tqm - q1 2015
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Total Quality Management
Wan Suffian Bin Wan Mansor
Quarter 1 Report (Feb ~Apr 15)
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Regional Best Power System Solution Provider
Report Outline
1. QMS Program Updates
2. Quality Assurance & Control
2.1 Status of CA and PA
2.2 New Procedure
2.3 Equipment Calibration Status
2.4 Incoming Product Quality
2.5 In-process Product Quality
2.6 Outgoing Product Quality
2.7 Control of Nonconforming Material
3. ADP Status
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Regional Best Power System Solution Provider
1. QMS Program Update
No QMS Program No. of
Milestone
No. of
milestone
should
start
Milestone Status Remark
Started Completed
1 Quality
Environment (5S)
11 4 1. Review 5S
Policy and
Objectives
Set the direction of 5S
activity
2. Define roles &
responsibility for
5S structure
To ensure each
committee understand
their roles and responsibility
3. Review 5S Audit
Evaluation
Criteria -
4. Main Committee
Meeting
1st meeting 22/4/15.
Participation 44.4%.
2 SIRIM
Recertification
11 3 1. Reply SIRIM NCR -
2. Prepare and
submit evidence
for SIRIM NCR
In-progress. To submit
1st week of June
3. Establish/review
procedure -
3 My Idea (Employee
Suggestion
Scheme)
8 0 - - - Start 1st milestone end
of May 2015
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.1 Status of CA and PA
No Corrective Actions Source Deadline Responsibility Implementation
Status
Remark
1 Review customer satisfaction
survey WI
Internal Audit 6/3/2015 Nadia Not started
Coaching by WSM
2 Establish WI for tendering
performance data analysis
Internal Audit 6/3/2015 Noorhayati Not started
Coaching by WSM
3 Establish WI for Training Need
Analysis
Internal Audit 25/3/2015 Noraini Not started
Coaching by WSM
4 Improve Training Effectiveness
Evaluation form
Internal Audit 9/3/2015 Noraini
Done Need to review the
effectiveness of change
5 Establish Design procedure SIRIM Audit 29/5/2015 Wan Suffian
Not started -
6 Brief all employee involved in
Purchased Material Receiving &
Inspection procedure
SIRIM Audit 17/4/2015
Al-Hafiz Done -
7 Revise Control of Document
procedure
SIRIM Audit 11/5/2015 Wan Suffian In-progress -
8 Set planned interval for Project
Monthly Meeting which is on the
2nd week of every month
SIRIM Audit 14/4/2015
Hamdan Not started
Coaching by WSM
9 Establish Monthly Project Status
Report which is in-line with Project
Quality Plan
SIRIM Audit 30/4/2015
Hamdan Not started
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.2 New Procedure
No new procedure established.
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Regional Best Power System Solution Provider R
EP
AIR
No Equipment Problem Action Findings
Remark
1 -NIL-
2 -NIL-
2. Quality Assurance and Control
2.3 Equipment Maintenance
Testing Equipment
PU
RC
HA
SE
No Equipment/Accessories Reason for Purchase Quantity
1 -NIL-
2 -NIL-
3 -NIL-
CA
LIB
RA
TE
No Equipment Cost
(RM) Quantity
1 DIGITAL EARTH TESTER 160.00 1
2 DIGITAL MULTIMETER FLUKE 110.00 2
3 DIGITAL CLAMP METER 120.00 1
4 AC/DC INSULATION TESTER 200.00 1
5 DIGITAL CALIPER 35.00 1
TOTAL + GST(6%) 662.50
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.4 In-coming Product Quality
267
83.7% 79.3%
29.8%
8.3% 0.0% 0.0%
4.9%
40.4%
0
50
100
150
200
250
300
350
400
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mar '15 Apr '15
Qu
an
tity
Rec
eiv
ed
Rate
, %
Month
In-coming Enclosure Defective Rate Trend
Project Supplier Problem Qty
(defect) Counter Measure
RCB
(1556/2014)
Detik
Kreatif
Pre-punch holes for nameplate at
front door did not match with
nameplate size. 72
Install longer nameplate to
cover holes .
KTPC
Paint coating thickness below 60m
at door and roof. 36 Change door and roof.
