* 6TOOL GUIDE 21st. Feb. 2004 India Pvt Ltd 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 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 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 q’ty  . 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 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 * OS&D Stickers 1. SUPPLIER DEFECT 2. WORKMANSHIP DEFECT 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 * Sequential inspection Guide ITEM PROCESS NAME  Sequential inspection guide * Sequential inspection Sticker 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 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, Customer’s 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 Board MAJOR PROCESS SPECIFIC PROCESS CRITICAL PROCESS 550MM 145MM Main Process Control Sheet Production Q’ty Defective Q’ty 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 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. TIME CHECK SHEET  CHECKED BY(SUPERVISOR): APPROVED BY(MANAGER): LINE PROCESS NAME DURATION (  /  / ) ~ (  /  /  ) CYCLE EVERY ( ) HR OPERATOR’S NAME SUPERVISOR’S 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 * Time Check Process Board TIME CHECK PROCESS 550MM 145MM TIME CHECK BOARD Time Check Sheet 09:00~11:00 11:00~01:00 02:00~04:00 04:00~06:00 LINE : ________ ITEM : _________ OPERATOR SUPERVISOR 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 customer’s 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. 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 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 Q’ty Rej Q’ty 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 Q’ty APC used Qty Rejection Q’ty APC Rej. Rate Date Rate (Unit : PPM) 50 100 150 200 300 APC rej. Qty Shop Rejection Rate  APC TARGET * 
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