1、6TOOL GUIDEIndia Pvt Ltd1. 6TOOL ?100 PPM QUALITY PROCESSOS&D*Sequential InspectionMain Process ControlTime CheckQuality AuditReview Meeting123456PerfectCheckSystemPerfectCheckSysteCultivatingTeamSkillCultivatingTeamSkillImplement6TOOL*OS&D : Over, Shortage & Defect2. 6TOOL-1 / OS&D ActivityA system
2、 to improve quality of components found defective by monitoring , analyzing &acting on actual real time data & material supplied by suppliers. OS&D ImageOS&D ImageEstablish full inspection systemEstablish quality information system- Real information system . Real data. Real material- Computerized OS
3、&D managementEstablish vendor appraisal system- Quality contract (agreement of target quality)- I&P System Innovation FlowInnovation Flow*I&P : Incentive & PenaltyFACTORYSUPPLIERS ImprovementActivitiesDefectFoundReal & QuickInformationImprovedMaterialInnovation ActivitiesInnovation Activities Attach
4、 tag after finding a defecton the line Place collection box for defectivesin the line Collect rejection & analysis of samefrom IQC members Display rejection due to supplier Request for urgent delivery in exchangeof total rejection. Supplier must receive real informationand have improvement meeting(o
5、nce/week) = Q-manager attend Receive improved material & follow-up2. 6TOOL-1 / OS&D Activity (RULE)PRODUCTION PURCHASE IQC MATERIAL SUPPLIERActivitiesActivities- Find defective parts-Attach tag. Supplier defect : Red. Transportation : Blue. Work defect : Yellow- Store defective parts- Issue OS&D NCR
6、(once/day)- Provide additional partsin lieu of defected qty. Emergency delivery- Hold improvement M/Twith supplier. Sunrise M/T - Collect the defective parts (once/day)- Analyze and evaluate the cause of rejection. Classify the reasontheir types like internalwork error or transportation or vendor- R
7、ecord 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 m
8、eeting(Q-manager attend)MaterialMaterialWork defect Vendor defect &TransportationReturnDataDataReplacement for defective partsSelf-inspection Check-listPreparedByCheckedByApprovedByMACHINE / MODEL BUYER ORIGIN DATE REVISED DATEPROCESS NAMEDRAWING PART SPECIFICATION SELF-INSPECTION METHODREVISION NO*
9、 OS&D Stickers1. SUPPLIER DEFECT 2. WORKMANSHIP DEFECTOS&D ReportPreparedByCheckedByApprovedByProduction Line : DATE : / / S/No Part Name Part No Defect Description VendorProd. QCWorkmanshipProd. QC TotalDefect StatusVendorNameQCSupervisor ManagerPRODRemarksPro-Inspec-tion3. 6TOOL-2 / Sequential ins
10、pectionTo 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 Process 2nd Process 3rd ProcessInspect 100% in assembly processSequential in
11、spection 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 operatorsin the review meeting- Make countermeasuresWork-ingPro-Inspec-tionPre-Inspec-tionWork-ingPro-Inspec-tionPre-Inspec-tionWork-ing* Sequential inspection GuideITEM PROCESS NAMESequential inspection guide* Sequential inspection Sticker