Inner door scratch and bending 20 Change inner door
RCB details:
50 Units from KTPC 217 Units from Detik Kreatif
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.4 In-coming Product Quality
0 0 0 0 0
18
3.2%
11.2%
6.8%
0.0%
05101520253035404550
0%2%4%6%8%
10%12%14%16%18%20%
Aug '14 Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mac '15 Apr '15
Qu
an
tity
Re
ce
ive
d
% R
ati
o
Month
In-coming Annunciator Defective Rate Trend
0 0 0 0 0 0 0.0%
25.6%
05101520253035404550
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
Aug '14 Sept '14 Oct '14 Nov '14 Dec '14 Jan '15 Feb '15 Mac '15 Apr '15
Qu
an
tity
Rec
eiv
ed
% R
ati
o
Month
Illuminated Push Button Defective Rate Trend
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.5 In-process Product Quality
Month
Rela
y
Rela
y b
ase
Cam
Rota
ry
Sw
itch
Ann
un
cia
tor
Illu
min
ate
d p
ush
butt
on
C
ha
ng
e O
ve
r
Sw
itch
Lig
ht In
dic
ato
r
AU
X C
on
tact
Lam
p b
ulb
Am
me
ter
Enclo
sure
Sem
aph
ore
Tra
nsd
uce
r
Feb 15 0 0 0 0 0 0 0 0 0 0 0 0 0
Mar 15 2 1 2 0 0 0 0 0 0 0 9 0 0
Apr 15 6 1 0 1 0 0 0 0 0 0 3 2 1
Q1 15 8 2 2 1 0 0 0 0 0 0 12 2 1
68
13
0
14 14
28
0
10
20
30
40
50
60
70
80
Q3'14
Q4'14
Feb'15
Mar'15
Apr'15
Q1'15
Qu
an
tity
Month
Material Defect during In-Process Trend
Item Supplier Problem Qty
RCB Enclosure Internal Earthings stud broken 3
Annunciator 14W Datmeltech Hang 1
Relay 541 Alstom Relay always booting 1
Semaphore TMS Indicator not
functioning 2
Relay 1P & 2P Schneider Not functioning 5
Transducer TMS Output nor accurate 1
Base relay Schneider Screw loose at
terminal 14 1
Highlights
Earthings stud broken while tighten the nut.
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.6 From Site Product Quality
Q1-2015
Defect
PPU/SSU
Total PPU Pinji
Lane
PPU
Bangunan
MAS baru
PPU
33/11kV
Bangsar
South
PMU
Cheras
Jaya
SSU Lion
Eco
PPU
Hospital
Rehab
SSU IDP
Pengerang
COMPONENT FAULTY
Annunciator - - - 14 - - - 14
Relay - - - - - - 2 2
Resistor - - 1 - 1 - - 2
Bulb - - 1 - - - - 1
Trip link - - - 4 - 1 - 5
Isolator switch - - - - 1 - - 1
Terminal block - - - - - 1 - 1
Heater - - - 1 - - 1
WRONG LABEL - - - - - 1 - 1
MISSING LABEL/NAME PLATE 1 1 8 4 6 - - 18
MISS COMPONENT
Terminal block - - - - 2 - - 2
Comb link 1 - 12 - - - - 12
Bulb - 12 - - - - - 12
DRAWING RELATED 1 1 - 1 - - 2
3 13 23 23 11 3 2 74
Bulb sent
separately
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.6 From Site Product Quality
Month
Category
Wro
ng
Lab
el
Mis
sin
g L
ab
e/
Nam
e P
late
Co
mp
on
en
t
Fau
lty
Lo
ose
Wir
e
Mis
s W
irin
g
Dra
win
g
Rela
ted
Mis
s
Co
mp
on
en
t**
Q3 14 17 15 33 15 8 25 4
Q4 14 7 12 30 0 0 2 10
Feb 15 0 9 2 0 0 2 10
Mar 15 1 9 27 0 0 0 4
Apr 15 0 2 1 0 0 1 13
Q1 15 1 20 30 0 0 3 27
117
61
23
41
17
81
0
20
40
60
80
100
120
140
Q3 '14 Q4 '14 Feb'15
Mar'15
Apr'15
Q1 '15
No
. o
f D
efe
ct
Month
Defect from Site Trend
** Miss component category includes
accessories
Highlights
Components Faulty category give the highest defective numbers for 3 consecutive quarter.
