ch 7 qm

1

CHAPTER 7

QM PILLAR

Contents

7.1 Objective Background and aim

7.1.1 Vision and Goal

7.1.2 Targets and Master Plan

7.2 QM Approach and Concept

7.2.1 QM Defect Identification

7.2.2 QA & QM Matrix\

7.2.3 Defect Reduction Activities

7.3 KAI Cumulative Trends

7.4 QM Results

7.5 QM Future Plan

MR.BALAJI

1

QM PILLAR CHAIRMAN

2

TPM ACTIVITY

REPORTSub Title : AFTER PRE AUDIT , QM ACTIVITY FLOW

Slide Title : 7 QM PILLAR

Vision & Goal

KMI / KPI / KAIKMI / KPI / KAIKMI / KPI / KAI

Organization Chart

Back Ground

QM Target

QM Master Plan

Type of defects

QA / QM Matrix

Assessor Observation and

Background

New Addition

New Addition

New Addition

New Addition

A

3

TPM ACTIVITY

REPORTSub Title : AFTER PRE AUDIT , QM ACTIVITY FLOW


A

Defect reduction

4M Condition

Q Component

PM analysis

Kaizen Samples

KK Results

Future Plan

Case studyNew Kaizen added

Improvement after pre assessment

New addition after pre audit

Assessor Comments and Countermeasures

Updated

New Addition

New Addition

4

TPM ACTIVITY

REPORTSub Title : 7.1.1 VISION AND GOAL


VISION AND GOAL

VISION (KMI) GOAL (KPI) KAI ResponsibilityPrimary / Secondary

P – Enhance Productivity

Q – Meet Quality

C – Reduce Cost

D – On time

S – Environment

M – High for Employees QM / PM

QM / SHE

QM / PM

QM / PM

QM / AM

QM / PM

TO GROW BUISSNESS

WITH DIGNITY AND

RESPECT INTEGRITY

CUSTOMER LOYALTY

CONTINUAL IMP

IMPROVEMENT AND INNOVATION

UNCOMPROMISING QUALITY EMPOWERMENT TO INDIVIDUALS

5

TPM ACTIVITY

REPORTSub Title : 7.1.2 QM PILLAR ORGANISATION CHART


7.1.2 - QM PILLAR ORGANISATION CHART

C

PILLAR CHAIRMANMR.BALAJI New members

6

TPM ACTIVITY

REPORTSub Title : 7.1.3 - QM PILLAR Background

7.1.3 - QM PILLAR Background


Assessor Comments: 1. How many people really understood on QM Concept?2. What is the time taken for all the quality testing and what is the time reduction done need to be identified

7

TPM ACTIVITY

REPORTSub Title : 7.1.4 - QM TARGETS

7.1.4 - QM TARGETS


After pre audit – new targets

8

TPM ACTIVITY

REPORTSub Title : 7.1.5 - MASTER PLAN

7.1.5 - MASTER PLAN


C

After pre audit – New process included - Welding

9

TPM ACTIVITY

REPORTSub Title : 7.2.1- QM PILLAR CONCEPT

7.2.1- QM PILLAR CONCEPT

Input Raw Materials

Inspection Send back to supplier

Process

O/p Products

Inspection

Dispatch to Customer

CustomerProblem if any

Investigation / Analysis

Kaizen / Countermeasures

Update 4M Conditions

ok

Defect

Man

Method

Material

Machine

Monitor 4M Conditions

DO NOT SEND A DEFECT

DO NOT PRODUCE A DEFECT

DO NOT ACCEPT A DEFECT

Not ok

ok

Not ok

QA Activities

QM Activities

Input Raw Materials

Inspection


10

TPM ACTIVITY

REPORTSub Title : 7.2.2 - CONCEPT QC, QA, QM


7.2.2 - CONCEPT QC , QA , QM

Input control Output control No control

Maintaining 4M basic conditions Re-setting process conditions No control mechanism

Zero defects Few defects More defects

By Operator By Operator By QC inspector

Continuous monitoring of 4M conditions

Periodic sample inspection of products Extensive inspection of products

Defect PreventionDefect DetectionDefect Detection

On-line InspectionOn-line InspectionOff-line Inspection

Quality Maintenance (QM)Quality Assurance (QA)Quality Control (QC)

AFTER TPMBEFORE TPM

After pre audit – Zero flash improvements

11

TPM ACTIVITY

REPORTSub Title : 7.2.3 – STATUS BEFORE / AFTER TPM IMPLEMENTATION


7.2.3 – STATUS BEFORE / AFTER TPM IMPLEMENTATION

S. No.

DESCRIPTION

BEFORE TPM IMPLEMENTION

AFTER TPM IMPLEMENTION

BENCH MARK PRESENT STATUS TARGETUPTO 2005

( QC CONCEPT )

2006 - 2009

( QA CONCEPT )

2010 - 2011 ( QM

CONCEPT )

1Customer complaint

More, No Clear

Structure For Approach

Few, Clear Structure For

ApproachNo

2 Quality Defects

3Control

MechanismNo Approach Reactive Approach Pro active Approach

4Understanding of

DefectsNo understanding Defect Phenomena

Action plan for eliminating chronic

defects.

