MANUAL FOR QUALITY PROBLEMS analysis

1. Acceptance data

1.Informationt about the incident

(1) The number of lots / batches
(2) defects of the goods, the percentage of disability
(3) scene (Incoming, process (before, after, during, etc.), Outgoing, market, and other tests
(4) The conditions and rules of use
(5) Conditions that facilitate the cause of
defects (temperature, load, difficulty inserting the pressure side, knocking etc.)
(6) The focus and systematic defects lot involved

2. Confirmation

2. Confirmation defects
(1) Confirmation of defect occurrence
(Confirm defects repeat or not? ...... Conditions for
repeat defects (temperature, load, rating, lateral pressure, knock, etc.), events
Occur randomly or regularly?
(2) Ensure that where defects occur
3. Investigation & Analysis

3. Understanding the situation
(1) Special Features defects, defect pattern of real
(2) Verification & compare specifications of the customer

(4) Comparison between OK and NG (parts,failure etc)

(A) Analysis 1 (3) Refer to the drawing
(B) (Check the state of equipment, installation, dimensions and parameters,
normal) properties (characteristik) etc.

(5) Test material conversion between OK & NG products
(Swaping test).
(6) Causes of defects (equipment, materials, machines,
workers, design, etc.)
(7) The product is made of the original or re-use of materials
re?

(B) Analysis 2 (1) To identify and validate factors with
diagrams

Fishbone (Fishbone) by checking
all factors that can influence
failure (elimination method)

(2) Check the product samples, the remaining stock
(3) Check all materials (tools, materials, machines,
operations, stations, cavities etc.) one at a time
(4) Detect trail in the process.
(5) Test rebuilt product defects
(6) Ask the expert opinion
(7) Compare and analysis of competitors' products.
(8) Compare with theory

(C) Check the records

while (1) Check the records of claims / claims last (happened
the same defects or not)

(D) Investigation

in the 1 (1) Standard output (PCC, OI, limited sample,
 finite differences, specification investigations, painting)
or not?
(2) the latest version or not?
(3) Standard output is right or not, have
any weaknesses or not?
(4) Installed and checked in accordance with product standards
or not?
(5) Ways and means of treatment on disability
Division / separation (preventing
 adulteration of product defects repaired

(E) Investigation of abnormalities, changes

(1) Evaluation old record for the material (designs,
product installation regulations etc.)
(Evaluation of the material) (2) Incoming data, samples
(3) abnormal production process and data
Control of the manufacturer
(4) Lot production, receipt records (lots, date
receipt, quantity etc.)
(5) Records of special drawing for a particular purpose.

(F) The process of investigation 2

 (1) The process of investigation on the quality of records
(Source, installation). Inspection track record of data (chart
control P)
. Abnormal process occurs or not
. Record defect analysis
. Control data (machine, product quality)
. Employee records (change operator)
(Records of daily work)
. History machine (repair, renovation, records
maintenance, the difference cavities)
. Rework or repair materials
(2) Ask the supervisor & operator
(3) Check the records of any changes in circumstances
production
(4) Compare the quality of records
(5) Compare the daily production performance
(Different lots) and
production capacity
(6) Records of Special Drawing

(G) Changes / designs (1) changes in engineering drawings

(2) The records of changes in customer specifications

(H) such other action
(1) Inspect each production lot (phenomenon,
open open check etc.)
(2) Check the sample storage products
(3) Check your stockpile (process, store, customers etc.)
(4) The quantity of material stocks (process, store,
Quantity receiving, production,
supplies, etc.),

(I) Target Lot (1) The quantity of production and delivery of each lot
(2) Detection of trace materials and products on

4.Penyelesaian 4. Evaluation of re-examination (sorting)
(1) The trend of the results of the examination are
indicators (compare with the defect rate)
or not

5. Validation on action
corrections and solutions
(1) Examine the treated product.
(2) Compare the data before and after
actions
. Performance, power, dimensions / parameters etc.
. Incoming
. Product defects in the process
. Quality received by customers

6. Applications clones on other models

(1) The Clone actions on other models
related
(2) Make changes to the standards
production
(3) Make changes in design standards
and engineering drawings.

Note: This manual is only for reference, the settlement should be changed in line with the trend (a newer and more effective and efficiently)
This manual only shows the steps to create or solve problems.
This manual has been and is being used by the Company Matsushita and many Japanese companies