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QCD 101 | For Assembly

Visualization

Q: Create a situation where 4M changes, quality problems (in the line) of the day, past quality problems (in-coming and in-line quality), are easily observed.

C: Cost & profit should be visible on a daily basis by controlling the profit by lines.

D: By using inventory control plans, the inventory plans and the results should be visible.

By using the production control board, hourly production progress should be visible.

Visual Control

Q: Check hourly progress vs. the plan. If a quality problem is observed, identify the cause, describe the counter measures on a post-it, and put it on the Information Control Board.

C: Check the profit of each product on a daily basis. If the target is not reached, identify the cause, describe the counter measures on a post-it, and attach it on the Information Control Board.

D: Check the hourly progress vs. the plan, if delay is observed, identify the cause, describe the counter measures on a post-it, and attach it on the Information Control Board.

Supervisors should confirm the content on the Production Control Board, and follow up on the effectiveness and the progress of the counter measures.

Improvement Activities

Q: Regarding quality problems, if observed, call up all concerned personnel, conduct information center activities, determine and implement both tentative and permanent counter measures within the same day.

C: If it becomes obvious that the actual cost does not meet the standard or target cost, identify the cause and take measures to close the gap.

D: Regarding production abnormalities (any obstacles in process flow personnel, inventory, equipment), call up all concerned personnel, conduct information center activities, determine and implement both tentative and permanent counter measures within the same day.