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TAHAP 4, DIPLOMA KEMAHIRAN MALAYSIA

TAHAP 4 : JAMINAN KUALITI INDUSTRI


UNIT PEMBELAJARAN

CU1 CUSTOMER REQUIREMENT ESTABLISHMENT


CU2 PRODUCT CONTROL PLAN ESTABLISHMENT
CU3 MANUFACTURING / SYSTEM AUDIT
CU4 CONTINUOUS QUALITY IMPROVEMENT
CU5 MEASUREMENT SYSTEM ANALYSIS (MSA)
CU6 NON CONFORMITY ASSESSMENT
CU7 CUSTOMER FEEDBACK ANALYSIS
CU8 QUALITY ASSURANCE DOCUMENT CONTROL
CU9 STATISTICAL PROCESS CONTROL ANALYSIS (SPC)
CU10 SUPPLIER QUALITY ASSURANCE
CU11 PRODUCT LIABILITY ANALYSIS

Co1 LA 1. IDENTIFY CUSTOMER NEEDS, REQUIREMENT AND SPECIFICATION GUIDELINES (C01/L4)


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IDENTIFY PRODUCT LIABILITY SERVICES REQUIREMENT AND PRODUCT
CONTAINMENT
3.1 Product liability services activity and shelf 3.6 Determine product liability services
life requirement activities and product shelf life requirement
3.2 Product technical specification 3.7 Interpret product technical specifications
3.3 Product liability services activity 3.8 Determine product liability services activity
requirements workflow requirements workflow
3.4 Method of containment 3.9 Confirm method of product containment
3.5 Product liability services work activities 3.10 Ascertain product liability services work
procedure, tools and equipments, facilities and, activity procedure
work schedule 3.11Prepare applicable tools and equipments
3.12 Confirm product liability services facilities
3.13 Arrange product liability work schedule and
timeline

1.1 Product specification


1.2 Product delivery schedule
1.3 Packaging requirement
1.4 Product manufacturing flow
1.5 Customer needs, requirements and specification
1.6 Applicable product standard
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1.7 Determine product specification


1.8 Determine delivery schedule
1.9 Identify packaging style
1.10 Determine manufacturing process flow
1.11 Confirm customer requirements
1.12 Interpret applicable specification and requirement

LA 2. EVALUATE CUSTOMER REQUIREMENT FULFILMENT (C01/L4)

2.1 Recording format


2.2 File and record keeping procedures
2.3 Checklist
2.4 Quality Function Deployment (QFD)
2.5 Product / process interpretation technique
2.6 Information accuracy checklist
2.7 Customer requirements
2.8 Customer relation
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2.9 Check the information accuracy


2.10 Assess the customer requirement adequacy
2.11 Determine recording format
2.12 Adhere to file and record keeping procedures
2.13 Compile customer requirement
C03
1. Identify types of audit
2. Identify audit
procedure and
requirement
3. Prepare audit
schedule and checklist
4. Prepare audit
document
5. Execute audit
activities
6. Evaluate audit finding
completion and
accuracy
7. Report of auditing
activities

IDENTIFY TYPES OF AUDIT (

1.1 Type of audits 1.15 Determine type of audit


1.2.1 Internal quality audit 1.16 Determine product / process to be audit
1.2.2 Supplier audit 1.17 Determine audit flow
1.2.3 Third party audit 1.18 Determine audit procedure
1.3 Product / process flow 1.19 Interpret audit requirement
1.4 Audit process flow 1.20 Determine the area to be audited
1.5 Audit procedure 1.21 Confirm audit schedule
1.6 Audit requirement 1.22 Arrange auditor / audited
1.7 Area to be audited 1.23 Produce audit checklist
1.24 Items and criteria to be audit
1.8 Audit schedule 1.25 Previous audit concern
1.9 List of auditors 1.26 Acquire audit document
1.10 Audit checklist 1.27 Arrange document location
1.11 Items and criteria 1.28 Identify audit samples
1.12 Audit documents
1.13 Document location
1.14 Audit samples

2 EXECUTE AUDIT ACTIVITIES (C03.05 / L4)

2.1 Audit notification 2.5 Notify auditee


2.2 Audit opening meeting procedure 2.6 Conduct audit opening meeting
2.3 Audit technique 2.7 Observe audit findings
2.4 Classification of non conformance 2.8 Classify audit non conformance
2.9 Conduct audit closing meeting

3 EVALUATE AUDIT FINDING COMPLETION AND ACCURACY (C03.06 / L4)

3.1 Product / process audit compliance 3.5 Assess number of non conformance
3.2 Type of non conformance 3.6 Assess audit compliance
3.3 Audit completion 3.7 Check audit completion
3.4 Audit reporting