5Defects

Identifications QC Inspector Plant Supervisor Plant Operator

6 Quality skill QC Department Supervisor Operator

7Quality depends

on Inspector Functional heads Operator

8 Inspection OFF-Line OFF-Line

With Quick Measurement

ON -Line

OFF-LINE MEASUREMENT ON-LINE MEASUREMENT

12

TPM ACTIVITY

REPORT

7.2.4 - Step 1 : Preparation of QA matrix

Sub Title : 7.2.4 - Step 1 : Preparation of QA matrix


Seriousness Past Occurrence

Đ Develop into major defects Δ Frequent

Ψ Reprocessing possible @ Occasional

Ø Not occurred

Đ

Đ

13

TPM ACTIVITY

REPORT

7.2.5 - Step 2 : Prepare production – input condition analysis table

Sub Title : 7.2.5 - Step 2 : Prepare production – input condition analysis table


Target

LSL

USL

Adjustment

C – Type

First-Off Inspection

Stabilisation

First Piece of setting.

W/O Adj.

A – Type

ACTION TAKEN by the operator. Adjustment of the equipment / tools / jigs / fixtures to achieve stabilisation.

Measurement & Adjustment

1/3 of Tolerance

Caused during change overDue to inadequate setup procedures and lack of skills in fixturing & setting of equipments, tools, measuring instruments, etc. and also wrong selection of the above.

Stabilization

Mass production

B – Type

UCL

LCL

ACTION NOT TAKEN by the operator. No adjustments made.

Setting

Defect - Abnormal

Accepted - Normal

Target = (LSL+USL) / 2

Defect - Abnormal

Chance / Chronic Causes Identify root cause using PM analysis.

To

lera

nc

e

Assignable / Sporadic CausesIdentify root cause using Why-Why analysis.

14

TPM ACTIVITY

REPORTSub Title : 7.2.5.1 - TYPE OF DEFECTS

7.2.5.1 - TYPE OF DEFECTS


After pre audit – defect type added

15

TPM ACTIVITY

REPORTSub Title : 7.2.5.2 - UNDERSTANDING OF QUALITY DEFECT

7.2.5.2 - UNDERSTANDING OF QUALITY DEFECT


After pre audit – Zero flash improvements

16

TPM ACTIVITY

REPORT

7.2.5.3 - DEFECT REDUCTION ACTIVITIES

Sub Title : 7.2.5.3 DEFECT REDUCTION ACTIVITIES

Activities

• 4M Condition set for Major Defects • Why – Why Analysis done

• Counter measures Plan

• One Point Lesson

• Training

• Kaizens

• 4M Conditions Revisions plan

• Visual Control

• Poke - Yoke

0

200

400

600

800

1000

PPM 858 324 185 92

High wall thickness

Blow holes

Warpage Sink mark

0

100

200

300

400

500

600

PPM 482 215 92

Insufficient pressure

High Inj speed

High MB proportion

DEFECTWISE IND PRODUCT SCRAP PPM PARETO ANALYSIS : AVG JAN 2011 – SEP 2011

Split up of IND product Scrap Split up of high wall thickness

A type

High wall thickness dueto A type defect


17

TPM ACTIVITY

REPORT

7.2.6 - Step 3: Prepare Problem chart

Sub Title : 7.2.6 - Step 3: Prepare Problem chart


S.No. Details of Case Study Tools Used

1 Wall thickness variation in TT tub. PM Analysis

2 Gate point shift on Jumbo crates Why ? Why ? Analysis

3 Blow holes on TT tub. Why ? Why ? Analysis

4 Warpage on Rad tub. Why ? Why ? Analysis

18

TPM ACTIVITY

REPORT

7.2.7 - Step 4: Evaluate seriousness of problems ( FMEA 1)

Sub Title : 7.2.7 - Step 4: Evaluate seriousness of problems ( FMEA 1)


