美资企业品质管理培训资料.ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,05 十一月 2026,美资企业品质管理培训资料,1.6TOOL?,100 PPM QUALITY PROCESS,OS&D*,Sequential Inspection,Main Process Control,Time Check,Quality Audit,Review Meeting,1,2,3,4,5,6,Perfect,Check,System,Cultivating,Team,Skill,Implement,6TOOL,*OS&D:Over,Shortage&Defect,100 PPM,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.,OS&D Image,Establish full inspection system,Establish quality information system,-Real information system,.Real data,.Real material,-Computerized OS&D management,Establish vendor appraisal system,-Quality contract,(agreement of target quality),-I&P System,Innovation Flow,*I&P:Incentive&Penalty,FACTORY,SUPPLIERS,Improvement,Activities,Defect,Found,Real&Quick,Information,Improved,Material,Innovation Activities,Attach tag after finding a defect,on the line,Place collection box for defectives,in the line,Collect rejection&analysis of same,from IQC members,Display rejection due to supplier,Request for urgent delivery in exchange,of total rejection.,Supplier must receive real information,and have improvement meeting,(once/week)=Q-manager attend,Receive improved material&follow-up,100 PPM,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),-Provide additional parts,in lieu of defected qty,.Emergency delivery,-Hold improvement M/T,with supplier,.Sunrise M/T,-Collect the defective,parts(once/day),-Analyze and evaluate,the cause of rejection.,.Classify the reason,their types like internal,work error or,transportation or vendor,-Record and manage,current defect status,and feed back,-Display the defective,parts,-Organize the receipt/,issuing of alternated,parts to the line,-Receive the defective,parts,-Analyze the reason,-Hold improvement,meeting,.Daily meeting,.Weekly innovation,meeting,(Q-manager attend),-Monthly evaluation,meeting,(Q-manager attend),Material,Work defect,Vendor defect&,Transportation,Return,Data,Replacement for defective parts,100 PPM,Self-inspection Check-list,Prepared,By,Checked,By,Approved,By,MACHINE/MODEL,BUYER,ORIGIN DATE,REVISED DATE,PROCESS NAME,DRAWING,PART,SPECIFICATION,SELF-INSPECTION METHOD,REVISION NO,100 PPM,*OS&D Stickers,1.SUPPLIER DEFECT,2.WORKMANSHIP DEFECT,100 PPM,OS&D Report,Prepared,By,Checked,By,Approved,By,Production Line:,DATE:/,S/No,Part Name,Part No,Defect Description,Vendor,Prod.,QC,Workmanship,Prod.,QC,Total,Defect Status,Vendor,Name,Q,C,Supervisor,Manager,P,R,O,D,Remarks,Pro-,Inspec-,tion,3.6TOOL-2/Sequential inspection,To filter all the rejection on the line by inspecting pre-processed work totally(100%),at the next process.,Sequential inspection image,After checking pre-processed work,do own process activities,Start,Assembly Line,1st Process,2nd Process,3rd Process,Inspect 100%in assembly process,Sequential inspection image,-Setting sequential inspection points,of each process,-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,-Make countermeasures,Work,-ing,Pro-,Inspec-,tion,Pre-,Inspec-,tion,Work,-ing,Pro-,Inspec-,tion,Pre-,Inspec-,tion,Work,-ing,100 PPM,*Sequential inspection Guide,ITEM,PROCESS NAME,Sequential inspection guide,100 PPM,*Sequential inspection Sticker,100 PPM,Individual result-Sequential inspection,N,O,Name,LINE:MONTH:,Prepared,By,Checked,By,Approved,By,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,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Pt,Repair Record,NO,Fault,SHOP/:DATE :/,Prepared,By,Checked,By,Approved,By,Cause,Action Taken,Item,Qty,Concerned,Operation,TOTAL,PROD.QTY,%REPAIR,Remarks,100 PPM,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.,Main Process Operation,-Install sign boards such as:,.Major process:Customer Complain,Line Defect,.Specific process:Time Check process,Customers requirement,.Critical process:Critical items,Standard items,-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,*TDRE:Tear Down&Re-Engineering,100 PPM,*Sign Board,MAJOR PROCESS,SPECIFIC PROCESS,CRITICAL PROCESS,550MM,145MM,100 PPM,Main Process Control Sheet,Production Qty,Defective Qty,Defective Rate,Date,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 Total,Defect,Rate,(ppm),1,000,2,000,SHOP,PROCESS