4 REPORT OF AUDITING ACTIVITIES (C04.07 / L4)

4.1 Reporting format 4.4 Determine reporting format


4.2 Supplier performance 4.5 Record supplier performance
4.3 Record and data control procedure 4.6 Adhere to record keeping procedure

C04
LA 1. IDENTIFY ACTIVITIES OF CQI PROGRAMME (C04.01,C04.02/L4)

1.1 List of continuous quality improvement 1.4 Determine activation of CQI


1.2 Improvement guidelines and flow 1.5 Determine area improvement
1.3 Improvement scope 1.6 Determine improvement dateline
LA 2. PREPARE QUALITY IMPROVEMENT PLAN ACTIVITY(C04.03/L4)

2.1 Quality improvement tools 2.4 Determine quality improvement tools


2.2 Suitable improvement activity 2.5 Decide suitable improvement activity
2.3 Area of improvement 2.6 Confirm area of improvement

LA 3. EXECUTE VALUE ADDED VALUE ENGINEERING (VA/VE) (C04.04, C04.05/L4)

3.1 VA/VE elements 3.9 Determine VA/VE elements


3.2 VA/VE task force 3.10 Form VA/VE task force
3.3 VA/VE technique 3.11 Apply VA/VE technique
3.4 Reject rduction programme 3.12 Conduct reject reduction programme
3.5 Process capability 3.13 Apply process capability
3.6 Calculation technique 3.14 Calculation technique
3.7 Equipment capability 3.15 Calculate equipment capability
3.8 Capability index table 3.16 Refer capability index table

EXECUTE QUALITY FUNCTION DEPLOYMENT (QFD) C04.07, C04.08, C04.09 / L4

4.1 QFD technique 4.5 Apply QFD technique


4.2 Operating characteristic of product against 4.6 Compare operating characteristic of
customer needs product against customer needs
4.7 Assess effectiveness of improvement
4.3 Effectiveness of improvement activities activities
4.4 Product / process improvement result 4.8 Check product / process improvement
4.9 Compare improvement result

C06 CONFIRM PROCESS, PRODUCT, METHOD, ASSESSMENT OF NON


CONFORMITY
Identify product/process non-conformance control requirements

Plan non-conformance control parts activity

Segregate non-conformance product/process

Execute non-conformance product disposition

Conduct corrective action meeting

Monitor corrective action effectiveness

Report product/process non-conformance control activities


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1.1 Process non conformity assessment material 1.9 Interpret incoming materials process
requirement non conformity assessment requirement
1.2 List of product specifications 1.10 Refer product specification
1.3 Process non conformity assessment work 1.11 Determine process non conformity
scope assessment work scope and workflow
1.4 Incoming process non conformity assessment 1.12 Determine applicable and purposes of
workflow product and process non conformity
1.5 Purposes and applicable of non-conformity procedure
assessment procedure 1.13 Determine non conformity
1.6 Product/process non conformity assessment assessment sheet and procedure
sheet 1.14 Obtain non conformity assessment
1.7 Non conformity assessment sheet and location sheet and location
1.8 Method and technique of non-conformity 1.15 Obtain method and technique of non-
assessment conformity assessment

LA 2. EVALUATE NON CONFORMITY ASSESSMENT RESULT

2.1 Non conformity accuracy, specification and 2.6 Confirm non conformity accuracy,
appearance within tolerance and requirement specification and requirement
2.2 Non conformity result 2.7 Asses non conformity result
2.3 Non conformity report, format, criteria and completeness
record keeping procedure 2.8 Determine non conformity activities
2.4 Critical control points reporting, format, writing procedure and
2.5 Critical control items technique record keeping procedure

C07 NALYSE CUSTOMER FEEDBACK INFORMATION / SURVEY (C07/L4, C08/L3)


IDENTIFY PRODUCT LIABILITY SERVICES REQUIREMENT AND PRODUCT
CONTAINMENT

3.1 Product liability services activity and shelf 3.6 Determine product liability services
life requirement activities and product shelf life requirement
3.2 Product technical specification 3.7 Interpret product technical specifications
3.3 Product liability services activity 3.8 Determine product liability services activity
requirements workflow requirements workflow
3.4 Method of containment 3.9 Confirm method of product containment
3.5 Product liability services work activities 3.10 Ascertain product liability services work
procedure, tools and equipments, facilities activity procedure
and, work schedule 3.11Prepare applicable tools and equipments
3.12 Confirm product liability services facilities
3.13 Arrange product liability work schedule
and timeline
EVALUATE PRODUCT LIABILITY SERVICE WORK ACTIVITIES

