Explanation

Q-SFM Manual
(Quality Shop Floor Management)

Mr. Wachirawat Yotharat

Supplier Performance Improvement section
Purchasing Engineering & Project Management Div. / TDEM
Revision 5
 Content
CONFIDENTIAL

• Background of Q-SFM
• Why SFM is necessary?
• What is purpose of shop floor management?
• What is visualization in shop floor?
• Who have to manage shop floor?
• Q-SFM content explanation (3 step)
– Step 1 A : Set basic rules/standards
– Step 1 B : Preventing outflow to market
– Step 2 C : Preventing outflow to following process
– Step 3 D : Sustain standardized work and skill
– Others

2
 Enhance Supplier Self Capability (S,Q,D,Envi)

Conceptual diagram:
Take iceberg as Shop floor management at supplier

❶ Result KPIs : Fatal accident/

Field action defect/
Stop production
Above sea level = Result KPIs, Problems ❷Result KPIs : Absent accident/ Obvious Problems
solving case by case after problem Critical defect, Func.A/
Wrong part delivery
occurrence (Reactive improvement) Please do not relax even if
❸Result KPIs : Near miss accident/ no accident or near miss
General defect/
Delay delivery

Below sea level = Process KPIs, SFM Hidden Problems

Supplier have to identify
abnormalities/weak points assessments => need to be eliminated
and kaizen (Proactive improvement) Top mgt. to lead to establish
Fundamental process - Safety/Quality culture
management - Audit system (SFM)

Process control

SFM is an assessment tools for;

(1) To ensure fundamental process control items are ‘under control’

(2) To identify abnormalities/weak points and kaizen by suppliers

before they cause accident/part defect/delay – PREVENTIVE process control

(3) Most of the recent quality field actions have been caused by lack of fundamental shop floor management.

Bad performance seen on the surface. But, we have to identify abnormalities/

weak points and kaizen by suppliers before they cause accident
/part defect/delay delivery.
Why is SFM necessary? CONFIDENTIAL

1) To ensure fundamental process control items are ‘under control’

(ทำมั่นใจว่ำ หัวข ้อทีจ
่ ำเป็ นในกำรควบคุมกระบวนพืนฐำน
้ อยู่
ภำยใต ้กำรควบคุม)
2) To identify abnormalities/weak points and kaizen by suppliers
before they cause accident/part defect/delay – PREVENTIVE
process control
่ บ่้ งสิงผิ
(เพือชี ่ ดปกติ/จุดอ่อน และ ทำกำรปร ับปรุงอย่ำงต่อเนื่ องโดยผู ้ผลิตชินส่
้ วน
่ นเหตุให ้กิดอุบต
ก่อนทีเป็ ั เิ หตุ หรือ Defectแ ละกำรจัดส่งที่ ล่ำช ้ำ - กระบวนกำรป้ องกัน
กำรเกิดปัญหำ)
3) Most of the recent quality field actions have been
caused by lack of fundamental shop floor management.
่ ดรอดไปถึงลูกค ้ำ มักเกิดจำกกำรบกพร่องใน
(โดยส่วนใหญ่ปัญหำคุณภำพทีหลุ
้ นฐำน
กำรบริหำรจัดกำรโรงงำนขันพื ้ )
 What is purpose of shop floor management? CONFIDENTIAL

1) Speedy Identify the Abnormality ้

ระบุบ่งชีความผิ
ดปกติอย่างรวดเร็ว
Visualization of
Abnormality in a shop
การทาให้ความผิดปกติใน Abnormality jump
Into our eyes at glance
shop สามารถมองเห็นได้
สามารถมองเห็นความผิดปกติ
３ Moving Items
่ เคลื
3 สิงที ่ อนไหว
่ ได้อย่างทันที
４ ５ ่
１ ２ ３ 1) สิงของต่ างๆ Physical Goods
Standard 2) งาน (คน) Work(People)
Abnormal 3) ข้อมู ล MGMT Info.(data)

มี
3) The proper understanding of Floor Mgmt Task
2) Speedy problem Solving แก้ไขปั ญหาอย่างรวดเร็ว ่ กต้องเกียวก
ความเข้าใจทีถู ่ ับงานใน
shop
Kanban Fluctuation
กำรมี kanban มำก
Over Box Height
Competitive
วำงกล่องสูง
Production/Quality เกิOver
นไปMax
มีความสามารถในการ เกินไป
Problem
้ ณภาพ
ผลิตสู งขึนคุ
Over Flow

้
ของชินงานดี ึ้
ขน
The Shop Floor Mgmt in Toyota is การบริหาร shop floor ของโตโยต
Immediate Provide ①An Abnormality jumps into our eyes at glance
Subordinates
กำรทำให ้ควำมผิดปกติสำมำรถมองเห็นได ้อย่ำ
Problem Solving OJD
อนวิธแี ก้ไขปั ญหาให้แก่ Developed

