Identify customer needs.

Turn customer requirements into internal needs and ultimately into product and service needs.

Improve customer satisfaction with products

Good cooperation and communication with customers

Leaders lead by example

Provide employees with necessary resources and create a good working atmosphere for employees

Responsibilities and authorities should be clearly demarcated

High-performance setting of company development goals (long, medium and short-term goals)

Provide employees with plans and strategies

Every employee must take responsibility

Each employee actively strives for improvement in his/her job position

Improve your abilities, knowledge and experience

Create customer value

identification process

Clarify methods and means of process control

Process results and feedback

Scope of continuous improvement: product quality, quality management system, service, customer satisfaction

Company quality goals and data statistical analysis

Regularly conduct internal quality management system audits and management reviews

employee training

Collect various operational data of the company

Analyze data results

Take corrective and preventive actions based on the results reflected in the data

A win-win situation for all stakeholders of the enterprise, that is, a win-win situation for shareholders, communities, suppliers, employees, customers, etc.

Stakeholders become a community of life

Stakeholders work together to grow and develop

Exterior

size, structure

Electrical characteristics

Physical and chemical properties

Mechanical properties

Appearance inspection: general visual inspection, hand feel, and limited sample.

Dimensional inspection: straight/draw ruler, vernier caliper, micrometer, three-dimensional measuring instrument, etc.

Structural inspection: tension gauge, torque gauge, etc.

Characteristic inspection: use more instruments, such as metallographic analyzers, oscilloscopes, multimeters, etc.

Inspect materials according to incoming inspection items

Sampling method: Full inspection is used for materials with small quantity and high price, and random inspection is used for large quantity or recurring materials.

Determination standards: Determine qualified materials or unqualified materials according to the standards specified in the MIL-STD-105E sampling plan.

Purpose of first inspection

First inspection time

First inspection requirements

First inspection items

Purpose of inspection

Inspection timing

Inspection requirements

Inspection items

Inspection before warehousing

Shipping inspection

A. Serious shortcomings (CR): shortcomings that result in personal injury or the inability to use the product.

B. Major Disadvantages (MA): Disadvantages that may cause product dysfunction and reduce its functionality.

C. Minor shortcomings (MI): Functional or appearance shortcomings that do not affect the normal use of the product

Define the responsibilities and authorities for determining and handling defective products

Mark and isolate defective products to prevent misuse or misinstallation

Keep records of defective products

Evaluate defective products and propose reasonable treatment methods

Find the causes of defective products and provide suggestions for improvement

Rework: Measures taken to make defective products meet requirements

Rework: Measures taken to make defective products meet expected requirements

Downgrade: Change the grade of defective products so that they meet requirements different from the original requirements.

Scrap: Defective products are confirmed to be unable to be reworked or accepted at concessions, or the cost of rework is too high, and should be disposed of directly as waste.

Don't let go until the reason is found out. If the cause cannot be found, prevention and correction cannot be carried out, and the recurrence of quality problems cannot be prevented.

Those responsible will not be let go until they are found out. The purpose of identifying the responsible person is to prevent, improve the operating skills of the responsible person, improve work methods and attitudes, and ensure the stability of quality.

Don’t let go until improvement measures are implemented. Regardless of identifying the cause or the person responsible, the goal is to implement improvement measures to further improve product quality.

record checklist

Inspection record sheet

Clarify the purpose (object and scope of data collection)

Determine the angle of the layers

Decide what items to inspect

Decide on the format of the checklist

Decide how to record data

Decide how data will be collected (5W1H)

Person: Group, class, age, years of service, education level, gender, training level, professional title

Raw materials: batch type, supplier type, origin type, composition type, grade, part type

Machinery and tools: machine number, form, speed, location, new and old, tools

Operating conditions: temperature, pressure, speed, rotation speed, humidity, sequence, operating method

Products: batches, varieties, new and old products

Time: time, day, week, month, year, before and after improvement

Classification of causes of problems

Determine the data collection cycle

In order of the number of occurrences, record the items and times in the defective analysis table

Make statistical tables based on classified items and statistical data to calculate the cumulative number of defective items and the cumulative defective rate

Use a chart to draw the vertical and horizontal axes. The left side represents the number of defects, the right side represents the degree of impact. The horizontal axis represents the project. Point on the number of defects and the degree of impact and connect them with a polyline.

