TQM - Q1 2015

Total Quality Management

Wan Suffian Bin Wan Mansor

Quarter 1 Report (Feb ~Apr 15)

Regional Best Power System Solution Provider

Report Outline

1. QMS Program Updates

2. Quality Assurance & Control

2.1 Status of CA and PA

2.2 New Procedure

2.3 Equipment Calibration Status

2.4 Incoming Product Quality

2.5 In-process Product Quality

2.6 Outgoing Product Quality

2.7 Control of Nonconforming Material

3. ADP Status


1. QMS Program Update

No QMS Program No. of

Milestone

No. of

milestone

should

start

Milestone Status Remark

Started Completed

1 Quality

Environment (5S)

11 4 1. Review 5S

Policy and

Objectives

Set the direction of 5S

activity

2. Define roles &

responsibility for

5S structure

To ensure each

committee understand

their roles and responsibility

3. Review 5S Audit

Evaluation

Criteria -

4. Main Committee

Meeting

1st meeting 22/4/15.

Participation 44.4%.

2 SIRIM

Recertification

11 3 1. Reply SIRIM NCR -

2. Prepare and

submit evidence

for SIRIM NCR

In-progress. To submit

1st week of June

3. Establish/review

procedure -

3 My Idea (Employee

Suggestion

Scheme)

8 0 - - - Start 1st milestone end

of May 2015


2. Quality Assurance and Control

2.1 Status of CA and PA

No Corrective Actions Source Deadline Responsibility Implementation

Status

Remark

1 Review customer satisfaction

survey WI

Internal Audit 6/3/2015 Nadia Not started

Coaching by WSM

2 Establish WI for tendering

performance data analysis

Internal Audit 6/3/2015 Noorhayati Not started

Coaching by WSM

3 Establish WI for Training Need

Analysis

Internal Audit 25/3/2015 Noraini Not started

Coaching by WSM

4 Improve Training Effectiveness

Evaluation form

Internal Audit 9/3/2015 Noraini

Done Need to review the

effectiveness of change

5 Establish Design procedure SIRIM Audit 29/5/2015 Wan Suffian

Not started -

6 Brief all employee involved in

Purchased Material Receiving &

Inspection procedure

SIRIM Audit 17/4/2015

Al-Hafiz Done -

7 Revise Control of Document

procedure

SIRIM Audit 11/5/2015 Wan Suffian In-progress -

8 Set planned interval for Project

Monthly Meeting which is on the

2nd week of every month


Hamdan Not started

Coaching by WSM

9 Establish Monthly Project Status

Report which is in-line with Project

Quality Plan


Hamdan Not started

-



2.2 New Procedure

No new procedure established.

Regional Best Power System Solution Provider R

EP

AIR

No Equipment Problem Action Findings

Remark

1 -NIL-

2 -NIL-


2.3 Equipment Maintenance

Testing Equipment

PU

RC

HA

SE

No Equipment/Accessories Reason for Purchase Quantity

1 -NIL-

2 -NIL-

3 -NIL-

CA

LIB

RA

TE

No Equipment Cost

(RM) Quantity

1 DIGITAL EARTH TESTER 160.00 1

2 DIGITAL MULTIMETER FLUKE 110.00 2

3 DIGITAL CLAMP METER 120.00 1

4 AC/DC INSULATION TESTER 200.00 1

5 DIGITAL CALIPER 35.00 1

TOTAL + GST(6%) 662.50



2.4 In-coming Product Quality

267

83.7% 79.3%

29.8%

8.3% 0.0% 0.0%

4.9%

40.4%

0

50

100

150

200

250

300

350

400

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mar '15 Apr '15

Qu

an

tity

Rec

eiv

ed

Rate

, %

Month

In-coming Enclosure Defective Rate Trend

Project Supplier Problem Qty

(defect) Counter Measure

RCB

(1556/2014)

Detik

Kreatif

Pre-punch holes for nameplate at

front door did not match with

nameplate size. 72

Install longer nameplate to

cover holes .