4.1 Field failure investigation and analysis 4.7 Conduct field failure investigation and
4.2 Corrective and preventive action technique analysis
4.3 Assessment of customer satisfaction
4.8 Apply corrective and preventive action
related to product liability technique
4.4 Assessment of corrective and preventive
4.9 Asses customer satisfaction related to
action effectiveness product liability
4.5 Supplier delivery, quality performance,
4.10 Asses effectiveness of corrective and
product conformances and performance chart
preventive action
4.6 Reporting format, supplier performances
4.11 Asses supplier delivery, quality
and, record and data control procedure
performances
4.12 Review supplier product conformances
and update supplier performance chart
4.13 Record product liability services activities
LA 3. PLAN PRODUCT/PROCESS NON CONFORMANCE CONTROL REQUIREMENTS
(C06.01/L3,C06.02/L3)

3.1 Type of product/process non 3.9 Determine type of non-conformances


conformances 3.10 Determine product/process non
3.2 Product /process specifications and conformance area
requirements 3.11 Classify product/ process non-
3.3 Product/process non conformance area conformances
3.4 Product/process non-conformances 3.12 Determine type of product/process
3.5 Non-conformance control parts status deviation
3.6 Procedure of controlling of non 3.13 Determine non conformance control parts
conformance parts status
3.7 Non conformance working schedule 3.14 Determine procedure of controlling of non
3.8 Non-conformance control parts manpower conformance parts
allocation 3.15 Determine non conformance working
schedule

LA 4. EXECUTE NON CONFORMANCE PRODUCT/PROCESS NON CONFORMANCE


CONTROL REQUIREMENTS (C06.03/L3,C06.04/L3)

4.1 Sort non conformance parts containment 4.8 Sort non conformance parts containment
4.2 Separate good and bad product/process 4.9 Separate good and bad product/process
4.3 Quarantine non conformance product/part 4.10 Quarantine non conformance
4.4 Track conformance product/part product/part
movements 4.11 Track conformance product/part
4.5 Disposition category movements
4.6 Quarantine disposition item 4.12 Determine disposition category
4.7 Disposition item specification 4.13 Quarantine disposition item
4.14 Conform disposition item specification

LA 5. CONDUCT CORRECTIVE ACTION (C06.05/L3,C06.06 /L3, C06.07/L3)

5.1 Product/process non conformance data 5.8 Gather product / process non conformance
collection technique data
5.2 Root cause of problem investigation 5.9 Investigate root cause of problem
technique 5.10 Initiate process deviation correction
5.3 Effective corrective action flowchart 5.11 Initiate corrective action
5.4 List of conformances status 5.12 Asses non conformances status
5.5 Non conformance product/part segregation 5.13 Asses non conformance product/part
guidelines segregation
5.6 Assessment of non conformance 5.14 Asses non conformance product/part
product/part corrective action effectiveness corrective action effectiveness
5.7 Report product/process non conformance 5.15 Record product/process non
control activities conformance control activities

3.1 Type of customer companies


3.2 Customer feedback workflow
3.3 Customer suggestion
3.4 Method to rectify customer feedback
3.5 Customer feedback information/ survey
data
3.6 Customer feedback information/ survey
data location
3.7 Customer feedback information/ survey
analysing technique

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3.8 Determine type of customer companies


3.9 Determine customer suggestion
3.10 Determine customer feedback workflow
3.11 Confirm method to rectify customer feedback
3.12 Identify customer feedback information/ survey data
3.13 Obtain customer feedback information/ survey
3.14 Analyse customer feedback information/ survey
3.15 Suggest problem solving customer feedback

REPORT CUSTOMER SATISFACTION MEASUREMENT (C07/L4,C08/L3)

4.1 Customer feedback analysis timely activities reporting format


4.2 Customer feedback analysis timely reporting criteria
4.3 Procedure to write Customer feedback analysis timely report
4.4 Record keeping procedures
4.5 Customer feedback satisfaction accuracy within tolerance
4.6 Customer feedback satisfaction according to specification
4.7 Customer feedback satisfaction appearance according to requirement
4.8 Customer feedback satisfaction completeness
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4.9 Determine customer feedback analysis timely activities reporting format


4.10 Determine customer feedback analysis timely reporting criteria
4.11 Determine procedure to write customer feedback analysis timely report
4.12 Adhere to record keeping procedures
4.13 Confirm customer feedback satisfaction accuracy within tolerance
4.14 Confirm customer feedback satisfaction according to specification
4.15 Asses customer feedback satisfaction appearance according to requirement
4.16 Asses customer feedback satisfaction completeness