Quality Maintenance

(Hinshitsu Hozen)
 Background – QM Pillar

No structured approach
to analyze defects

Defects were high

for survival

Background
No customer
No sustained efforts satisfaction
For defect prevention

High process
Process condition are
variation
not standardized
 Why Quality

Survival

Zero Globalization
Defect
Quality

Competition
Customer
Satisfaction Customer
Demand
 Aim – QM Pillar

To overcome the deficiency in Quality Assurance

system & to produce defect free product at a
reduced Quality cost.
 Target – QM Pillar

Sr. Parameters Unit Benchmark Target

no
1 Customer PPM
complaint
2 Warranty Rejection PPM

3 In process PPM
Rejection /Scrap
4 In process Rework PPM
 QM Master Plan

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 stage 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.
 QM Master Plan

Year 2020 2021

Target Activity details BM Target A M J J A S O N D J F M

Data Collection on Customer Complaints.

A ) To achieve Customer Complaints Stratification. 1000

0 PPM
Customer PPM
complaint zero.
Analysis of C.C phenomena.
( A. Inspection side action ).

B. Cause side action.

List defects &analyse present status.

Classification of defects & defect 5000 2500

definition. PPM PPM

Prepare QA matrix

B) To achieve Devloping 4M conditions.

Inhouse
rejection below
5000 PPM. Analyse Causes for defect.

Defect elimination projects.

Standardise 4M condition.

Sustenance for zero defect. ( QM matrix).

Revision of standards.
C) To achieve
Data Collection on Warranty Rej.
Warranty
rejection below
Analysis of Warranty phenomena. 2000 < 100
100
( A. Inspection side action ). PPM PPM
PPM.

B. Cause side action.

Started Completed
 10 Steps of Quality Maintenance

1) Verify present status

2) Survey of process which generated defect
3) Survey and analysis of 4M conditions
4) Study of malfunction countermeasures
5) Analysis of conditions for non-defective units that are not
confirmed
6) Improve 4M condition defects
7) Setting 4M conditions
8) Intensification and improvement of check methods
9) Deciding check reference value
10) Standard revision and trend control

QM Steps
Step-1:- Confirmation of the actual condition (Verify present
status )
Step- 2:- Investigation of processes in which defects occur
(Survey of process which generated defect)
Step3:- Survey and Analysis of 4MT Conditions
Step-4 :- Problem Countermeasures study and restoration
Step-5:- Analysis of unconfirmed items for acceptable items
Step-6:- Improvements of 4MT condition defects
Step-7:- Establishment of 4MT Condition for Quality products a) Review of standards
(Setting 4MT conditions)
Step-8:- Streamlining and Improvement of Inspection Items b) Flow chart for streamlining inspection items
(Intensification & improvement of checking method)
Step 9:- Determination of standard values for inspection
(Deciding check standard value)
Step 10:- Revision of Standards
QM 10 Step Approach
Activity
a) Confirmation of quality standards / Quality characteristics
b) Quality defect status and phenomena identification.
1. Understanding the condition under which quality defect arise
2. Defect phenomenon stratification
Data
c) Confirmation of equipment mechanisms, functions and processing principles and sequences
Preparation,
Survey &
a) Prepare QA mapping and QA Matrix for quality characteristics based on process survey and defect
occurred.
Analysis
Survey and analysis of 4MT Conditions
a) Confirmation and restoration of equipment condition
1. Study of countermeasures for items whose cause are clear, 2. Establishment of countermeasure
plans, 3. Implementation of countermeasures, 4. Confirmation of effects
a) Organization of defect causes
1. Clarification of defect causes, 2. Defect causes by level
Kaizens & studies
3. Selection of PM Analysis items (Prioritization) /
b) Implementation of PM analysis
Countermeasures
c) Establishment of ideal conditions and optimization of process conditions and set up methods.
a) Manifestation of defects
b) Restoration (to normal) or Improvement QM Matrix
c) Confirmation of effects
1. Review of standards, 2. Review of inspection items (4M 1T
conditions) &
b) Review of inspection items
a) Categorization, streamline and improvement of inspection items Sustenance
C) Review 4M conditions set before and after actions implementation.
a) Review of standards Inspection
b) Creation of quality maintenance matrix (QM Matrix)
c) Improving inspection reliability, simplification of inspection and labour saving
Improvement &
d) Reflection of improvements in inspection standards Standardization
a) Reflection of revisions in standards and establishment of formal standards
b) Indication of Q -Components
c) Confirmation of trend control and results
 Step-1 – Verify present status

Data Collection on defects

• Identify total no. of defect phenomena
• Shop /Cell wise stratification
• Preparation of Defect matrix
• Selecting component for further study based on priority
• Study the component drawing for inspection &
inspection standard availability
Defect Classification
 Defect Classification

‘A’ TYPE DEFECT

Limit of output OK •The output is (OK ) initially

specification •Becomes Not ok
NOT-OK •Corrective action action by
operator
•Becomes OK
Action taken
by Operator

Root causes analysis Tool

LSL OK USL Why Why Analysis

 A Type Defect

‘A’ Type defect: During normal production, products are produced with in the
tolerances of Upper Side Limit and Lower Side Limit. But suddenly one defect occurs.
Operator takes action for rectifying the cause of this defect occurred. When he starts
production, the next product is OK. Defects occurring in this situation are called as
A-Type Defect.