Precautions

1. Determine the characteristics of the problem

2. Prepare a piece of paper and draw the skeleton of the characteristic factor diagram. The characteristics are at the right end. Draw a thick trunk line (general line) from the left to represent the manufacturing process.

3. Divide the causes into several major categories, draw each major category on the bone, and classify it according to the process. Generally, it is classified into people, machines, materials, methods, and environment.

4. Explore the big reasons and then subdivide the small and medium reasons.

5. Determine the order of the influencing factors, point out the most likely influencing factors, and mark them in order on the diagram.

1. Be optimistic about the collection of more than 50 data.

2. Determine the number of groups

3. Determine the group distance C = full distance R (maximum - minimum) / number of groups K, and find the appropriate data closest to the C value from the data that is an integer multiple of the measurement unit as the group distance

4. Determine the boundaries of each group,

5. Find the center value of each group

6. Make a rep allocation table

7. Distribute the statistical table according to the number of times to make a histogram. The horizontal axis is the characteristics and the vertical axis is the number of times.

Normal type: left and right symmetrical distribution, indicating stable process

Missing tooth type: indicates an abnormality in the manufacturing process.

Skewed type: The manufacturing process has a skewed distribution, and a certain factor affects the spread to the left (right).

Cliff type: Insufficient process capabilities

Bimodal type: 4M layers required

Island type: engineering changes, raw material abnormalities or measurement errors

1. Clarify the purpose and determine the object of investigation

2 Collect data, 50~100 pairs of data

3. Find the maximum and minimum values ​​of the two types of data respectively

4. Draw the vertical and horizontal axes and make appropriate scales. Usually the horizontal axis is the factor and the vertical axis is the characteristic.

5. Dot the paired data on the graph

6 Record necessary matters

Positive correlation

non-significant positive correlation

negative correlation

non-significant negative correlation

Not relevant

curve correlation

1. Determine the characteristics of data collection

2. Collect data in chronological order

3. Drawing: take the characteristic value on the vertical axis and mark it with a scale, and take the time scale on the horizontal axis

4. Click the collected data into the corresponding location

5. Connect points with polylines

Different personality traits, attitudes towards work, and understanding of product quality are different

Use different methods for people with different personalities, make the best use of their talents, and learn to be good at using people

Equipment, tools and other production auxiliary tools

Materials, semi-finished products, accessories, auxiliary materials and other product materials

The rules and regulations followed during the production process, including various operating procedures/work instructions, production plans, drawings, etc.

Environmental requirements during product production.

Plan(P)

Execute(D)

Check(C)

Processing(A)

1. Analyze the column status and find out the existing quality problems

2. Analyze the causes and influencing factors

3. Find out the main influencing factors

4. Develop measures, propose action plans and expected results (5W1H)

5. Execute plans or measures

6. Check the execution results of the plan (compare the execution results with the predetermined goals through self-inspection, mutual inspection, process handover, special inspection, etc.)

7. Summarize experience (what has been solved should be documented and standards formulated)

8. If the problem is unresolved or the effect is not significant, do not avoid it and reflect it realistically to the next cycle.

Large loops within small loops, small environmental protection loops, promoting the big cycle

Keep moving forward and keep improving. Just like climbing stairs, one cycle ends, the quality improves by one step, and then enters the next cycle, running again, improving again, constantly moving forward, and constantly improving.

Closed circuit ascent. Every time a PDCA cycle is passed, a summary must be made, new goals must be proposed, and then the next PDCA cycle must be carried out.