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.,.,*,6TOOLGUIDE,21st.Feb.2004,100 PPM,IndiaPvtLtd,1.6TOOL?,100PPMQUALITYPROCESS,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&DActivity,Asystemtoimprovequalityofcomponentsfounddefectivebymonitoring,analyzing&,actingonactualrealtimedata&materialsuppliedbysuppliers.,OS&DImage,Establishfullinspectionsystem,Establishqualityinformationsystem,-Realinformationsystem,.Realdata,.Realmaterial,-ComputerizedOS&Dmanagement,Establishvendorappraisalsystem,-Qualitycontract,(agreementoftargetquality),-I&PSystem,InnovationFlow,*I&P:Incentive&Penalty,FACTORY,SUPPLIERS,Improvement,Activities,Defect,Found,Real&Quick,Information,Improved,Material,Innovation Activities,Attach tag afterfindinga defect,on the line,Place collectionboxfordefectives,in the line,Collectrejection&analysisofsame,fromIQCmembers,Displayrejection due tosupplier,Requestforurgent deliveryin exchange,oftotal rejection.,Suppliermust receive real information,andhaveimprovementmeeting,(once/week)=Q-manager attend,Receiveimprovedmaterial&follow-up,100 PPM,2.6TOOL-1/OS&D Activity(RULE),PRODUCTION,PURCHASE,IQC,MATERIAL,SUPPLIER,Activities,-Find defectiveparts,-Attachtag,.Supplier defect:Red,.Transportation:Blue,.Work defect:Yellow,-Storedefective parts,-IssueOS&DNCR,(once/day),-Provide additionalparts,in lieuof defectedqty,.Emergencydelivery,-Hold improvement M/T,withsupplier,.Sunrise M/T,-Collect the defective,parts(once/day),-Analyze and evaluate,thecause ofrejection.,.Classify the reason,their typeslikeinternal,workerror or,transportation or vendor,-Recordandmanage,currentdefect status,andfeedback,-Display the defective,parts,-Organize the receipt/,issuingof alternated,parts totheline,-Receive the defective,parts,-Analyze the reason,-Hold improvement,meeting,.Daily meeting,.Weeklyinnovation,meeting,(Q-manager attend),-Monthly evaluation,meeting,(Q-manager attend),Material,Workdefect,Vendor defect&,Transportation,Return,Data,Replacementfordefective parts,100 PPM,Self-inspectionCheck-list,Prepared,By,Checked,By,Approved,By,MACHINE/MODEL,BUYER,ORIGIN DATE,REVISEDDATE,PROCESSNAME,DRAWING,PART,SPECIFICATION,SELF-INSPECTIONMETHOD,REVISIONNO,100 PPM,*OS&D Stickers,1.SUPPLIERDEFECT,2.WORKMANSHIP DEFECT,100 PPM,OS&DReport,Prepared,By,Checked,By,Approved,By,Production Line:,DATE:/,S/No,PartName,PartNo,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 filterall the rejection onthelineby inspecting pre-processed work totally(100%),at the next process.,Sequentialinspection image,Aftercheckingpre-processed work,do own processactivities,Start,Assembly Line,1st Process,2nd Process,3rd Process,Inspect 100%inassemblyprocess,Sequentialinspection image,-Settingsequentialinspection points,of each process,-Check pre-processwork,-Attach atagon the defectedposition,-Feed back tothe concerned operator,-Record and managerepair history,-Notify the defective contents tooperators,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,Sequentialinspection guide,100 PPM,*Sequential inspection Sticker,100 PPM,Individualresult-Sequentialinspection,N,O,Name,LINE:MONTH:,Prepared,By,Checked,By,Approved,By,1 23456789 101112 13 1415 16 1718 19 202122 2324 25 262728 29 3031,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 ProcessControl,Establishvisual management for main process(Heavy rejection,Customer complaints,critical etc.)and concentrateon improvement,activity like Fool Proof.,MainProcess Operation,-Installsignboards such as:,.Major process:Customer Complain,Line Defect,.Specificprocess:TimeCheck process,Customersrequirement,.Criticalprocess:Criticalitems,Standarditems,-Registerdefectiveprocess:Whendefect occurs,-Withdrawmainprocess:whenno defectoccurs,-Ifrejectionoccurs establish countermeasure:attachtheprocess,-TDRE*activity when defect occurscontinuously,-Make a permanent countermeasure:FoolProof,-Establish check&appraisalsystem,*TDRE:Tear Down&Re-Engineering,100 PPM,*Sign Board,MAJORPROCESS,SPECIFIC PROCESS,CRITICAL PROCESS,550MM,145MM,100 PPM,MainProcess ControlSheet,ProductionQty,DefectiveQty,DefectiveRate,Date,123456789101112131415 16 17 18 19 20 21 22 23 24 25 26 27 28 29 3031 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 assurecomponentquality which are processed inhouse,checkmaincontrol pointregularly,TimeCheckImage,FlowChart,Activity,-Check qualityperiodically,and take action,-Initialinspection:,.Assure initial sett
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