A Type defect example :

Methodology of solving A – Type defect Phenomena

 Why Why Analysis
Defect Phenomenon - Seat height low

W1 : Seat Height low

W2 : Excess material removal from seat area in seat grinding process.

W3 : excess pressure of pusher while loading in collet.

W4 : No gap between ejector rod and unloading cylinder rod.

Root Cause : No Gap

Idea : Gap provision

 Defect Classification
‘B’ TYPE DEFECT

Limit of output OK •The output is (OK ) initially

specification
•Becomes Not ok
NOT-OK
•NO action taken by operator
•Becomes OK
No Action by
operator

Root causes analysis Tool

LSL OK USL FTA

 B Type Defect

‘B’ Type defect: This type of defect also occurs during normal production. But the difference from A
type defect is that the next product is OK . We say that these defects are due to chance causes. These
defects occur and disappear by themselves without any corrective action taken.
This type of defect is dangerous as the we do not get to know the reason for the cause and how to
prevent them from repeating again.

B Type defect example :

FTA Analysis is the tool which is used to prevent this type of defect from
occurring. At times by looking at the process sequence in detail w.r.t.
defect and changing the sequence could eliminate the defect.
 Defect Classification
‘C’ TYPE DEFECT

Limit of output Not OK

specification •The output is (Not OK ) initially
•Action taken by operator
•Becomes OK (Setting scrap)
OK
Action by taken
operator

Root causes analysis Tool

LSL OK USL Why ,Why Analysis

 C Type Defect

‘C’ Type defect: Defect occurred initially for some time and found Ok after taking action is called “C”
type defect.

Some defects occur during set up time and changeovers. Trial production and corrective measures are
taken to ensure defect free state so that the regular production begins. This condition arises due to
inadequate set-up procedures and lack of skills in jigs and fixtures positioning and setting

C Type defect example :

Methodology of solving C – Type defect Phenomena
 Defect & Physical Phenomenon

Defect Physical Physical Physical Physical

Phenomenon Phenomenon 1 Phenomenon 2 Phenomenon 3 Phenomenon 4
Valve Face Damage Radius Damage End Damage Stem Damage
Damage

Dent on Dent of Teeth edge Dent on Gear Dent on ID Dent on teeth OD

Gear surface

Key Points :
1. One defect phenomenon shall have one or more physical phenomenon.
2. CFT approach to be adopted to eliminate physical phenomenon.
3. Physical Phenomenon’s wise analysis & action to be initiated.
 Actions with example
Action Definition Example No 01 Example No 02
Corrective action Actions taken to eliminate the defect Inspection side
Inspection side
• Restoring / modifying 4M1T conditions • Drill Size confirmation freq inspection increased
• Confirmation of spatter free threaded holes by 100%
• Should include cause side and inspection side from twice to 4 times in shift .
inspection of minor diameter by pin gauge.
action. Process side
• Inspection marking near threaded hole
Reactive approach • Drill replacement after 1000 Nos started to
Process side - CO2 Welding parameter change.
address tool wear.
• Current 140~160Amp and Voltage 18~25 V to
80~110Amp and 15~18 V respectively for spatter free
welding
• Masking of threaded hole

