taehwa 6 tool motor audit english

8/7/2019 Taehwa 6 Tool Motor Audit ENGLISH

1/15

C&M Go

2010. 7.28

CONTENTS

3

2

Process audit overall1

Q-System audit result

5

Process audit list : 6 Tool

Process audit list :Condition control

Process audit list : T5S

Auditor : Gu, Jin-Mok

4Process Audit List :

Outgoing assurance /CTQ Control

6 NC point of Process Audit


2/15

1 / 7

Vendor) Q-System audit result approvalIn charge approval

C&M Biz. Team

Gu, Jin-Mok

27 th J u ly 10

Vendor Motor line, Taehwa Ent. India Pvt.

Ltd.

Audit dt. 27 th July 10 Obtained

mark

Grade

Auditor Gu, Jin-Mok Attended byfrom Taehwa

QA manager /Koreansupport team

55 A, B, C, D

category Item Allottedmark

Obtainedmark

6-tools

Qualitymeeting

9 2.4

OS&D control 8 3.8

Seq uentialinspection

8 1.9

Key processcontrol

8 1.6

T/Check 9 5.4

Q-a ud it 8 1.6

Total 50 16.7

4 M control

Man 5 1.8

Machine /tools 5 1.3Materials 5 3.0

Metho d 10 6.2

Information of 4 M changes

5 1.3

Total 30 13.6

Outgoing qualityassurance /CTQ control

20 4.7

T5S 50 20

Opinion aboutoverall audit

result

[Good points]-M/C 5S ( du e to no work time increases)

[Major problems]-Pro du ction is carrie d ou t witho u t basic 6 tool con d ition control

in Q-system.- No q u ality training to workers an d QA personal does not have

concept abo u t qu ality.- No q u ality ass u rance du ring pro du ct o u tgoing.

(No OQC control.)

Audit historyAudit dt. Mark Grade Audit dt. Mark Grade

27 th July10

55 D

Grade (Grade A : 150~131 points, Grade B : 130~111 marks,Grade C : 110~91 mark, Grade D : lower than 90)F/up of result (Higher than Grade B : Pass, to publish NCR report,Lower than Grade C : re-audit and to link to biz wrap up???)


3/15

A udit check list 6 tools

2 / 7Profitable Market Share Growth

ItemDetaile d a ud it item

Excellent -- Ba d calc u lation

Obtaine d mark Opinion from a ud itor

5 4 3 2 1

1) Q u alitymeeting

(9 points)

1) Is d aily q u ality meeting being hel d? z

2.4

1) Q u ality meeting not being calle d .2) Weekly an d monthly q u alitymeeting not being hel d .

Qu ality meeting itself is notbeing hel d .

2) Is d aily q u ality meeting recor d being maintaine d properly ?

z

3) Is Q u ality in d ex being recor d e d in the q u alitystat u s boar d?

- Part RTN d efect rate (monthly) , process d efect rate ( d aily , monthly)

z

4) Is weekly q u ality improvement meeting being hel d? z

5) Is monthly review meeting being d one ? z

6) Is F/Up for the d eci d e d item being d one z

2) OS&Dcontrol(8 points)

- Ret u rn setcontrol

1) Is RTN , IQC reject , an d claim receive d set beingrecovere d imme d iately ?

z

3.84

1) RTN sample not being ret u rne d imme d iately. : 1 no. of d ispatche d Q member to L G .2) Q u ality training to operator nil.3) N G set d isplaye d d ie notavailable.4) Except NC report an d co u ntermeas u re against L G qu ality meeting , no d oc u mentavailable.

2) Is N G set being d isplaye d for a specifie d perio d? z

3) Is d efect phenomena being ta u ght to operator ? (Isoperator aware abo u t NG? )

z

4) Is co u ntermeas u re for the NC item being replie d in time ? z

5) Is the d etail regar d ing 2 nd ven d or being F/B an d isits co u ntermeas u re being followe d?

z

3)Seq u entialinspection

1) Is self/seq u ential inspection item being set an d followe d? z

1.9

1) Overall , seq u ential inspectionactivity is lacking.2) No training recor d abo u tseq u ential inspection for operator.

