,6TOOL GUIDE,21st. Feb. 2004,India Pvt Ltd,1. 6TOOL ?,100 PPM QUALITY PROCESS,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),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,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, 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 Board,MAJOR PROCESS,SPECIFIC PROCESS,CRITICAL PROCESS,550MM,145MM,Main Process Control Sheet,Production Qty,Defective Qty,Defective Rate,Date,1