doneperio d ically
Eq u ipment in chargeposte d an d operate d
8
Habit uate d cleaningan d maintainingcleanness
Basic improvementactivity is being doneto prevent
contamination
4 points
No in charge assigne d No separate cleaning toolbox
3R Right location , right q uantity , Right container
10
Inventory stacke d on gangway , floor.
Part , tools left onthe floor
2
Having concept of gangway an d havingsimple concept of rightlocation level.
4
Controlling thesystem by whichlocation , item , an d amo unt can befigu re d ou t.
6
Right container , rightquantity is beingcomplie d an d kept atright location
8
The system bywhich 3 R is beingcomplie d . Bin /pallet/container
10
4 points
Unnecessary item is mixe d in lineNo stan dar d container
Visiblemanagement
Find ing o u tabnormality , han d ling theabnormality
10
The system bywhich normal an d abnormal can not befigu re d ou t.
2
The system by whichoperator can not reportby self when anyproblem is occ u rre d .
The con d ition inwhich only relate d personal han d les.
4
The system bywhich operator canreport by self whenany problem isocc u rre d .
Controlling done bylinking to relate d dept.
6
The system in whichanyone can fin d ou tproblem an d solve
Abnormal con d itionis controlle d cumu lativeway an d linke d toimprovement
8
Problem con d itionis being controlle d inthe form of data , systemization
10 2 points
The system by whichproblem from line can notbe fig u re d ou t
Stat us boar d control
10
The system bywhich pro du ctionstat us , loss can notbe fig u re d ou t.
2
Pro du ction stat us , loss stat us not beingcontrolle d
Stat us boar d controllacking
1
Pro du ction target vs.res u lt control
Cleanness of Stat us boar d so so
6
Time wise target an d res u lt, line loss stat us isbeing marke d .
Stat us boar d isbeing maintaine d itemwise an d element wise.
10
Pro du ction stat usan d d istrib u tion stat usof loss can be seenimme d iately
Maintainingcleanness of datasheet in stat us boar d
10
6 points
Pro du ct loss can be seenpartially.No pro du ction stat usboar d in ME line.
Total 20marks
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Non conformity item in process audit (Before and after improvement)
Profitable Market Share Growth
No. Process NC item Phenomena Improvementcountermeasure
After improvement Incharge
Schedule
completion
Remark
1 Slot
insertion
Core preparation
work station notproperly kept.Core left
anywhere
Training to operators an d now
maintaining properly.
Producti
onleader
Done
2 Winding J u mp wire beingpu lled (Wire c u t)
Improve d tools u sing at allwind ers
P.E. Done
3 Winding No inner pin inTransfer tool
All tool change d now on everyWin d er.
Production
leader
Done
4 1 st
formingLea d wire d ent atG ripper
Ou t G ripper 90 t u rn Mr.Lee
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NC item during process Audit (Before and after improvement)
Profitable Market Share Growth
No. Process NC item P henomena Improvementcountermeasure
After improvement Incharge
Schedule
completion
Remark
5Winding
Excessive amo u ntof Coil d ispose d asscrap du ringwind ing an d left inline.
Now after toolImprovement scrap
re du ce d
Production
leader
6 Crimping
Wire c u t NG du e tocoil being p u lled du ring coilstripping.
7 Manualprocess
Wiring N G set leftwitho u tid entification
Now u sing bins to keepNg sets (Apart from
Ru nning mo d els)
8 Manualprocess
Jigs an d tools lyingon floor
All jigs & fixtu res keepingin rack only.
Production
leader
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NC item during process audit (before and after improvement)
Profitable Market Share Growth
No. Process NC item Phenomena Improvementcountermeasure
After improvement Incharge
Schedule
completion
Remark
9 Manual
work
Coil is being p u lled after ins u lationplastic insertion =>
wire c u t
After tool improvement.
10 Manualwork
NG set mixe d witho u t marking
Now u sing stickers towrite any d efect.
Production
leader &
Quality
Done
11Repair
Fan r u nning whilelying on floor
5S maintaine d an d nowthis kin d of activities are
notd oing
Production
leader
Done
12Manualwork
Congeste d linemakes workinefficient
No congeste d line (reworkat the same time)
Production
leader
Target date-22.10.10
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NC item during process audit (before and after improvement)
Profitable Market Share Growth
No. Process NC item Phenomena Improvementcountermeasure
After improvement Incharge
Schedule
completion
Remark
17 Line
Jigs an d toolsBu ffing notproperly d one
Before shift starting , bu ffing of tools on d aily
basis.
Production
leader
Done
18 Rework
Core lying on floor Rework witho u t st d .
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Audit ( , )
Profitable Market Share Growth
No. Process NC item Phenomena Improvementcountermeasure
After improvement Incharge
Schedule
completion
Remark
20Line
No pro du ctionstat u s boar d thu s , loss can not befigu re d ou t exceptMA line
TAR G ET DATE-25-10-10
21 Line
G age not eq u ippe d .(may have large
no. of N G set)
TAR G ET DATE-27-10-10
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NC item during process audit (Before and after improvement)
Profitable Market Share Growth
No. Process NC item Improvement countermeasure Incharge
Schedule
completion
Remark
2Return defect Ret u rn N G set not being collecte d
imme d iately : It takes 2~3 d ays (1 no. of CSd ept.)
2LQCinspection
N G st d . set1) Kept in line with r u st witho u t Mod el marking2) Master sample for meas u ring instr u ment notbeen kept.3) Inspector not checking appearance N G
inspecting only f u nction.
3*Qualitymeeting*Signboard inkeyprocessing
Not being hel d No signboar d operation
4* Sequentialinspection
Nee d to start from stan d ar d setting1) To train its concept an d self training2) To set seq u ential inspection item per each
process
5* Line Audit * No a ud it plan
64M changereporting
4M changes reporting not being complie d 1) No 4M changes reporting history.
7Quality boardin the shopfloor
Stat u s boar d abo u t Improvement contents1) All are being ma d e man u ally2) Not reasonable for operator to u nd erstan d
8
Dismantletest
Stator Asm d ismantle test1) Not being carrie d ou t.
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