2) Is N G set being recognize d by p u tting tag or marking with marker ?

z

3) Is N G set being kept in d efect box ? z

4) Is operator wise recor d being maintaine d? z

5) Is co u ntermeas u re for the d efect been set ? z

6) Is prize being awar d e d as per the achievement of eachoperator ?

z

|x in

1.8

|x in

1. 6

|x in

1.9


4/15

A udit C/List 6 Tools


Item Detaile d a ud it item

Excellent -- Ba d calc u latio

n

Obtaine d

mark Opinion from a ud itor 5 4 3 2 1

4) Keyprocesscontrol(8 points)

1) Has key process sign boar d been attache d on theproblem process ?

z

1.6

1) There is no signboar d operationr u le.

2) Is check sheet being ma d e an d is s u pervisor checkingthe performance ?

z

3) Is key process control like d with history control an d improvement activity ?

z

5) T/Check

1) Is T/Check being carrie d ou t time wise (initial , mid, final) ? z

5.4

2) T/Check of resistance checkitem only being d one2) Has s u rface plate , meas u ring eq u ipment , jig, an d check

sheet etc. been d isplaye d?z

3) Is act u al set being kept as first set , mid pro du ction set , an d final set wise ?

z

4) Is line lea d er , pro du ction hea d checking whether T/Checkis being d one ?

z

5) Is N G imme d iately correcte d an d its improvement activitybeing carrie d ou t?

z

3)Sequentialinspection

1) Is Q-a ud it system been assigne d? z

1.6

3) No a ud it assessment is beingma d e.

2) Is A-a ud it being carrie d ou t on a monthly basis ? z

3) Is checking being carrie d ou t as per Check stan d ar d? z

4) Is Q-A ud it eval u ation sheet being ma d e ? z

5) Is improvement activity being carrie d ou t for the NC item ? z

6) Is a ud it res u lt (mark , NC point) being d isplaye d an d share d?

z

|x i

n2 .3

|x i

n 1.8

|x in

1. 6


5/15


6/15

5 / 7

A udit C/List - 4 M control

Profitable Market Share Growth

Item Detaile d a ud it itemExcellent -- Ba d

Calc u lationObtain

e d mark

Opinion from a ud itor 5 4 3 2 1

4) Method(10 marks)

1) Is QC , 4M control chart been ma d e ? z

6.2

1) Operator d o not u nd erstan d thecontent of work stan d ar d

2) There is no working metho d revisionhistory.

3) There is no a ud it report for the 2 nd

ven d or.4) History for the Calibration of

meas u ring instr u ment omitte d .

2) Is working stan d ar d been d isplaye d in the process ? (more than 80%)

z

3) Is working st d . an d work matching an d is workingcon d ition being complie d (to check key process)

z

4) Is change d contents of working metho d an d inspectionmetho d been revise d an d controlle d (process chart , stan d ar d ) in chase working metho d an d inspectionmetho d are change d?

z

5) Is d rawing from c u stomer been entere d in d rawing log

book an d is its history being controlle d an d is its latestversion being marke d?

z

6)Is specification log book being recor d e d an d is its contentsbeing arrange d in d rawing an d is it being fee d /back torelate d d ept ?

z

7) Is process a ud it an d ven d or a ud it report for 2 nd ven d or been prepare d an d is perio d ical a ud it being carrie d ou t?

z

8) Is incoming q u ality inspection an d history control for the2nd ven d or being carrie d ou t?

z

9) Is necessary meas u ring instr u ment available an d

calibration being carrie d ou t perio d ically ? (Meas u ringeq u ipment history car d )

z

3)Materials(5 marks)

1) Is raw materials report (st d .) available ? z

1.3

1) Lacking in d oc u ment.

2) Is incoming low wise materials report (mill sheet) beenobtaine d an d controlle d?

z

3) Is materials incoming an d ou tgoing log book beingcontrolle d?

z

4) Is tracing system available in case there is problem in rawmaterials ?

z

|x i

n2 .0

|x i

n 1


7/15

A udit C/List Outgoing quality assurance/CTQ control


Item Detaile d a ud it itemExcellent -- Ba d

Calc u lationObtain

e d mark

Opinion from a ud itor 5 4 3 2 1

Outgoingqualityassurance(20 marks)

1) Is separate OQC inspector been assigne d in QCorganization chart an d is it being operate d?

z

4.7

1) No OQC system is available.