19

TPM ACTIVITY

REPORT

7.2.8 - Step 5 : Use PM Analysis to track down causes of problemsGrasping Quality defect phenomena

Sub Title : 7.2.8 Step 5 : Use PM Analysis to track down causes of problems Grasping Quality defect phenomena


PHENOMENA MECHANISM ANALYSIS FOR WALL THICKNESS

20

TPM ACTIVITY

REPORT

7.2.8.1 - STEP 5 – PHENOMENA MECHANISM ANALYSIS FOR WALLTHICKNESS

Sub Title : 7.2.8.1 - STEP 5 – PHENOMENA MECHANISM ANALYSIS FOR WALL THICKNESS


S No. Contributing Condition Primary 4M Condition Secondary 4M Condition

a) MB Dosageb) Weighta) RM Mixb) End of Speed drop

3) Consistent Pressure Drop pressure setup Pressure Saturation

Setting speed

Mixing ratio1)

2)

Higher Master batch proportion

Higher Injection Speed

21

TPM ACTIVITY

REPORT

7.2.9 – STEP 6: Assess impact of the countermeasures taken (FMEA 2)

Sub Title : 7.2.9 – STEP 6: Assess impact of the countermeasures taken (FMEA 2)


FMEA OF VARIATION OF WALLTHICKNESS IN TT

22

TPM ACTIVITY

REPORTSub Title : 7.2.9.1 - QM MATRIX

7.2.9.1 - QM MATRIX


After pre audit – QM Matrix revised for SSR part

23

TPM ACTIVITY

REPORT

7.2.9.2 - “ Q” COMPONENTS IN INJECTION MOLDING MACHINES



After pre audit – Mold manifold heater - Q Component added

24

TPM ACTIVITY

REPORT

7.2.9.3 - “ Q” COMPONENTS IN INJECTION MOLDING MACHINES



TOTAL Q COMPONENT – 8 NOS

MOLD Heater

After pre audit – Q component added

25

TPM ACTIVITY

REPORT

7.2.9.4 - DEFECT REDUCTION ACTIVITIES



360-370kgf.cm2

60- 80%

180 - 220oC

180 – 200 kg/cm2

4 – 5 mm

250 – 300 kg.cm2

120-150kgf.cm2

CONTROL VALUES

Flash

Shrink

Shortfill

Shrinkage

Shortfill

FLASH

FLASH

CONTROL QUALITY

Pressure Q 7

SpeedInjectInjection speed mmiQ 6

Temp of materialBarrel HeaterQ 5

PRESSUREInjection pressureQ 4

SIZENozzle IDQ 3

Plattern movingMoving plattern open / close

GaugeQ 2

Core pressureMold Core in / out gaugeQ 1

CONTROL

PARAMETERSCOMPONENT NAME

Progress

Injection speed

Mold locking gauge

Mold locking gauge

12 to 15 ohms FlashTemperature Q 8 Mold Heater

After pre audit – Q 8 added

26

TPM ACTIVITY

REPORTSub Title : 7.2.10 - STEP 7 – IMPLEMENT IMPROVEMENTS


7.2.10 - STEP 7 – IMPLEMENT IMPROVEMENTS

Valve

seal Changed

Focus on seal by QM

Pillar

Oil to Inj mode

Oil Retraction

27

TPM ACTIVITY

REPORTSlide Title : 7 QM PILLAR

Sub Title : 7.2.10.1 - QM KAIZEN

7.2.10.1 - QM KAIZENAfter pre audit – Kaizen added

28

TPM ACTIVITY

REPORT

7.2.10.2 - DEFECT REDUCTION - OPL SAMPLE



After pre audit – OPL added

29

TPM ACTIVITY

REPORTSub Title : 7.2.11 - Step 8: Review production – input conditions

Table for Wall thickness


7.2.11 - Step 8: Review production – input conditionsTable for Wall thickness

Quality test is performed

Quality test of R/D product is

performed every shift

Optimum blend ratio

implemented.