KTPC

Paint coating thickness below 60m

at door and roof. 36 Change door and roof.

Inner door scratch and bending 20 Change inner door

RCB details:

50 Units from KTPC 217 Units from Detik Kreatif



2.4 In-coming Product Quality

0 0 0 0 0

18

3.2%

11.2%

6.8%

0.0%

05101520253035404550

0%2%4%6%8%

10%12%14%16%18%20%

Aug '14 Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mac '15 Apr '15

Qu

an

tity

Re

ce

ive

d

% R

ati

o

Month

In-coming Annunciator Defective Rate Trend

0 0 0 0 0 0 0.0%

25.6%

05101520253035404550

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

Aug '14 Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mac '15 Apr '15

Qu

an

tity

Rec

eiv

ed

% R

ati

o

Month

Illuminated Push Button Defective Rate Trend



2.5 In-process Product Quality

Month

Rela

y

Rela

y b

ase

Cam

Rota

ry

Sw

itch

Ann

un

cia

tor

Illu

min

ate

d p

ush

butt

on

C

ha

ng

e O

ve

r

Sw

itch

Lig

ht In

dic

ato

r

AU

X C

on

tact

Lam

p b

ulb

Am

me

ter

Enclo

sure

Sem

aph

ore

Tra

nsd

uce

r

Feb 15 0 0 0 0 0 0 0 0 0 0 0 0 0

Mar 15 2 1 2 0 0 0 0 0 0 0 9 0 0

Apr 15 6 1 0 1 0 0 0 0 0 0 3 2 1

Q1 15 8 2 2 1 0 0 0 0 0 0 12 2 1

68

13

0

14 14

28

0

10

20

30

40

50

60

70

80

Q3'14

Q4'14

Feb'15

Mar'15

Apr'15

Q1'15

Qu

an

tity

Month

Material Defect during In-Process Trend

Item Supplier Problem Qty

RCB Enclosure Internal Earthings stud broken 3

Annunciator 14W Datmeltech Hang 1

Relay 541 Alstom Relay always booting 1

Semaphore TMS Indicator not

functioning 2

Relay 1P & 2P Schneider Not functioning 5

Transducer TMS Output nor accurate 1

Base relay Schneider Screw loose at

terminal 14 1

Highlights

Earthings stud broken while tighten the nut.



2.6 From Site Product Quality

Q1-2015

Defect

PPU/SSU

Total PPU Pinji

Lane

PPU

Bangunan

MAS baru

PPU

33/11kV

Bangsar

South

PMU

Cheras

Jaya

SSU Lion

Eco

PPU

Hospital

Rehab

SSU IDP

Pengerang

COMPONENT FAULTY

Annunciator - - - 14 - - - 14

Relay - - - - - - 2 2

Resistor - - 1 - 1 - - 2

Bulb - - 1 - - - - 1

Trip link - - - 4 - 1 - 5

Isolator switch - - - - 1 - - 1

Terminal block - - - - - 1 - 1

Heater - - - 1 - - 1

WRONG LABEL - - - - - 1 - 1

MISSING LABEL/NAME PLATE 1 1 8 4 6 - - 18

MISS COMPONENT

Terminal block - - - - 2 - - 2

Comb link 1 - 12 - - - - 12

Bulb - 12 - - - - - 12

DRAWING RELATED 1 1 - 1 - - 2

3 13 23 23 11 3 2 74

Bulb sent

separately



2.6 From Site Product Quality

Month

Category

Wro

ng

Lab

el

Mis

sin

g L

ab

e/

Nam

e P

late

Co

mp

on

en

t

Fau

lty

Lo

ose

Wir

e

Mis

s W

irin

g

Dra

win

g

Rela

ted

Mis

s

Co

mp

on

en

t**

Q3 14 17 15 33 15 8 25 4

Q4 14 7 12 30 0 0 2 10

Feb 15 0 9 2 0 0 2 10

Mar 15 1 9 27 0 0 0 4

Apr 15 0 2 1 0 0 1 13

Q1 15 1 20 30 0 0 3 27

117

61

23

41

17

81

0

20

40

60

80

100

120

140

Q3 '14 Q4 '14 Feb'15

Mar'15

Apr'15

Q1 '15

No

. o

f D

efe

ct

Month

Defect from Site Trend

** Miss component category includes

accessories

Highlights

Components Faulty category give the highest defective numbers for 3 consecutive quarter.

