07 k instationquality6tools

07K InStationQuality6Tools.ppt

In Station Quality and 6 Tools Review

Supplier NOS Training

June 2009

2In Station Quality Review

NOS House Pillars


In-Station Quality (ISQ)• ISQ in essence means never letting a defect pass into

the next station. There is quality at the source

• For ISQ to work, problems must be made visible

• ISQ can be summarized as GET IT RIGHT THE FIRST TIME

• Three only’s Only accept good quality Only make good quality Only pass on good quality

“Defects do not leave my workstation”


Pre-requisites of ISQ

• 5S /Visual factory• Line Balancing /

Standardized Work• Andon system

• PDCA/ Kaizen


Inspect Inspect InspectProcess 1Process 1 Process 2Process 2 Process 3Process 3

Process 1Process 1 Process 2Process 2 Process 3Process 3Inspect Inspect

Types of Inspections

Successive Inspection

Self Inspection


Discovery of mistakes before processing

Feedback and corrective action

A Process with Zero Defects

Source Inspection


InspectionType

InspectionImpact

Situation

Factory

Customer

Level 1

Defects

DefectsLeave

factory

Does notidentify defects

None

Operations

Errors

Defects

JudgmentInspected

Level 2

Non-defective

items

Most DefectsDo not Leave

factory

Identifiesdefects, but

does notremove

Operations

Errors

Defects

Inspections

InformativeInspection

Level 3

Non-defective

items

Defectsdecrease

LowerDefects by

givingfeedback

Operations

Errors

Defects

Inspections

Improve

Self-Checkswithin process

Level 4

Non-defective

items

Defectsdon’t leavethe process

Defectsdiscovered

Beforeproduct leaves

process

Operations

Errors

Defects

Inspections

Improve

SourceInspection

Level 5

Non-defective

items

ZERODEFECTS

Skips feedback

and catcheserrors at source

Operations

Errors

Inspections

Improve


With ISQ Tools

1. Incoming Material O,S & D Control (Overage,

Shortage, and Defectives)

2. Self Inspection

3. 1st Product Check

4. Key Process Management

5. Quality Audit

6. Quality Review Meeting

Application of these tools will vary depending on Material Type and Construction

How Do We Improve ISQ?


ISQ Tools

5. Q-Audit1. O,S & D 2. Self Inspection

“Zero” defective in Component Q-AuditProcess Q-AuditProduct Q-Audit

6. Quality Review Meeting

Input Quality(Vendor, Components)Input Quality

(Vendor, Components)Line Quality

(Process)Line Quality

(Process) Output Quality

(Product) Output Quality

(Product)

No defectivesto next process

4. Key ProcessManagement

Critical to Quality, Critical to Process

3. 1st Product Check

Check the product/component with CFM shoe, PFC & Checklist

Regular quality meeting for continuous improvement & habituation


1

• 100% components inspection before put into production

• Set up quick information flow process - Feedback quality issue with physical

defective - Replenish defectives within 2hrs for

existing SKU’s or 24hrs for new SKU’s. - Prevent recurrence by PDCA

• Vendor evaluation system - QA contract by Policy Deployment - QA Certification Program

Working Station

Supplier / PreviousWork station

Feedback with defective

ImprovementThru PDCA

Immediate communication with vendor/ previous workstation on Over, Shortage & Defective with physical component

O, S & D (Overrun, Shortage, Defective)


• Set up and post quality check points on

Standardized worksheet in each process

• Check components before processing and

give feedback to previous workstation to

correct if any quality problem

• Make sure to check quality for

components before sending to next process

• Encourage operators to use Andon and

stop the line if same defective occurs twice

in a row

Inspect

Reject

My ProcessSelf

-correction

To enhance quality mind and to prevent defectives from passing down the line, the operators check quality by themselves when receiving and before sending components

2

Reject

Next Process

Previous Process

Inspect

Self Inspection


• Whenever there are changes in (4M) Men/ Machine/ Material/ Method, check the 1st product with sample, process flow chart and checklist

•1st product in the morning, after lunch, finish work, and shift change.

• If any problem is found, share the information with T/L, G/L and give a feedback to related process to solve problem with education and training

• Line Stop if needed

• Problems are called out during quality review meeting

Line Stop

100% re-inspection

Solve problem with training

No good

Good

List up check points

Check sample

Keep monitoring

Check 1st product with CFM Shoe, PFC and Checklist

31st Product Check


• Supplement PFC (Nike

Standard) with CTQ, CTP

• Critical To Quality

• Critical To Process

• Manage to execute customer’s expectation for premium product with craftsmanship

• Tracking the trend of problems on display board to prevent recurrence

Checking key features for Quality & Process through visual management

Check CTP process

4Key Process Management


• Component Q-Audit - Audit of components from vendor to improve quality level in advance

• Process Q-Audit - Audit for line management mainly focused on 6 tools

• Product Q-Audit - Audit of finished goods from the customer point of view

• Reflection and continuous improvement through Quality meeting

Supplier

Line Process Q-Audit

Component Q-Audit

Self and team evaluation activities to improve quality level of component, process and finished product from Development to Manufacturing

Final product Product Q-Audit

5Quality Audits


Problem Solving System

• Daily review meeting – T/L, G/L• Weekly improvement meeting -

Manager• Monthly strategic meeting - GM• Quarterly GM meeting -

President

• Biannual QA and Craftsmanship contests

• Policy deployment for quality

Quality Review Meetings

Regular quality meeting to solve any quality problem and to share the information for continuous improvement from management to line workers

Daily Review Meeting

Weekly Improvement

Meeting

Quarterly GM

Meeting

-GM~MgrsReview Policy Deployment

6

Monthly Strategic Meeting

Documents

07 k instationquality6tools