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1、 6TOOLGUIDE 21st Feb 2004 IndiaPvtLtd 1 6TOOL 100PPMQUALITYPROCESS PerfectCheckSystem CultivatingTeamSkill Implement6TOOL OS D Over Shortage Defect 2 6TOOL 1 OS DActivity Asystemtoimprovequalityofcomponentsfounddefectivebymonitoring analyzing actingonactualrealtimedata materialsuppliedbysuppliers OS
2、 DImage Establishfullinspectionsystem Establishqualityinformationsystem Realinformationsystem Realdata Realmaterial ComputerizedOS Dmanagement Establishvendorappraisalsystem Qualitycontract agreementoftargetquality I PSystem InnovationFlow I P Incentive Penalty FACTORY SUPPLIERS ImprovementActivitie
3、s DefectFound Real QuickInformation ImprovedMaterial InnovationActivities AttachtagafterfindingadefectonthelinePlacecollectionboxfordefectivesinthelineCollectrejection analysisofsamefromIQCmembersDisplayrejectionduetosupplierRequestforurgentdeliveryinexchangeoftotalrejection Suppliermustreceivereali
4、nformationandhaveimprovementmeeting once week Q managerattendReceiveimprovedmaterial follow up 2 6TOOL 1 OS DActivity RULE Activities Finddefectiveparts Attachtag Supplierdefect Red Transportation Blue Workdefect Yellow Storedefectiveparts IssueOS DNCR once day Provideadditionalpartsinlieuofdefected
5、q ty Emergencydelivery HoldimprovementM Twithsupplier SunriseM T Collectthedefectiveparts once day Analyzeandevaluatethecauseofrejection Classifythereasontheirtypeslikeinternalworkerrorortransportationorvendor Recordandmanagecurrentdefectstatusandfeedback Displaythedefectiveparts Organizethereceipt
6、issuingofalternatedpartstotheline Receivethedefectiveparts Analyzethereason Holdimprovementmeeting Dailymeeting Weeklyinnovationmeeting Q managerattend Monthlyevaluationmeeting Q managerattend Material Workdefect Vendordefect Transportation Return Data Replacementfordefectiveparts Self inspectionChe
7、ck list PreparedBy CheckedBy ApprovedBy MACHINE MODEL BUYER ORIGINDATE REVISEDDATE PROCESSNAME DRAWING PART SPECIFICATION SELF INSPECTIONMETHOD REVISIONNO OS DStickers 1 SUPPLIERDEFECT 2 WORKMANSHIPDEFECT OS DReport PreparedBy CheckedBy ApprovedBy ProductionLine DATE S No PartName PartNo DefectDescr
8、iption Vendor Prod QC Workmanship Prod QC Total DefectStatus VendorName QC Supervisor Manager PROD Remarks Pro Inspec tion 3 6TOOL 2 Sequentialinspection Tofilteralltherejectiononthelinebyinspectingpre processedworktotally 100 atthenextprocess Sequentialinspectionimage Aftercheckingpre processedwork
9、 doownprocessactivities Start AssemblyLine 1stProcess 2ndProcess 3rdProcess Inspect100 inassemblyprocess Sequentialinspectionimage Settingsequentialinspectionpointsofeachprocess Checkpre processwork Attachatagonthedefectedposition Feedbacktotheconcernedoperator Recordandmanagerepairhistory Notifythe
10、defectivecontentstooperatorsinthereviewmeeting Makecountermeasures Work ing Pro Inspec tion Pre Inspec tion Work ing Pro Inspec tion Pre Inspec tion Work ing SequentialinspectionGuide ITEM PROCESSNAME Sequentialinspectionguide SequentialinspectionSticker Individualresult Sequentialinspection NO Name
11、 LINE MONTH PreparedBy CheckedBy ApprovedBy 12345678910111213141516171819202122232425262728293031 Pt Pt Pt Pt Pt Pt Pt Pt Pt RepairRecord NO Fault SHOP DATE PreparedBy CheckedBy ApprovedBy Cause ActionTaken Item Qty ConcernedOperation TOTAL PROD QTY REPAIR Remarks 4 6TOOL 3 MainProcessControl Establ
12、ishvisualmanagementformainprocess Heavyrejection Customercomplaints criticaletc andconcentrateonimprovementactivitylikeFoolProof MainProcessOperation Installsignboardssuchas Majorprocess CustomerComplain LineDefect Specificprocess TimeCheckprocess Customer srequirement Criticalprocess Criticalitems
13、Standarditems Registerdefectiveprocess Whendefectoccurs Withdrawmainprocess whennodefectoccurs Ifrejectionoccursestablishcountermeasure attachtheprocess TDRE activitywhendefectoccurscontinuously Makeapermanentcountermeasure FoolProof Establishcheck appraisalsystem TDRE TearDown Re Engineering SignBo
14、ard MAJORPROCESS SPECIFICPROCESS CRITICALPROCESS 550MM 145MM MainProcessControlSheet ProductionQ ty DefectiveQ ty DefectiveRate Date 12345678910111213141516171819202122232425262728293031Total DefectRate ppm 1 000 2 000 SHOP PROCESSNAME CATEGORY OPERATOR OPENINGDATE SUPERVISOR TARGET 5 6TOOL 4 TimeCh
15、eck Toassurecomponentqualitywhichareprocessedinhouse checkmaincontrolpointregularly TimeCheckImage FlowChart Activity Checkqualityperiodicallyandtakeaction Initialinspection Assureinitialsettingcondition Intermediateinspection Check4Mvariation Correctspecificationvariationof4Matmidofproductionday Fi
16、nalinspection Assurethequalityoffinishedproduct Decidecheckpoint Takesample Check Keepsample Recording InitialIntermediateFinal Everytwohour OK NG Stopproduction checkearlyLot Recheckall 100 Changeworkingcondition repair Isolaterejectedlot Stopthedefectiveinputtothenextprocess Decidelimitlevelandsegregate Repairordisposal Findoutdefectcause Establishpermanentsolutionwithconcerneddept TIMECHECKSHEET CHECKEDBY SUPERVISOR APPROVEDBY MANAGER LINE PROCESSNAME DURATION CYCLE EVERY HR OPERATOR SNAME SU