NAME,CATEGORY,OPERATOR,OPENING DATE,SUPERVISOR,TARGET,100 PPM,5.6TOOL-4/Time Check,To assure component quality which are processed in house,check main control point regularly,Time Check Image,Flow Chart,Activity,-Check quality periodically,and take action,-Initial inspection:,.Assure initial setting,condition,-Intermediate inspection:,Check 4M variation,.Correct specification,variation of 4M at mid,of production day,-Final inspection:,Assure the quality of,finished product,Decide,check point,Take sample,Check,Keep sample,Recording,Initial,Intermediate,Final,Every two hour,OK,NG,Stop production,&check early Lot,Recheck all,(100%),Change working,condition&repair,-Isolate rejected lot,-Stop the defective input to,the next process,-Decide limit level and segregate,-Repair or disposal,-Find out defect cause,-Establish permanent solution,with concerned dept.,100 PPM,TIME CHECK SHEET,CHECKED BY(SUPERVISOR):,APPROVED BY(MANAGER):,LINE,PROCESS NAME,DURATION,(/)(/),CYCLE,EVERY()HR,OPERATORS NAME,SUPERVISORS NAME,No,Check,items,Signature by supervisor,MON(/),TUE(/),WED(/),THU(/),FRI(/),SAT(/),09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,09:00,11:00,11:00,01:00,02:00,04:00,04:00,06:00,Specs,100 PPM,*Time Check Process Board,TIME CHECK PROCESS,550MM,145MM,TIME CHECK BOARD,Time Check Sheet,09:0011:00,11:0001:00,02:0004:00,04:0006:00,LINE:_,ITEM:_,OPERATOR,SUPERVISOR,100 PPM,6.6TOOL-5/Q-AUDIT,We will compare the required quality level&the quality level of our,products/processes and then narrow the gap.,Flow Chart,Select model,Find problems/,Register task,Do Q-Audit,Keep Record,Improvement,Manage,till innovated,Process,Class,Step 1,Step 2,Step 3,Outgoing Audit,Step 1+Line Audit,Step 2+Process,(Parts)Audit,M,A,I,N,F,O,C,U,S,Rem-,arks,-Understand,customers needs,Establish outgoing,inspection,parameters.,Do 100%inspection,Find out weak point,&improve.,Establish line process,parameters.,Do regular audit.,Find out line problems,&improve.,-Find out process or,parts problem&solve,them permanently,Regular Audit by QA along with production&sometimes,from Customer.,100 PPM,Establish control,Parameters.,7.6TOOL-6/Review Meeting,We must naturalize ourselves to prevent defect input&improvement,of such defects through systematic review.,Daily Meeting,Weekly Meeting,Monthly Meeting,-Describe process&parts defect,with actual material,-Conducted by supervisor with,all operators,-Do daily,-Weekly meeting to make counter-,measure(OS&D,Line Rejection),-Supervisor&Manager,-Once per week,-Review monthly target&result,establish next month plan,-Supervisor&All Managers,-Once per month,100 PPM,Quality Review Report,LINE,DATE,/,Prepared,by,A,P,P,R,O,V,A,L,Prepared,by,Checked,by,HOD,LQC Status,1.Rejection rate,(/)(/),Prod,Qty,Rej,Qty,PPM,APC,used,APC,rej,PPM rej,2.Worst 5 items,(Customer/Line),1,2,3,4,5,Problem&Cause,Countermeasure,Date,Resp.,Sign,A,P,C,S,H,O,P,REJECTION STATUS,MONTH,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,Total,Production,Qty,APC used,Qty,Rejection,Qty,APC Rej.,Rate,Date,Rate,(Unit:,PPM),50,100,150,200,300,APC rej.,Qty,Shop,Rejection Rate,APC TARGET,Monthly Line Rejection Rate,2004,REJECTION RATE,(PPM),JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC,50,100,150,200,Prod,Qty,APC used,Rej.,Qty,APC Rej.,Rate,APC rej.,Shop,Rej.Rate,APC TARGET,1-1 6 Sigma Concept,level,PPM,6 3.4,5233,46210,366,807,2308,537,Process Defects,Capability Opportunity,Sweet Fruits,(Perfect Design),Bulk of fruits,(Optimization),Lower fruits,(7 QC tools),Ground fruits,(Straight viewpt),1-1 6 Sigma Concept-I,3 Sigma Level Company,6 Sigma Level Company,10 15%of sales is failure cost,Having 66,807 defects per Million,Depends on the detection of defects,Believes that high Quality is expensive,Doesnt follow systematic approach,Benchmarking against competing,companies,Believes 99%is good enough,Defines CTQs internally,5%of sales is failure cost,3.4 defects per Million,Focus on process not to produce Defects,Believes that high Quality creates low cost,Uses D-M-A-I-C Know how,Benchmarking to be the Best in the World,Believes 99%is unacceptable.,Defines CTQs from customer point of view,