Miss Component category trend is increasing. Missing bulb from PPU Bangunan

Mas Baru is avoidable.




ITEM QTY

Transduser Amp 1

Illuminated Push Button 5

Base relay 4

Selector Switch 8

Discrepancy Switch 2

Relay MVAX 1

Indicator Bulb 1

Semaphore 2

Contactor Siemens 1

Tranducer Datamax DMT-AL 3

Resistor SR25 4KOJ 1

Buzzer 5

CT 3

Tranducer DMT-R3U 1

Power Supply Unit 1

Contactor LS 1

Relay P541 1

Relay 1P & 2P 10

Trip Counter 1

Annunciator 2

Terminal Block 3

TOTAL 57

ITEM QTY

Magnetic counter 1

Ammeter 2

TOTAL 3

ITEM QTY

Resistor 25W 2KJ 38

Relay Kuep 5

Pilot Lamp 1

Resistor SR25 1K5J 1

Heater vitar 1

Fuse link 1

Lamp Holder 19

Bulb Philip 18W 12

Relay RSB 1A120BD 1

Relay RSB 2A080BD 3

Resistor 25W 2KJ 1

TOTAL 83

Supplier repair without cost

Supplier repair with cost

In-house repair

In-house reuse

Scrap

Category

Highlights

Sending 5 unit of Relay MCAG14 to United Kingdom

(UK) (total weight = 20kg) cost

Matrix RM805.00 + RM103.22

(insurance) using DHL.

Sending 4 unit of Relay P541 & P542 to Singapore, cost Matrix

RM 751.20 include insurance

RM 94.00 using Nationwide

Express

ITEM QTY

Relay MCAG 14 5

Relay P541 3

Relay P542 1

TOTAL 9




Disposal of Compact Fluorescent Light

A 11W CFL bulb contains 2mg

mercury and this will be go up in

accordance with the bulb size Malaysia Regulation do not state that

household need to

properly dispose their

CFL.

No proper disposal and collection system

available in Malaysia.

Current initiative taken by IKEA Damansara

for CFL processing

before sending to

Kualiti Alam

PROPOSAL:

1. Expanding the scope of Matrixs CSR by: 1) Provide a collection bin to collect

used bulb.

2) Encourage Matrixs employee to bring their used bulb from home to

be disposed together.

3) Send bulb to collection center at

IKEA once reach certain quantity.

or

2. Collect all bulb in a sealed plastic bag to

prevent dispersion of mercury and

dispose in general waste bin.


3. ADP Status

C1: EFFICIENT AND EFFECTIVE WORK

# OF URGENT CALIBRATION

Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan

Target 0 0 0 0 0 0 0 0 0 0 0

Actual 1 1

Definition Frequency of TQM members has to send or take test/measuring equipment on their own instead of by the service provider in a month.

S

t

a

t

u

s

U

p

d

a

t

e

s

Initiatives Status Status Description Owner Original

Due Date

Current

Due Date

Study the calibration scheduling

and criticality for product testing of

every measuring equipment.

Done - Al-Hafiz 30/4

30/4

Upgrade MPSSB-QMS-WI-002-01

Calibration Control of Measuring

and Monitoring Equipment WI into

Procedure

In-

progress

Started. Al-Hafiz 29/5 29/5

Action Items / Initiatives

Details

1.5

8.7

0

0.5

1

1.5

0

5

10

Mar Apr

No. Loss of

manhour

Month

Loss of manhour

Frequency


3. ADP Status


% OF DEFECT


Target 10% 10% 10% 10% 10% 5% 5% 5% 5% 5% 5%

Actual 24.0% 11.8%

Definition The % of product defect at site from Wrong Label plus Missing Label category. The formula is (Wrong label quantity + Missing label quantity)/ Total defects x 100.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Develop before FAT physical

inspection check sheet.