2) Is item wise OQC inspection item been assigne d an d isinspection history car d available ?

z

3) Is OQC inspection history being controlle d per every lot ? (Control with inspection report & system)

z

4) Is OQC inspector controlling the q u ality problem an d spec.changes history ?

z

5) Is Lot tracing possible by classifying o u tgoing lot wisepro du ction d ate ?

z

6) Is i d entification car d attaching for the inspection rea d y/inspection completion/ N G item been classifie d?

z

7) Is meas u rement an d item wise possible meas u ringinstr u ment been eq u ippe d as per o u tgoing inspectionitem ?

z

8) Is perio d ical gage R&R being carrie d ou t with c u stomer for the o u tgoing item ?

z

9) Is important q u ality been selecte d as CTQ item an d isCTQ item a d ju stment history been controlle d on amonthly basis ?

z

10) Is CTP control item been selecte d for the satisfaction of cu stomer ?

z

11) Is improvement activity being carrie d ou t du ring processcapa. analysis an d when target val u e (Z) is notachieve d?

z

|x in

4


8/15

C/List T5S


Aud it item G ra de E G ra de D G ra de C G ra de B G ra de A Obtaine d mark

Opinion from A ud itor

5S Arrangementan d organization

10

Unnecessary item , NG item , left over from pro du ction areleft at site witho u tmarking

2

Unnecessary itembeing han d led witho u tany plan

Part mixe d stacke d .4

Temporaryd isposal placeassigne d, perio d icallyd ispose d

Depot area control6

Whenever unnecessary item isfound, it is d ispose d asper r u le

Stan d ar d inventory/stock q uantity is beingcomplie d

8

Basic system toprevent defectrec u rrence isavailable

Linke d todecreases ininventory/ stock

10

4 points

OK pro du ct , NG pro du ctidentification not proper.Model of inventory can notbe i dentifie d .

Cleaning an d cleanness

10

Floor , wall notcleane d an d d irty.

2

Cleaning toolscontrol , d rinking water control , d ressing placecontrol OK

Floor , wall , an d ceiling is clean

4

Cleaning area , incharge freq uencyclear.

Corner , d rinkingwater , d ressing area

6

Eq u ipment cleaningis being doneperio d ically

Eq u ipment in chargeposte d an d operate d

8

Habit uate d cleaningan d maintainingcleanness

Basic improvementactivity is being doneto prevent

contamination

4 points

No in charge assigne d No separate cleaning toolbox

3R Right location , right q uantity , Right container

10

Inventory stacke d on gangway , floor.

Part , tools left onthe floor

2

Having concept of gangway an d havingsimple concept of rightlocation level.

4

Controlling thesystem by whichlocation , item , an d amo unt can befigu re d ou t.

6

Right container , rightquantity is beingcomplie d an d kept atright location

8

The system bywhich 3 R is beingcomplie d . Bin /pallet/container

10

4 points

Unnecessary item is mixe d in lineNo stan dar d container

Visiblemanagement

Find ing o u tabnormality , han d ling theabnormality

10

The system bywhich normal an d abnormal can not befigu re d ou t.

2

The system by whichoperator can not reportby self when anyproblem is occ u rre d .

The con d ition inwhich only relate d personal han d les.

4

The system bywhich operator canreport by self whenany problem isocc u rre d .

Controlling done bylinking to relate d dept.

6

The system in whichanyone can fin d ou tproblem an d solve

Abnormal con d itionis controlle d cumu lativeway an d linke d toimprovement

8

Problem con d itionis being controlle d inthe form of data , systemization

10 2 points

The system by whichproblem from line can notbe fig u re d ou t

Stat us boar d control

10

The system bywhich pro du ctionstat us , loss can notbe fig u re d ou t.

2

Pro du ction stat us , loss stat us not beingcontrolle d

Stat us boar d controllacking

1

Pro du ction target vs.res u lt control

Cleanness of Stat us boar d so so

6

Time wise target an d res u lt, line loss stat us isbeing marke d .

