6TOOL GUIDE21st. Feb. 2004India Pvt Ltd1. 6TOOL ?100 PPM QUALITY PROCESSOS&D*Sequential InspectionMain Process ControlTime CheckQuality AuditReview Meeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D : Over, Shortage & Defect2. 6TOOL-1 / OS&D ActivityA system to improve quality of components found defective by monitoring , analyzing &acting on actual real time data & material supplied by suppliers. OS&D ImageEstablish full inspection systemEstablish quality information system- Real information system . Real data . Real material- Computerized OS&D managementEstablish vendor appraisal system- Quality contract (agreement of target quality)- I&P System Innovation Flow*I&P : Incentive & PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal & QuickInformationImprovedMaterialInnovation 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-up2. 6TOOL-1 / OS&D Activity (RULE)PRODUCTIONPURCHASEIQCMATERIALSUPPLIERActivities- 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)MaterialWork defectVendor defect &TransportationReturnDataReplacement for defective partsSelf-inspection Check-listPreparedByCheckedByApprovedByMACHINE / MODEL BUYERORIGIN DATEREVISED DATEPROCESS NAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTION METHODREVISION NO* OS&D Stickers1. SUPPLIER DEFECT2. WORKMANSHIP DEFECTOS&D ReportPreparedByCheckedByApprovedByProduction Line : DATE : / / S/NoPart NamePart NoDefect DescriptionVendorProd.QCWorkmanshipProd.QCTotalDefect StatusVendorNameQCSupervisorManagerPRODRemarksPro- Inspec-tion3. 6TOOL-2 / Sequential inspectionTo filter all the rejection on the line by inspecting pre-processed work totally (100%) at the next process. Sequential inspection imageAfter checking pre-processed work,do own process activitiesStartAssembly Line1st Process2nd Process3rd ProcessInspect 100% in assembly processSequential 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 countermeasuresWork-ingPro- Inspec-tionPre-Inspec-tionWork-ingPro- Inspec-tionPre-Inspec-tionWork-ing* Sequential inspection GuideITEMPROCESS NAMESequential inspection guide* Sequential inspection StickerIndividual result - Sequential inspectionNONameLINE : MONTH : PreparedByCheckedByApprovedBy1 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 31PtPtPtPtPtPtPtPtPtRepair RecordNOFault SHOP / : DATE : / / PreparedByCheckedByApprovedByCauseAction TakenItemQty ConcernedOperationTOTAL PROD. QTY % REPAIR Remarks 4. 6TOOL-3 / Main Process ControlEstablish 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* Sign BoardMAJOR PROCESSSPECIFIC PROCESSCRITICAL PROCESS550MM145MMMain Process Control SheetProduction QtyDefective QtyDefective RateDate1 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 TotalDefectRate(ppm)1,0002,000SHOPPROCESS NAMECATEGORYOPERATOROPENING DATESUPERVISORTARGET5. 6TOOL-4 / Time CheckTo assure component quality which are processed in house, check main control point regularlyTime Check ImageFlow ChartActivity- Check quality periodically and take action- Initial inspection : . Assure in。