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CONTENTS
TOPICS
S. NO.
QM
SLIDE NO.
Background
Aim
Structure- QM Pillar
Targets
Scope
08-19
20-28
29-50
51-69
10
Future Plan
70
TPM - The Prime Mover Towards Excellence
BACKGROUND
QM
In-house Rejection
Warranty Rejection
WHY
QM ?
Inspection standard
not adequate
Customer Complaint
Reactive Approach
Aim- QM Pillar
QM
QM Pillar - STRUCTURE
QM
SK Verma
(PILLAR CHAIRMAN)
Mr. Sanjay
Verma
Mr.
Surender
Kumar
Mr. RN Singh
( Machine Shop )
Mr. VK
Singh
Mr. Gaurav
Tyagi
Mr. DD Giri
( HT & Plating )
Mr. Ajoy
Mukharji
Mr. Manoj
Bangali
QM-Targets
QM
QM SCOPE
QM
QM ACTIVITY
Customer complaint
prevention
activities
In process
defect
prevention
activities
Vendor component
defect prevention
activities
Warranty
M/c Shop
Bought out
Components
EFR
Heat
treatment
Job Work
Customer
Complaint
s
plating
In house
QM
WARRANTY
Warranty Claims Analysis
Flow
QM
Analysis by CFT
members of all
interfacing function
Action identification
Manufacturing
related
Non
conformance
(NC to drawing
specification)
Design related
Basic
Design
Error
Robustness
to support
Mfg. &
Service
Field related
Periodic
maintenanc
e issues
Usage
issues
WARRANTY
Non Conformance
(NC to drawing
specification)
Analysis
Manufacturing related
Can detect
Make it detectable
Inspection Side
Inspectio
n Poka
Inspection
Plan
inadequate
Cause Side
Difference
in
standards
Inspection
Method wrong
Daily Check
List
MICRO
Feedback
Feedback
Update PQCP
Update PRBFM
Update Check sheets
TPM
Update
Inspection agreement
TURNERS
PANTNAGAR
Material
nonconformanc
e
Feedback
Surface
coating
nonconformanc
e
Dimensional
nonconformance
Feedback
Cannot detect
Cause Side
Inspection
Plan
Poka
Yoke
QM
e
Machine
PM &
JH
Material
PPC &
QM
Method
KK, JH &
PM
Men
Tool
E&T &
QM
KK &
PM
10
WARRANTY
QM
11
WARRANTY
QM
12
WARRANTY
QM
13
WARRANTY
QM
14
WARRANTY
ANALYSIS
&ACTION
Part name
Model:
Phenomena
QM
: Shaft Kick
: All Model
: Crack / Broken
Probable Causes
Actions
5.
6.
Weak Design
Sr.
no.
15
WARRANTY
QM
Action
Action: :Ensure
Ensure100
100%%Hydrogen
Hydrogende-embrittlement
de-embrittlementTreatment
Treatmentduring
duringPlating
Plating
MICRO TURNERS PANTNAGAR
16
WARRANTY
QM
IMPROVEMENT SHEET
Problem/Status:- Crack / Broken
BEFORE
AFTER
Probable Cause:-
Counter Measure:-
-Weak Design.
1.
2.
Idea:-
Change Design
17
WARRANTY RESULTS
Action
ActionTaken
Taken
July,10
July,10
QM
G
O
O
D
Old
OldPart
Part
Manufactured
Manufactured
ininmarch,10
march,10
18
WARRANTY
QM
19
QM
20
EARLY FAILURE
As per Mfg. NC
As per Mfg. NC
QM
G
G
O
O
O
O
D
D
21
QM
22
EARLY FAILURE
QM
23
QM
24
QM
Noisy
Drive Assembly
OK
OK
1.
2.
3.
Tooth Profile
Error More
OK
OK
OK
OK
OK
OK
1.
2.
3.
Tooth Profile
Error More
OK
OK
KAIZEN
25
QM
26
EFR RESULTS
New
NewParts
Parts
Supply
Started
Supply Started
QM
GG
OO
OO
DD
Action
Action
Taken
Taken
27
WARRANTY
QM
28
QM
29
QM
30
CUSTOMER COMPLAINT
QM
1.1. BAL
BALQ
QBronze
BronzeAwardAward-Oct,
Oct,2008
2008
2.2. BAL
Q
Silver
AwardApr,2009
BAL Q Silver Award- Apr,2009
3.3. BAL
BALQ
QGold
GoldAwardAward-QualifiedQualified-Apr,2010
Apr,2010
New
NewParts
PartsSupply
Supplystarted
started
31
CUSTOMER COMPLAINT
QM
32
CUSTOMER COMPLAINT
QM
33
CUSTOMER COMPLAINT
QM
34
QM
35
CUSTOMER COMPLAINT
QM
IMPROVEMENT SHEET
Problem/Status:- Step on Dia. In Drive Assly
BEFORE
AFTER
Counter Measure:- Plate & Bolt is attached with Machine to lock the
Horizontal Slide
36
CUSTOMER COMPLAINT
QM
37
CUSTOMER COMPLAINT
QM
IMPROVEMENT SHEET
Problem/Status:- Total length Over size Bearing
Race
BEFORE
AFTER
Root Cause:-
error.
38
QM
Zero Customer Complaint Sustained By:1. Counter-measures on components arrested at Final inspection
stage.
2. PDI operator recognition
3. Q Methodology Implementation.
39
QM
40
QM
41
QM
42
QM
Component Study
43
QM
44
QM
45
QM
46
QM
47
QM
48
QM
49
QM
50
QM
51
IN-HOUSE REJECTION
QM
52
IN-HOUSE REJECTION
QM
GOOD
53
IN-HOUSE REJECTION
QM
54
IN-HOUSE REJECTION
QM
55
IN-HOUSE REJECTION
QM
56
IN-HOUSE REJECTION
QM
57
IN-HOUSE REJECTION
Kaizen
QM
58
IN-HOUSE REJECTION
-Kaizen (Plating)
QM
59
IN-HOUSE REJECTION
QM
60
IN-HOUSE REJECTION
QM
61
IN-HOUSE REJECTION
QM
62
IN-HOUSE REJECTION
QM
63
IN-HOUSE REJECTION
QM
Defect
DefectPhenomena
Phenomena- -88nos.
nos.
HappenedHappened-22
Kaizen
Kaizen
- -22
PokaPoka- In-process
In-process
Yoke
Inspection
Yoke
Inspection
May
MayHappen
Happen- -66
Kaizen
Kaizen
PokaPokaYoke
Yoke
In-process
In-process
Inspection
Inspection- -66
64
IN-HOUSE REJECTION
QM
65
IN-HOUSE REJECTION
QM
66
IN-HOUSE REJECTION
QM
All
AllActions
ActionsCompleted
Completed
Results
Results
GG
OO
OO
DD
67
IN-HOUSE REJECTION
QM
68
IN-HOUSE REJECTION
QM
69
FUTURE PLAN
QM
70
QM
THANK
YOU
MICRO TURNERS PANTNAGAR
71