PILLAR 5 - Hinshitsu Hozen (QM) :

GOAL -
To overcome the deficiency in Quality system and to achieve and maintain defect free products.
QM activities is to set equipment conditions that preclude quality defects, based on the basic concept of maintaining perfect equipment to maintain perfect quality of products. The condition are checked and measure in time series to very that measure values are within standard values to prevent defects. The transition of measured values is watched to predict possibilities of defects occurring and to take counter measures before hand.
Policy :1. Defect free conditions and control of equipments.
2. QM activities to support quality assurance.
3. Focus of prevention of defects at source
4. Focus on poka-yoke. ( fool proof system )
5. In-line detection and segregation of defects.
6. Effective implementation of operator quality assurance.
Target :1. Achieve and sustain customer complaints at zero
2. Reduce in-process defects by 50 %
3. Reduce cost of quality by 50 %.
Data requirements :Quality defects are classified as customer end defects and in house defects. For customer-end data, we have to get data on
1. Customer end line rejection
2. Field complaints.
In-house, data include data related to products and data related to process
Data related to product :1. Product wise defects
2. Severity of the defect and its contribution - major/minor
3. Location of the defect with reference to the layout
4. Magnitude and frequency of its occurrence at each stage of measurement
5. Occurrence trend in beginning and the end of each production/process/changes. (Like pattern change, ladle/furnace lining etc.)
6. Occurrence trend with respect to restoration of breakdown/modifications/periodical replacement of quality components.
Data related to processes:1. The operating condition for individual sub-process related to men, method, material and machine.
2. The standard settings/conditions of the sub-process
3. The actual record of the settings/conditions during the defect occurrence.