Done Check sheet for CRP 33kV

panel.

Abd

Hafiz

28/2 28/2

Establish before FAT physical

inspection WI.

Not

started

- Abd

Hafiz

30/3 15/5

Obtain NIOSH-TNB safety passport

for site investigation.

Not

started

Need to confirm with HR on the

training schedule.

Abd

Hafiz

8/5 8/5


Details

17

7 1

15 12

20

0

10

20

30

Q3 '14 Q4 '14 Q1 '15

Qu

an

tity

Wrong Label

Missing Label

Moving Forward

1. Study which and type of label that have high

number of missing.

2. Identify the causes of missing label.


3. ADP Status


# OF DEFECTIVE MATERIAL DURING PRODUCT TESTING


Target 0 0 0 0 0 0 0 0 0 0 0

Actual 2 10

Definition The # of material found defective during assembly undetected during incoming inspection. Monitoring of this parameter will help to improve incoming inspection activity.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Establish incoming inspection WI

for A-eberle AVR.

In-

progress

Repaired AVR from Germany

arrived used to develop WI.

Al-Hafiz 30/4 30/4

Review annunciator incoming

inspection method.

Not

started

Annunciator hang during in-

house product testing.

Annunciator has passed

incoming inspection.

Abd

Hafiz

29/5 29/5


Details

Defective materials: 1) 1 unit annunciator

2) 1 unit relay P541 (Alstom)

3) 2 units semaphore

4) 1 units transducer

5) 5 units relay 1P and 2P (Schneider)

Moving Forward

1. Revisit incoming inspection for transducer.

2. Develop incoming inspection for semaphore .


3. ADP Status


% OF CORRECTIVE ACTIONS IMPLEMENTED


Target 55 55 70 70 70 85 85 85 100 100 100

Actual 11.1 22.2

Definition Corrective actions identified after root cause analysis. It is one of improvement approach as stated in QMS ISO9001. The more corrective actions implemented the better quality system will be.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Scheduled follow up session with

PIC responsible for corrective

actions implementation.

In-

progress

Follow up session need to be

made for CAR issued during

internal audit and NCR received

from SIRIM.

Wan

Suffian

28/2 15/5

Provide guidance and coaching to

the PIC responsible for corrective

actions implementation.

Not

started

Guidance and coaching will be

based on scheduled session.

Wan

Suffian

31/12 31/12


Details

As stated in section 2.1 Status of Corrective Actions


3. ADP Status

I1: DOCUMENT AND IMPROVE WORK FLOW

# OF PROCEDURE ESTABLISHED


Target 0 1 1 0 1 1 1 0 1 0 0

Actual 0 0

Definition The number of procedure established inline with business processes to spell out the WHAT to do.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Identify already available work flow

which documented in Work

Instruction.

Done - Wan

Suffian

23/2 23/2

Conduct workshop to review

workflow with process owner and

involved person.

Not

started

- Wan

Suffian

9/10 9/10

Perform audit to assess the

effectiveness of work processes.

Not

started

- Wan

Suffian

31/12 31/12


Details

Swim lane for Control of Nonconforming Product process completed. The write up of the procedure is in progress.


3. ADP Status

I2: IMPROVE MANAGEMENT OF INFORMATION & KNOWLEDGE

# OF DATA REQUIRED COMPLETE WITH DEFINITION


Target 1 1 1 1 1 1 1 1 1 1 1

Actual 0 0

Definition The few data identified will able to show the companys level of goals and objectives achievement based on target set during business planning.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Study the organizations goals and objectives.

Completed - Wan

Suffian

30/4 30/4

Benchmark with other Baldrige

Winner for common data.