Preventive Action taken to Prevent the defect. Inspection Side Inspection Side
action • Defect can not be generated or defective parts
can not pass through the cell. Process side Process side
• Interlock of defect generating stage through • Drill 4.2 mm tool life interlock in drilling machine. • CO2 Welding parameter interlock with machine
control of contributing parameter or fool • Interlocking masking clamp with weld cycle
proof inspection of product (eg. No
declamping, no OK sticker generation, no
engraving etc)
Sustenance Monitor actions taken to prevent defect Inspection Side Inspection Side
generation / arrest defective delivery through fool • Pin OD monitoring
proof inspection. • 3 layer audit
Process side
• Verification of tool life monitoring Pokayoke Process side
• Process parameter monitoring
System side To document Preventive and Sustenance actions • Tool life to be update n IPO.
• CO2 Welding parameter standard up dation.
for preventing defects in similar process / product • Tool life interlock addition in PRBFM/PFMEA
• For welding of parts with threads , holes, studs etc.,
in future • Tool life study to be done before SOP wherever it
establish process for generating minimum spatter.
is CTQ
.
 PHENOMENA WISE MONTHLY REJECTION QUANTITY
MATRIX ROTOR ASSEMBLY
Sr. DEFECT PHENOMENON DEFECT
Sept'07 Oct'07 Nov'07 Dec'07 Jan'08 Feb'08 Mar'08 Apr'08 May'08 Jun-08 Jul-08 Aug-08
No. (IN-PROCESS) TYPE
1 Drill hole through during balancing C 27 6 5 0 0 0 0 0 0 0 0 0
2 Rivet head damage A 5 4 0 1 0 2 0 0 0 0 0 0
3 Bolt broken B 25 24 13 0 4 3 0 0 0 0 0 0
4 Double marking A 11 12 0 0 0 0 0 0 0 0 0 0
5 Pip radius oversize (>57.75mm) B 121 140 7 0 3 0 0 0 0 0 0 0
6 Boss thread damage A 0 25 21 12 17 8 26 15 8 21 12 10
7 Magnet case scratch mark A 31 32 1 2 0 0 0 0 0 0 0 0
8 Plate starter clutch damage A 77 67 12 7 2 11 7 0 0 0 0 0
9 Magnet case up B 57 124 11 2 1 8 4 0 0 0 0 0
10 Pip radius undersize (<57.95mm) B 60 80 29 0 0 0 0 0 0 0 0 0
11 Magnet case shift A 31 35 7 3 0 0 1 0 0 0 0 0
12 Taper dent mark B 12 9 7 6 9 12 7 8 3 0 0 0
13 Keyway damage A 25 48 12 8 7 5 12 10 12 6 12 0
14 Pip damage A 11 15 12 9 11 15 12 10 9 12 9 9
15 Magnet case damage B 101 86 57 33 31 62 65 74 67 49 52 33

Sr. DEFECT PHENOMENON DEFECT

Sept'07 Oct'07 Nov'07 Dec'07 Jan'08 Feb'08 Mar'08 Apr'08 May'08 June'08 Jul-08 Aug-08
No. (VENDOR PARTS) TYPE
1 Cup notch shift A 21 6 32 5 0 0 0 0 0 0 0 0
2 Rotor ID gauge tight due to cup F/O more B 96 76 31 14 37 27 15 0 0 0 0 0
3 Rotor ID gauge tight due to cup Magnet profile B -- -- -- -- -- -- 17 0 0 0 0 0
4 Boss Ø 85 oversize A 8 27 14 9 3 3 2 2 5 0 5 0
5 Boss thread miss A 2 16 11 1 4 5 2 2 2 0 2 0
6 Boss thread oversize A 43 56 79 0 45 52 29 47 35 22 24 32
7 Cup poor plating -- 49 20 17 36 67 93 32 30 52 48 52 0
8 Boss thread undersize A 84 46 39 0 1 1 0 0 0 52 0 0
9 Others -- 18 27 46 32 8 12 6 0 0 0 0 0
 Step-2 – Survey of process which generated
defect

Study of possible and happened defect phenomena in past

for similar component.

• QA Matrix for quality characteristics based on process

survey (Possibility)
• QA Matrix updation based on defects occurred
 Prepare Quality Assurance matrix & reflection in
standards

QA Matrix – QA (Quality Assurance) Matrix is used to find

out sources of defects in product. QA matrix shows the
relation ship between defect/defect mode & the process
which causes it. It requires data collection for defects at
various process stages to prepare a QA Matrix. Hence QA
matrix is to be made quality defect wise, process wise and
machine wise.
Step-3 – Survey and analysis of 4M conditions

This analysis is a set of conditions with respect to Man,

machine, material and method for obtaining a good
products. It helps in identifying 4M standards and
checking is possible against these standards. Removing
this variability can some times eliminate Quality defects in
the product.
4M Condition to decide Quality
4M Condition to decide Quality
4M Condition to decide Quality
4M Condition to decide Quality
Step-4 – Study of malfunction countermeasures &
restore malfunctions.