1300

Optimum material blend ratio,

Plant D

Material Machine Method

(man)Defect mode

Sub process

Main process

Th

ick

ne

ss

va

ria

tio

n

Ma

teri

al

mix

, p

ara

me

trs

In

pu

t c

on

dit

ion

Additivedosage

As per StandardStandard need improvement ? Standard need x Std Impossible to follow

30

TPM ACTIVITY

REPORT

7.2.11.1 - 4M CONDITION EXAMPLE



190 ± 10 kgf/cm2

After pre audit – PART added in 4M Condition

31

TPM ACTIVITY

REPORTSub Title : 7.2.12 - Step 9: Consolidate and confirm checkpoints

Quality Check Matrix


7.2.12 - Step 9: Consolidate and confirm checkpointsQuality Check Matrix

Batch formation

Retain the inspection

Thickness

Seal

Every ShiftChecking interval

Right level of MixingStandard

PPCPCheck Item

Raw materials Equipment part

32

TPM ACTIVITY

REPORTSub Title : 7.2.12.1 DEFECT REDUCTION ACTIVITIES


7.2.12.1 - TT Tub : QM Check sheet

TT Tub : QM Check sheet

Quality Component

Control Conditions

ConditionChecking

MethodChecking Standard

TT TUB

Injection Pressure GaugeInjection Pressure to with stand up

to full cycleThickness

Fall rate should be in permissible limits

(180 - 200 kg/cm2)

33

TPM ACTIVITY

REPORTSub Title : 7.2.12 DEFECT REDUCTION ACTIVITIES


7.2.12 STEP 10 – Quality Component for wall thickness

Data are entered in Plant operating log Result

LaboratoryChecking method

Setting Speed and PressureChecking Standard

Per ShiftChecking interval

Quality Component : Seal, MB Mixing

34

TPM ACTIVITY

REPORTSub Title : 7.2.12 DEFECT REDUCTION ACTIVITIES


Question & Answers

Question & Answer

Q 5.1: How many people really understood on QM

Concept?

Yokoo Kazuyuki san

Countermeasures - 83% of our members are aware of QM concept (our quality rate by

the customer is 99.7%). This is happened because of TPM way of quality improvement.

Our members understanding regarding the quality is based on input controls. They also

understood the Q component, process point and process characteristics. Our operators

jointly working with QM Pillar. The mindset of quality checking in finished product is

converted in to in-build quality process.

Gemba Q1: What is the time taken for all the quality

Testing and what is the time reduction done, need to be

Nakano Tsuneo san identified.

Countermeasures: As per assessor advice we started monitoring the time taken for

each and every testing process carried out the laboratory included with both raw

material and performance testing on products. So far there are four issues were taken

for higher time consuming and we reduced up to average time of around 30minutes

from existing around 1 hr.

Pre audit Assessor Comments

35

TPM ACTIVITY

REPORTSub Title : 7.3 KAI CUMULATIVE TREND


KAI CUMULATIVE TREND

KAI CUMULATIVE TREND

WHY – WHY ANALYSISNos OPL DONENos TRAININGS CONDUCTEDNos

POKE YOKENos COUNTERMEASURESNos KAIZENSNos

C

TPM ACTIVITY

REPORTSub Title : 7.3.1 KAIZEN SAMPLE SHEETS


85 QM K

AIZEN

IMPLEMENTED

After Pre audit – kaizen updated

37

TPM ACTIVITY

REPORTSub Title : 7.4 QM RESULTS


P.1.1.12 – CRATE PRODUCTS SCRAP

PPM

Better

FROM 4365 PPM TO 98 PPM

BM – 4365 (JUN 07 )

38

TPM ACTIVITY



P.1.1.13 – FURNITURE PRODUCTS SCRAP

PPM

FROM 15002 PPM TO 501 PPM

BM – 15002 (JUN 07 )

Better

39

TPM ACTIVITY



P.1.1.14 – INDUSTRIAL PRODUCTS SCRAP

Better

%

FROM 1% TO 0.26%

BM – 15002 (JUN 07 )

40

TPM ACTIVITY



P.1.1.15 – FURNITURE REWORK

%Better

FROM 12% TO 2.52%

BM – 12 (JUN 07 )

41

TPM ACTIVITY



C 3.1.1 – INPROCESS SCRAP

%Better

FROM 3.9% TO 0.64%

BM – 3.9% (JUN 07 )

42

TPM ACTIVITY

REPORTSub Title : 7.5 QM FUTURE PLAN

FUTURE PLAN

Sl No Activity Target Date

1

2

3

4

5

To achieve 85 PPM in Crate Product Scrap

To achieve 350 PPM in Furniture Product Scrap

To achieve 0.15% in Industrial Product Scrap

To achieve 1.55% in Furniture Rework

To achieve 0.4% in in process Scrap

Dec 2011

Jan 2012

Feb 2012

Mar 2012

Feb 2012


C

43

CHAPTER 8

DM – PILLAR

Presentation By

Mr. Ramesh Kumar

ch 7 qm

Business

qm slide title

qm concept

qm approach

qm pillar7

qm results

qm pillarc

qm activity flowslide

qm targets slide title