ลู กน้องอย่างทันที ลู กน้องมีพฒ
ั นาการ ②We can count the number of physicals by1 piece unit at glance
่
Who have to manage shop floor? CONFIDENTIAL

Factory โรงงาน
< Top mgmt.>
ผู บ
้ ริหารระดับสู ง
Role :Follow up C/M & Support activities
หน้าที่ : ตืดตามการแก้ไขปญหาและสนับสนุ น
การทากิจกรรม

Shop Floor
<Operator>
Role: Follow the rule /STDW
หน้าที:่ ปฎิบต
ั ต
ิ ามกฎ/
มาตรฐาน

< Mgmt> <Group leader>

ผู บ
้ ริหาร หัวหน้างาน
Role: Assessment SFM /Implement and confirm C/M Role: Maintain good operation & Kaizen
หน้าที:่ ประเมินหน้างาน/ดาเนินกิจกรรมและตรวจสอบผลการแก้ไข หน้าที:่ ร ักษาสภาพการทางานให้ดแี ละปร ับปรุง
ปั ญหา อย่างต่อเนื่อง
Daily shop floor mgmt การบริหารหน้างานประจาว ัน
 CONFIDENTIAL

Q-SFM Evaluation
&
Criteria

7
Q-SFM content explanation (3 Steps) CONFIDENTIAL
Base on PMR step
Step for improving worksite capability
Step 5

Mizenboshi / JKK Result & Process

Occurrence

should be link
Step 4

NDC Find out

& Built-in Quality In-Process
DM Implement

Process KPI

Result KPI
Step 3

Sustain
Std. work & Skills
Step 2

Outflow prevention
Outflow

to Following process
P
Outflow prevention
A
Step 1

to Market
D
Set Basic
Rule/standards 1st priority C
Outflow prevention

Need to check process management condition

based on the Result KPI (PDCA)
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(1) Announce Div. Hoshin/Policy regarding quality.
No.1 : Quality management organization, Policy & improvement activity plan
No. Evaluation item Check point Criteria
There are team support this activity (Not only quality
1) Organization structure
section)
2) Job response each member Identification response job of each member
-Quality management
1 organization, Policy & 3) Quality Policy, Policy main KPI. Numerical target
improvement activity plan
4) Activities plan Actual updated

5) Top to down policy sharing. Sharing evident (Minimum requirement Top <=> Mgr.)

1) There are team support this activity (Not only quality section)

PD

QA

PC

MT

2) Identification response job of each member

 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(1) Announce Div. Hoshin/Policy regarding quality.
No.1 : Quality management organization, Policy & improvement activity plan
No. Evaluation item Check point Criteria
There are team support this activity (Not only quality
1) Organization structure
section)
2) Job response each member Identification response job of each member
-Quality management
1 organization, Policy & 3) Quality Policy, Policy main KPI. Numerical target
improvement activity plan
4) Activities plan Actual updated

5) Top to down policy sharing. Sharing evident (Minimum requirement Top <=> Mgr.)

3) Numerical target
5) Sharing policy info.

*Accepted (Top <-> Mgr.)

< Top mgmt.>

ผู้บริหารระดับสูง

< mgmt.>
ผู้บริหาร

4) Actual updated plan

< Leader.>
หัวหน้า งาน

< Operator.>
พนักงาน
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(2) Market (Customer) Quality information C/M activity
No.2 : Quality Target VS Result information sharing
No. Evaluation item Check point Criteria
There is claim routing/Procedure. And Quality info.
1) Receive market Q info. and Flow action
-Quality Target VS Result Visualization
information sharing of Using any tool are accepted. (5why, fish bone). Not
2) Problem analysis
2 - After market claim only inform problem
- Customer claim 3) Yokoten (expand) countermeasure There is method to YOKOTEN Countermeasure
- Internal defect
4) Countermeasure status Visualization C/M status with updating

1) There is claim routing/Procedure. And Quality info. Visualization

Sharing & Follow

by ASAKAI Meeting
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(2) Market (Customer) Quality information C/M activity
No.2 : Quality Target VS Result information sharing
No. Evaluation item Check point Criteria
There is clam routing/Procedure. And Quality info.
1) Receive market Q info. and Flow action
-Quality Target VS Result Visualization
information sharing of Using any tool are accepted. (5why, fish bone). Not
2) Problem analysis
2 - After market claim only inform problem
- Customer claim 3) Yokoten (expand) countermeasure There is method to YOKOTEN Countermeasure
- Internal defect
4) Countermeasure status Visualization C/M status with updating