Corrective action (Kaizen / Pokayoke) for the defect

phenomena.
Refer QA Matrix prepared earlier.
Consider all 4M conditions for the defect.
Analyze the defect & implement countermeasures for the
root cause and possible causes.
 Pokayoke for eliminating defects

Poka yoke is a technique for avoiding simple human errors at

work.
Poka is a Japanese word meaning “Inadvertent error” and Yoke
comes from Japanese word Yokerie meaning “to avoid”.
This has been termed as “Mistake / Fool Proofing”.
 Pokayoke for eliminating defects

ERROR ARE INEVITABLE BUT CAN BE ELIMINATED

People always make mistakes. These can be reduced or even

eliminated. Some of the Poka-Yoke devices, which can
help to avoid defects are:

Guide Pins / Locators of different sizes

Error Detection Buzzers & Alarms
Limit Switches, Proximity & Photo sensors
Counters
Checklists
 Basic classification of Poka yoke

• PREDICTION V/s DETECTION

• ALARM V/s SHOTDOWN Vs CONTROL
• CONTACT V/s FIXED VALUE V/s MOTION READING METHODS
 Pokayoke for eliminating defects

A. Prediction V/s Detection : When a Poka-Yoke is designed in a way

that it helps the operator to recognise the defect before it is about
to occur, it is called a Prevention or Prediction type Poka-Yoke.
When a Poka-Yoke helps the operator to know immediately on the
occurrence of the defect then it is called Detection type Poka-
Yoke.
Detection is “after” the defect is produced. The merit of this type of
Poka-Yoke is based on the stage at which the defect is detected.
 Pokayoke for eliminating defects

B. Alarm V/s Shutdown V/s Control :

• Alarm : Signals in form of buzzers, blinking lights are to warn when
an abnormality, has occurred (defect) / about to occur (predict)
• Shutdown : Normal function of machine or process is stopped when
defect predicted / detected.
• Control :
1. In Prevention type Poka-Yoke : control means that even intentional
errors are impossible or methods by which the cause of defect if
starts happening, it is automatically prevented from happening
(feedback mechanism)
2. In Detection type Poka-Yoke : Control means that the process is not
stopped but the defective items are automatically separated out &
are not allowed to pass on to next stage.
 Pokayoke for eliminating defects

C. Contact V/s Fixed Value V/s Motion Reading Methods for Poka-
Yoke classification :
These use the principle of physical or energy contact with the product
using sensing devices. They range from guide pins, limit switches,
photo electric beams, etc.
Contact methods often take advantage of parts that are designed
with an uneven shape. We can use guide pins or blocks that don’t
allow the product to be seated in a machines jig in the wrong
position.
Theme: To eliminate PCD shift in K10 rotor boss

Location: VMC Drilling

Seat check poka-yoke

Before After

No Seat check Poka-yoke provided to detect

correct location in teeth

Poka-yoke provided to confirm correct clamping

No poka-yoke
of component
 Pokayoke for eliminating defects

Type of sensing Devices :

1. Limit switches, Micro switches

2. Proximity switches
3. Photoelectric switches
4. Beam sensors
5. Sensor to detect changes in physical condition like temperature,
pressure etc. (Pressure switches, thermostats etc.)
 Pokayoke Sheet
POKA-YOKE SHEET Varroc Engineering Pvt Ltd.

Problem : Prevent Error

Prevent Error
Solution :

Key Improvement : Detect Error Control

Alarm

BEFORE AFTER

Sustenance Plan :
Action plan in 5W2H,6W2H
Format
 Step-5 – Analyze conditions for non defective units
that are not confirmed.

Study of other possible reasons for a defect, PM Analysis in

some cases.

Find out conditions / control items from actual defects &

possibility study for contributing non defective units.
 Step-6 – Improve 4M Condition defect
Step-7 – Setting 4M conditions

Survey, analysis & implementation of 4M conditions for

possible and happened defects.

Carry out possibility study, identify all 4M conditions to

ensure that defect does not occur.
QM MATRIX - SUSTENANCE
 Step-8 – Intensification & improvement of
checking method

Review 4M conditions set before and after actions

implementation.
 Step-9 – Deciding check standard value
Step-10 – Revise standards

Review QM Matrix for control items identified to produce

non defective items
Prepare inspection manual for control items, to simplify
inspection activity
Introduce control items as check points in JH, PM check
sheets for effective monitoring.
QM 10 Step Approach
Cost of Quality
 Cost of Quality

Quality Cost

Conformance Non-Conformance

Prevention Appraisal Internal failure External failure

Expenditure on cost Expenditure on :

Expenditure on :
of:
•Activities like checking. •Rework.
•Training.
•Inspection work. •Scrap.
•Establishing procedures
•Conducting audits
•Planning activities.
•Analysis of performance
for improvement..
Relationship between the pillars of TPM activities and
Quality maintenance

KK PM ANALYSIS
Quality Maintenance
KAIZENS

JH 7 STEPS OF JH EQUIPMENT: NOT PRODUCING QUALITYDEFECT

* DAILY INSPECTION

SETTING OF CONDITIONS (Decide Rightly)

Application of
PM Equipment diagnosis CONDITION MANAGEMENT (Follow Strictly)
Technology
Feedback
DM
MP DESIGN Fostering proficiency
of Employee in
Equipment operation
& maintenance

ACCOMPLISH
E&T
ZERO DEFECTS
THANK YOU