Stat us boar d isbeing maintaine d itemwise an d element wise.

10

Pro du ction stat usan d d istrib u tion stat usof loss can be seenimme d iately

Maintainingcleanness of datasheet in stat us boar d

10

6 points

Pro du ct loss can be seenpartially.No pro du ction stat usboar d in ME line.

Total 20marks


9/15

Non conformity item in process audit (Before and after improvement)


No. Process NC item Phenomena Improvementcountermeasure

After improvement Incharge

Schedule

completion

Remark

1 Slot

insertion

Core preparation

work station notproperly kept.Core left

anywhere

Training to operators an d now

maintaining properly.

Producti

onleader

Done

2 Winding J u mp wire beingpu lled (Wire c u t)

Improve d tools u sing at allwind ers

P.E. Done

3 Winding No inner pin inTransfer tool

All tool change d now on everyWin d er.

Production

leader

Done

4 1 st

formingLea d wire d ent atG ripper

Ou t G ripper 90 t u rn Mr.Lee


10/15

NC item during process Audit (Before and after improvement)


No. Process NC item P henomena Improvementcountermeasure


Schedule

completion

Remark

5Winding

Excessive amo u ntof Coil d ispose d asscrap du ringwind ing an d left inline.

Now after toolImprovement scrap

re du ce d

Production

leader

6 Crimping

Wire c u t NG du e tocoil being p u lled du ring coilstripping.

7 Manualprocess

Wiring N G set leftwitho u tid entification

Now u sing bins to keepNg sets (Apart from

Ru nning mo d els)

8 Manualprocess

Jigs an d tools lyingon floor

All jigs & fixtu res keepingin rack only.

Production

leader


11/15

NC item during process audit (before and after improvement)




Schedule

completion

Remark

9 Manual

work

Coil is being p u lled after ins u lationplastic insertion =>

wire c u t

After tool improvement.

10 Manualwork

NG set mixe d witho u t marking

Now u sing stickers towrite any d efect.

Production

leader &

Quality

Done

11Repair

Fan r u nning whilelying on floor

5S maintaine d an d nowthis kin d of activities are

notd oing

Production

leader

Done

12Manualwork

Congeste d linemakes workinefficient

No congeste d line (reworkat the same time)

Production

leader

Target date-22.10.10


12/15


13/15

NC item during process audit (before and after improvement)




Schedule

completion

Remark

17 Line

Jigs an d toolsBu ffing notproperly d one

Before shift starting , bu ffing of tools on d aily

basis.

Production

leader

Done

18 Rework

Core lying on floor Rework witho u t st d .


14/15

Audit ( , )




Schedule

completion

Remark

20Line

No pro du ctionstat u s boar d thu s , loss can not befigu re d ou t exceptMA line

TAR G ET DATE-25-10-10

21 Line

G age not eq u ippe d .(may have large

no. of N G set)

TAR G ET DATE-27-10-10


15/15

NC item during process audit (Before and after improvement)


No. Process NC item Improvement countermeasure Incharge

Schedule

completion

Remark

2Return defect Ret u rn N G set not being collecte d

imme d iately : It takes 2~3 d ays (1 no. of CSd ept.)

2LQCinspection

N G st d . set1) Kept in line with r u st witho u t Mod el marking2) Master sample for meas u ring instr u ment notbeen kept.3) Inspector not checking appearance N G

inspecting only f u nction.

3*Qualitymeeting*Signboard inkeyprocessing

Not being hel d No signboar d operation

4* Sequentialinspection

Nee d to start from stan d ar d setting1) To train its concept an d self training2) To set seq u ential inspection item per each

process

5* Line Audit * No a ud it plan

64M changereporting

4M changes reporting not being complie d 1) No 4M changes reporting history.

7Quality boardin the shopfloor

Stat u s boar d abo u t Improvement contents1) All are being ma d e man u ally2) Not reasonable for operator to u nd erstan d

8

Dismantletest

Stator Asm d ismantle test1) Not being carrie d ou t.

taehwa 6 tool motor audit english

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