Miss Component category trend is increasing. Missing bulb from PPU Bangunan
Mas Baru is avoidable.
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.7 Control of Nonconforming Material
ITEM QTY
Transduser Amp 1
Illuminated Push Button 5
Base relay 4
Selector Switch 8
Discrepancy Switch 2
Relay MVAX 1
Indicator Bulb 1
Semaphore 2
Contactor Siemens 1
Tranducer Datamax DMT-AL 3
Resistor SR25 4KOJ 1
Buzzer 5
CT 3
Tranducer DMT-R3U 1
Power Supply Unit 1
Contactor LS 1
Relay P541 1
Relay 1P & 2P 10
Trip Counter 1
Annunciator 2
Terminal Block 3
TOTAL 57
ITEM QTY
Magnetic counter 1
Ammeter 2
TOTAL 3
ITEM QTY
Resistor 25W 2KJ 38
Relay Kuep 5
Pilot Lamp 1
Resistor SR25 1K5J 1
Heater vitar 1
Fuse link 1
Lamp Holder 19
Bulb Philip 18W 12
Relay RSB 1A120BD 1
Relay RSB 2A080BD 3
Resistor 25W 2KJ 1
TOTAL 83
Supplier repair without cost
Supplier repair with cost
In-house repair
In-house reuse
Scrap
Category
Highlights
Sending 5 unit of Relay MCAG14 to United Kingdom
(UK) (total weight = 20kg) cost
Matrix RM805.00 + RM103.22
(insurance) using DHL.
Sending 4 unit of Relay P541 & P542 to Singapore, cost Matrix
RM 751.20 include insurance
RM 94.00 using Nationwide
Express
ITEM QTY
Relay MCAG 14 5
Relay P541 3
Relay P542 1
TOTAL 9
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Regional Best Power System Solution Provider
2. Quality Assurance and Control
2.7 Control of Nonconforming Material
Disposal of Compact Fluorescent Light
A 11W CFL bulb contains 2mg
mercury and this will be go up in
accordance with the bulb size Malaysia Regulation do not state that
household need to
properly dispose their
CFL.
No proper disposal and collection system
available in Malaysia.
Current initiative taken by IKEA Damansara
for CFL processing
before sending to
Kualiti Alam
PROPOSAL:
1. Expanding the scope of Matrixs CSR by: 1) Provide a collection bin to collect
used bulb.
2) Encourage Matrixs employee to bring their used bulb from home to
be disposed together.
3) Send bulb to collection center at
IKEA once reach certain quantity.
or
2. Collect all bulb in a sealed plastic bag to
prevent dispersion of mercury and
dispose in general waste bin.
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Regional Best Power System Solution Provider
3. ADP Status
C1: EFFICIENT AND EFFECTIVE WORK
# OF URGENT CALIBRATION
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 0 0 0 0 0 0 0 0 0 0 0
Actual 1 1
Definition Frequency of TQM members has to send or take test/measuring equipment on their own instead of by the service provider in a month.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Study the calibration scheduling
and criticality for product testing of
every measuring equipment.
Done - Al-Hafiz 30/4
30/4
Upgrade MPSSB-QMS-WI-002-01
Calibration Control of Measuring
and Monitoring Equipment WI into
Procedure
In-
progress
Started. Al-Hafiz 29/5 29/5
Action Items / Initiatives
Details
1.5
8.7
0
0.5
1
1.5
0
5
10
Mar Apr
No. Loss of
manhour
Month
Loss of manhour
Frequency
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Regional Best Power System Solution Provider
3. ADP Status
C1: EFFICIENT AND EFFECTIVE WORK
% OF DEFECT
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 10% 10% 10% 10% 10% 5% 5% 5% 5% 5% 5%
Actual 24.0% 11.8%
Definition The % of product defect at site from Wrong Label plus Missing Label category. The formula is (Wrong label quantity + Missing label quantity)/ Total defects x 100.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Develop before FAT physical
inspection check sheet.
Done Check sheet for CRP 33kV
panel.
