QUALITY

MAINTENANCE
MANUAL

Prepared by TPM Secretariat, IIL, Dolvi 195

AIM:
• Establish conditions that do not produce quality defects
• Constantly improve quality
Quality Maintenance means

•Setting conditions for Zero Failures

•Preventing quality defects by maintaining conditions within
standard value ranges
•Inspecting and measuring the conditions in time series and
•Predicting the possibility of quality defect occurrence by
reviewing the changes in the measured value; and based on these
Taking countermeasure in advance

QM Approach :

3. Quality Maintenance

2. Clarify relationship between QM and other

TPM pillars
1. Achieve Basic conditions (Preconditions)

Prepared by TPM Secretariat, IIL, Dolvi 196

Preconditions for successful QM :

• Equipment short life span due to

Forced Deterioration
•Frequent Breakdown leading to many
Eliminate Forced
quality problems
Deterioration
•Minimize Breakdown through
JH,KK,PM and E&T

•Leaks, Spillages, composition and etc

Eliminate Process
Problem •Eliminate through JH & KK

•Equipment competent operator (JH -4)

Develop Competent
Operator •Process competent Operator (JH-5)

Type of Defects:

“A” Type Defects

• “A” type defects are caused by Sporadic causes
• These defects occur suddenly and will continue till taking corrective
action or counter measure (can be solved by analyzing through Why
Why Analysis)
• By taking a corrective action or countermeasure the defect can be
corrected

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 OK

NOT OK

Action taken by
operator

LSL OK USL

“B” Type Defects

•“B” Type defects are caused by chronic causes.

•These defects develop gradually, occur and disappear by itself
without taking corrective action. (PM analysis to be applied)
•By taking countermeasure for all Abnormalities this type of defect
can be corrected.
•Periodical checking / inspection require sustaining zero.

OK

NOT OK

No Action
taken by
operator

LSL OK USL 198

“C” Type Defects

•“C’ type defects occur during set up changeover

•These defects occur in first product when the setup of the product is
changed
•By taking corrective action this defect can be corrected
NOT OK

Action taken
OK by operator

LSL OK USL

Defect Modes

Quality Defect Mode Description (Example)

1.Deviation from specified Chemical composition, properties such as

composition, physical
properties etc.
2.Contamination
3.Nonuniformity and dispersion
thermal stability, impurities
Rust, dust, broken machine parts
Colour variation, irregular grain size,
uneven thickness, unequal plate flatness

4.Visual defects Discoloration, dent, coagulation , other

visible defects
5.Packaging defects Underweight, improperly sealed,
mislabeled
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Basic Philosophy of Zero Defects

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The Relation between Quality Maintenance and other Pillars

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Flow Diagram for Implementing Quality Maintenance

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 Procedure for Implementing Quality Maintenance :

Step-1: Prepare QA matrix

Analyze relations between quality and processes/equipment:

• Check quality characteristics
• Investigate defect mode and sub process where defect occurs
• Assess seriousness of defect mode
Preparing a QA matrix involved the following four sub steps
1. Investigate the types of defects occurring in each process
2. Classify the product’s quality characteristics precisely and identify
the all defect modes related to each characteristics
3. Rank the defect modes according to their seriousness and indicate
which ones have caused problems in the past as frequent or
occasional. When assessing the seriousness of defects modes, be
sure to include a member of the quality assurance department in the
discussion.
4. Divide the process into the smallest possible units (sub processes)
and indicate the relationships between the defect modes.

Step -2 : Prepare production-input condition analysis table

•Check deficiencies in production-input conditions for each defect mode
in each sub process
•Check whether standards exist and are being followed

After preparing the QA matrix, analyze the production-input (3M)

conditions and organize the data in a table format.

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 For each defect mode in each sub process, identify all the conditions
for Man, Machine, Material and Methods which when established do
not give rise to defect. Be sure to check conditions on the spot, not
from behind a desk.
Next, determine whether standards for these quality
conditions exist and whether people follow them. Again, be sure to
investigate the level of standardization and adherence through on-the-
spot observation.