Not started - Wan

Suffian

30/4 30/6

Develop mechanism to collect data. Not started - Wan

Suffian

30/4 30/6


Details

Added Meeting Frequency as one of the data required for monitoring as commented by MD in last monthly meeting. Total no of data required for monitoring is 10.


3. ADP Status


FREQUENCY OF DATA UPDATE TO ALL EMPLOYEE


Target 1 1 1 1 1 1 1 1 1 1 1

Actual 4 4

Definition The data sharing is an explicit method of information and knowledge sharing

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Install information boards at easily

seen location.

Not

started

Location identified beside 5S

main board.

Al-Hafiz 1/4 31/5

Install LCD screen at strategic

location.

In

progress

LED screen surveyed. Cost

estimated RM1,500.

Al-Hafiz 31/5 31/5

Upload all monthly report into the

company server.

Done Uploaded report for March 2015

at Matrixinfo folder.

Wan

Suffian

31/5 31/5


Details

-


3. ADP Status


FREQUENCY OF KNOWLEDGE SHARING


Target - - 1 1 1 1 1 1 1 1 1

Actual - -

Definition Explicit knowledge sharing where a person attended an external course or training came back and share on what he/she has learnt with the rest of the employee.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Propose reward and recognition for

employees effort who share their knowledge and employees who

attend the session.

Not

started

- Wan

Suffian

28/3 15/5

Prepare one year schedule for

knowledge sharing session.

In

progress

Schedule share knowledge

session up to October 2015.

Noraini 9/3 4/5

Upload all presentation material

into the company server for

reference.

Not

started

- Noraini 31/1/16 31/1/16


Details

First session for knowledge sharing will commence on May


3. ADP Status

I4: ESTABLISH AND IMPROVE PROCESS MEASUREMENT

% OF MEASURE ESTABLISHED


Target 30% 30% 50% 50% 50% 70% 70% 70% 90% 90% 90%

Actual 15% 20%

Definition Current Total number of processes in Product Realization is 20. Measured process get better control.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Search measures from kpi library

website.

Not

started

- Wan

Suffian

30/4 30/4

Perform trial for each measures to

ensure its appropriateness.

Not

started

- Wan

Suffian

31/1/16 31/1/16


Details

Incoming inspection 3 days after material received FAT No. of FAT pass/fail Product Assembly Assembly lead time (e.g. CRP = 2 weeks) Purchasing % orders arrived on time = (Number of order arrived on time and in full) / (Total number of orders) x 100%


3. ADP Status

I5: CREATE SAFETY AND HEALTH AWARENESS

# OF SECTION COMPLIED


Target - 1 - - 1 - - 1 - - 1

Actual - 0

Definition The number of applicable section in OSHA,1994 whether in Act or their Regulations complied.

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Establish legal and other

requirements register.

In-

progress

Incomplete by trainee. Wan

Suffian

31/5 30/6

Establish Safety & Health

Committee.

In-

progress

Proposal prepared by Al-Miqdad.

In the process of reviewing.

Wan

Suffian

10/4 31/5


Details

-


3. ADP Status

L1: INCULCATE A3 THINKING

# OF REPORTS/PROPOSALS FOLLOW PDCA APPROACH


Target - 1 - 1 1 - 1 1 - 1 -

Actual - 0

Definition A report/proposal follow PDCA approach shows that the person preparing it is fully understand : 1) a problem that he/she is trying to solve, 2) program or project propose for review and approval

S

t

a

t

u

s

U

p

d

a

t

e

s


Due Date

Current

Due Date

Standardize the report/proposal

format.

In-

progress

Need to review the format

prepared by Al-Hafiz

Al-Hafiz 1/5 30/6

Conduct training on preparing

report and proposal using PDCA

approach

In-

progress

- Wan

Suffian

16/6 16/6

Post actual sample of report and

proposal on information board for

everybodys reference.

In-

progress

- Wan

Suffian

25/12 25/12


Details

-

Documents

TQM - Q1 2015