Abd
Hafiz
28/2 28/2
Establish before FAT physical
inspection WI.
Not
started
- Abd
Hafiz
30/3 15/5
Obtain NIOSH-TNB safety passport
for site investigation.
Not
started
Need to confirm with HR on the
training schedule.
Abd
Hafiz
8/5 8/5
Action Items / Initiatives
Details
17
7 1
15 12
20
0
10
20
30
Q3 '14 Q4 '14 Q1 '15
Qu
an
tity
Wrong Label
Missing Label
Moving Forward
1. Study which and type of label that have high
number of missing.
2. Identify the causes of missing label.
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Regional Best Power System Solution Provider
3. ADP Status
C1: EFFICIENT AND EFFECTIVE WORK
# OF DEFECTIVE MATERIAL DURING PRODUCT TESTING
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 0 0 0 0 0 0 0 0 0 0 0
Actual 2 10
Definition The # of material found defective during assembly undetected during incoming inspection. Monitoring of this parameter will help to improve incoming inspection activity.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Establish incoming inspection WI
for A-eberle AVR.
In-
progress
Repaired AVR from Germany
arrived used to develop WI.
Al-Hafiz 30/4 30/4
Review annunciator incoming
inspection method.
Not
started
Annunciator hang during in-
house product testing.
Annunciator has passed
incoming inspection.
Abd
Hafiz
29/5 29/5
Action Items / Initiatives
Details
Defective materials: 1) 1 unit annunciator
2) 1 unit relay P541 (Alstom)
3) 2 units semaphore
4) 1 units transducer
5) 5 units relay 1P and 2P (Schneider)
Moving Forward
1. Revisit incoming inspection for transducer.
2. Develop incoming inspection for semaphore .
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Regional Best Power System Solution Provider
3. ADP Status
C1: EFFICIENT AND EFFECTIVE WORK
% OF CORRECTIVE ACTIONS IMPLEMENTED
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 55 55 70 70 70 85 85 85 100 100 100
Actual 11.1 22.2
Definition Corrective actions identified after root cause analysis. It is one of improvement approach as stated in QMS ISO9001. The more corrective actions implemented the better quality system will be.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Scheduled follow up session with
PIC responsible for corrective
actions implementation.
In-
progress
Follow up session need to be
made for CAR issued during
internal audit and NCR received
from SIRIM.
Wan
Suffian
28/2 15/5
Provide guidance and coaching to
the PIC responsible for corrective
actions implementation.
Not
started
Guidance and coaching will be
based on scheduled session.
Wan
Suffian
31/12 31/12
Action Items / Initiatives
Details
As stated in section 2.1 Status of Corrective Actions
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Regional Best Power System Solution Provider
3. ADP Status
I1: DOCUMENT AND IMPROVE WORK FLOW
# OF PROCEDURE ESTABLISHED
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 0 1 1 0 1 1 1 0 1 0 0
Actual 0 0
Definition The number of procedure established inline with business processes to spell out the WHAT to do.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Identify already available work flow
which documented in Work
Instruction.
Done - Wan
Suffian
23/2 23/2
Conduct workshop to review
workflow with process owner and
involved person.
Not
started
- Wan
Suffian
9/10 9/10
Perform audit to assess the
effectiveness of work processes.
Not
started
- Wan
Suffian
31/12 31/12
Action Items / Initiatives
Details
Swim lane for Control of Nonconforming Product process completed. The write up of the procedure is in progress.
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Regional Best Power System Solution Provider
3. ADP Status
I2: IMPROVE MANAGEMENT OF INFORMATION & KNOWLEDGE
# OF DATA REQUIRED COMPLETE WITH DEFINITION
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 1 1 1 1 1 1 1 1 1 1 1
Actual 0 0
Definition The few data identified will able to show the companys level of goals and objectives achievement based on target set during business planning.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Study the organizations goals and objectives.
Completed - Wan
Suffian
30/4 30/4
Benchmark with other Baldrige
Winner for common data.
Not started - Wan
Suffian
30/4 30/6
Develop mechanism to collect data. Not started - Wan
Suffian
30/4 30/6
Action Items / Initiatives
Details
Added Meeting Frequency as one of the data required for monitoring as commented by MD in last monthly meeting. Total no of data required for monitoring is 10.