Step-3: Prepare problem chart

•Clarify production-input conditions for problems in each sub process

•Act promptly against problems that can be tackled on the spot. Care-
fully work out countermeasures for problems that cannot be dealt with
immediately
•Stratify defect modes. devise investigation techniques, and plan
countermeasures

Step-4: Evaluate seriousness of problems (FMEA 1)

This step directs the equipment improvement effort:
•Prioritize problems by assessing their impact on the quality defect
mode
•Decide on the assessment scale in advance

Examine the problems on the problem chart and rank them

in terms of their effects on the defect modes. Then, prioritize the
problems by scoring their frequency of occurrence, effect, and
difficulty of detection. Determine the assessment criteria in advance.
Multiply the scores for each problem together and use the results to
prioritize the improvement effort

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 Step-5: Use P-M analysis to track down causes of problems

•For the most serious problems in the preceding step, clarify the actual
phenomena
• Investigate using techniques such as P-M analysis and propose
countermeasures
PM - Analysis
1. To be used for most difficult and challenging problems
2. Carefully analyze and understand the phenomena in terms of
physical principles
3. Begin by stratifying the phenomena in terms of their type &
mode of occurrence identify the conditions that produce them
4. Uncover & consider all necessary conditions that produce them
5. List all conditions that produce them regardless of their
magnitude

Step- 6: Assess impact of proposed countermeasures (FMEA 2)

• Perform a preliminary evaluation of the post-improvement situation

using FMEA

Step-7 : Implement improvements

Step-8: Review production-input conditions

•Review the production-input conditions identified in Step 2

•Check whether the production-input conditions are appropriate and
correct

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 Step- 9 : Consolidate and confirm check points

•Use the results of Step 8 to summarize the inspection items

•Prepare a quality check matrix

Step-10: Prepare a quality component control table and assure quality

through strict condition control.

•Standards must be numerical and observable.

Data Collection:
Data Collection on defects is by stratifying the data. It may start with
customer complaints, rejection at final stage and in-process rejection.
Customer Complaints:
• Customer end line rejection
• Field complaints
In house rejections-
• Severity of the defect and its contribution – major/minor
• Location of the defect with reference to the layout
• Magnitude and frequency of its occurrence at each stage of measurement
• Occurrence trend in beginning and the end of each
• production/process/changes. (Like pattern change, Tundish change,
ladle/furnace lining etc.)
• Occurrence trend with respect to restoration of
breakdown/ modifications/ periodical replacement of quality components.

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Master Plan of QM:

Master Plan for Quality Maintenance is planning of

various activities in this pillar with respect to the time frame in
months and years. According to the stages of TPM implementation it
can start at various levels. In the beginning it will start with data
collection on defects to improving conditions to sustaining zero defect
conditions.

3M Analysis:

This analysis is a set of conditions with respect to the

machine, material and method for obtaining a good products. It helps
in identifying 3M standards and checking is possible against these
standards. Removing this variability can some times eliminate quality
defects in the product
PM Analysis:

PM analysis is one of the most effective techniques to

handle B type of problems. PM denotes P- Physical phenomena
M-Mechanism. This analysis will establish the relationship between
phenomena and the physical mechanism behind it which explain the
contributing conditions to cause such physical mechanisms. These
contributing conditions are then elaborated in terms of relationship
with primary (Man, Material, Machine & Method) conditions. Usually
these primary conditions are not measurable, so they are once again
converted into secondary conditions that can usually be physically
inspected against a standard.
After finding the standards a survey is performed to see the
variability against these standards and all such conditions are listed as
(Not Good). It is advisable to take countermeasures against all these
conditions simultaneously so as to eliminate most of the chance
causes in the system. This helps achieving zero defects in the product.

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 Master Plan of Hinshitsu-Hozen (TPM- Quality-Maintenance) Pillar

Sl.N Ja Fe Ma Ap Ma
o Activity n b r r y
1 Set Reduction/ elimination plan for zero defect & zero
customer complaints- based on prioritization for elimination of
defects as per business needs

2 Making of Quality Assurance Matrix- Defect Mode

3 Registration of Q.M. project- Defect mode wise & equipment

sub process wise- By cross functional team lead by operation
and supported by maintenance & Q.A. personnel

4 4M Relation Ship with defect Mode Defining optimal

condition for 4M - for selected defect mode

5 Ensure JH Step 1 & 2 on machine being focused under project

6 Define check method, tool, frequency to record deviation. Also

define corrective actions to be taken if deviations are observed

7 Perform inspection on machine to record deviation in optimal

conditions.

8 Conduct Why-Why analysis/ PM-analysis for identification of

root cause. Implement necessary countermeasures

9 Confirm effects

10 Review Check list implemented for identification

componenent ( Low Reliable Mechanism)

11 Do kaizen for identified low reliable or defective mechanism

12 Generate OPL to increase awareness of operator & Explore

Poka-Yoke technique to avoid human mistakes

13 Standardize / Revise operation & maintenance checklist

to ensure sustenance of effects

14 Revise 4M standards as per learning

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