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Regional Best Power System Solution Provider
3. ADP Status
I2: IMPROVE MANAGEMENT OF INFORMATION & KNOWLEDGE
FREQUENCY OF DATA UPDATE TO ALL EMPLOYEE
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 1 1 1 1 1 1 1 1 1 1 1
Actual 4 4
Definition The data sharing is an explicit method of information and knowledge sharing
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Install information boards at easily
seen location.
Not
started
Location identified beside 5S
main board.
Al-Hafiz 1/4 31/5
Install LCD screen at strategic
location.
In
progress
LED screen surveyed. Cost
estimated RM1,500.
Al-Hafiz 31/5 31/5
Upload all monthly report into the
company server.
Done Uploaded report for March 2015
at Matrixinfo folder.
Wan
Suffian
31/5 31/5
Action Items / Initiatives
Details
-
-
Regional Best Power System Solution Provider
3. ADP Status
I2: IMPROVE MANAGEMENT OF INFORMATION & KNOWLEDGE
FREQUENCY OF KNOWLEDGE SHARING
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target - - 1 1 1 1 1 1 1 1 1
Actual - -
Definition Explicit knowledge sharing where a person attended an external course or training came back and share on what he/she has learnt with the rest of the employee.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Propose reward and recognition for
employees effort who share their knowledge and employees who
attend the session.
Not
started
- Wan
Suffian
28/3 15/5
Prepare one year schedule for
knowledge sharing session.
In
progress
Schedule share knowledge
session up to October 2015.
Noraini 9/3 4/5
Upload all presentation material
into the company server for
reference.
Not
started
- Noraini 31/1/16 31/1/16
Action Items / Initiatives
Details
First session for knowledge sharing will commence on May
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Regional Best Power System Solution Provider
3. ADP Status
I4: ESTABLISH AND IMPROVE PROCESS MEASUREMENT
% OF MEASURE ESTABLISHED
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target 30% 30% 50% 50% 50% 70% 70% 70% 90% 90% 90%
Actual 15% 20%
Definition Current Total number of processes in Product Realization is 20. Measured process get better control.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Search measures from kpi library
website.
Not
started
- Wan
Suffian
30/4 30/4
Perform trial for each measures to
ensure its appropriateness.
Not
started
- Wan
Suffian
31/1/16 31/1/16
Action Items / Initiatives
Details
Incoming inspection 3 days after material received FAT No. of FAT pass/fail Product Assembly Assembly lead time (e.g. CRP = 2 weeks) Purchasing % orders arrived on time = (Number of order arrived on time and in full) / (Total number of orders) x 100%
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Regional Best Power System Solution Provider
3. ADP Status
I5: CREATE SAFETY AND HEALTH AWARENESS
# OF SECTION COMPLIED
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target - 1 - - 1 - - 1 - - 1
Actual - 0
Definition The number of applicable section in OSHA,1994 whether in Act or their Regulations complied.
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Establish legal and other
requirements register.
In-
progress
Incomplete by trainee. Wan
Suffian
31/5 30/6
Establish Safety & Health
Committee.
In-
progress
Proposal prepared by Al-Miqdad.
In the process of reviewing.
Wan
Suffian
10/4 31/5
Action Items / Initiatives
Details
-
-
Regional Best Power System Solution Provider
3. ADP Status
L1: INCULCATE A3 THINKING
# OF REPORTS/PROPOSALS FOLLOW PDCA APPROACH
Month Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Target - 1 - 1 1 - 1 1 - 1 -
Actual - 0
Definition A report/proposal follow PDCA approach shows that the person preparing it is fully understand : 1) a problem that he/she is trying to solve, 2) program or project propose for review and approval
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Initiatives Status Status Description Owner Original
Due Date
Current
Due Date
Standardize the report/proposal
format.
In-
progress
Need to review the format
prepared by Al-Hafiz
Al-Hafiz 1/5 30/6
Conduct training on preparing
report and proposal using PDCA
approach
In-
progress
- Wan
Suffian
16/6 16/6
Post actual sample of report and
proposal on information board for
everybodys reference.
In-
progress
- Wan
Suffian
25/12 25/12
Action Items / Initiatives
Details
-
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