2) Using any tool are accepted. (5why, fish bone). Not only inform problem

- Analysis method by internal formant

 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(2) Market (Customer) Quality information C/M activity
No.2 : Quality Target VS Result information sharing
No. Evaluation item Check point Criteria
There is clam routing/Procedure. And Quality info.
1) Receive market Q info. and Flow action
-Quality Target VS Result Visualization
information sharing of Using any tool are accepted. (5why, fish bone). Not
2) Problem analysis
2 - After market claim only inform problem
- Customer claim 3) Yokoten (expand) countermeasure There is method to YOKOTEN Countermeasure
- Internal defect
4) Countermeasure status Visualization C/M status with updating

3) There is method to YOKOTEN Countermeasure 4) Visualization C/M status with updating

Yokoten Log sheet

Yokoten Control Board

On plan / Delay
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(3) Sampling audit concern C/M activity
No.3 : Frequency and effectiveness of sampling audit by QC/QA
No. Evaluation item Check point Criteria

1) Sampling audit rule Action Flow /Procedure/Basic rule (Normal operation)

Normal
2) Recording Base on frequency in ATIS
condition
-Frequency and effectiveness 3) Visualization Easy to get data and know status
3
of sampling audit by QC/QA 4) Sampling audit rule Action Flow /Procedure/Basic rule (Abnormal operation)
Abnormal
5) Recording Base on NG items
condition
6) Visualization Easy to get data and know status

Normal condition
Patrol inspection sheet ทาการสุ่มตรวจสอบผลิตภัฑ ์ ่ ยวข้
เอกสารทีเกี ่ อง
(การสุ่มตรวจผลิตภัณฑ ์) ้
1) ตรวจสอบ Kanban ก ับเลขชินงาน - SDS
้
2) สุ ่มชินงาน ้
1 ชินจากกล่ อง - Internal
QC 3) ตรวจสอบค่าตามเอกสาร Sample data sheet (SDS) inspection sheet
Foreman 4) Record

OK

2) Data record: Base on frequency 3) Easy to get data and

in ATIS know status

SDS

1) Action Flow /Procedure/Basic rule (Normal ATIS

operation)
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(3) Sampling audit concern C/M activity
No.3 : Frequency and effectiveness of sampling audit by QC/QA
No. Evaluation item Check point Criteria

1) Sampling audit rule Action Flow /Procedure/Basic rule (Normal operation)

Normal
2) Recording Base on frequency in ATIS
condition
-Frequency and effectiveness 3) Visualization Easy to get data and know status
3
of sampling audit by QC/QA 4) Sampling audit rule Action Flow /Procedure/Basic rule (Abnormal operation)
Abnormal
5) Recording Base on NG items
condition
6) Visualization Easy to get data and know status

Abnormal condition
Patrol inspection sheet หากสุ่มตรวจสอบผลิตภัฑ ์แล้วไม่เป็ นไปตามมาตรฐาน ให้ทาดังนี ้ ่ ยวข้
เอกสารทีเกี ่ อง
(การสุ่มตรวจผลิตภัณฑ ์) 1) ทาการแยกผลิตภัฑ ์ทีไม่ ่ ได้มาตรฐาน - SDS
้
2) สุ ่มชินงานเพิ ่มอีก 1 ชินจากกล่
้ อง - Internal
QC 3) แจ้งหัวหน้างานให้ทราบพร ้อมทางานแก ้ไข inspection sheet
Foreman 4) วิเคาระห ์หาสาเหตุและดาเนิ นการแก ้ไขเชิงป้ องกน
ั -Analysis sheet

5) Data record: Base on NG items 6) Easy to get data and

NG
know status
Detail problem
Rank Temporary Action
SDS
Problem
Type
Due date

4) Action Flow /Procedure/Basic rule ATIS

(Abnormal operation)
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(4) Establish Part quality inspection (Total inspection/Sampling )
No.4 : Completion of inspection items as DRW, ATIS & etc. require
No. Evaluation item Check point Criteria
1) Drawing control Approval
Completion of inspection items Completed all requirement and Maintain (Random
4 2) ATIS ( All Toyota’s requirement)
as DRW, ATIS & etc. require check)
Actual updated in paper and follow as standardized
3) Items check
work

1) Drawing : Approval from Toyota

3) Actual updated in paper and follow as standardized work

SDS (Sampling)
:Measurement check

16
Inspection standard : Visual check

2) ATIS: Completed all requirement and

Maintain (Random check)
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(5) Establish a system to comply with regulations (R).
No.5 : Confirm that the production meet the regulation as ATIS require
No. Evaluation item Check point Criteria
1) Drawing Confirm delta R point

-Confirm that the production 2) ATIS Must reflect delta R point

5 meet the regulation as ATIS 3) Items check in WI/EIS Identification delta R point
require 4) Control list Have control list of delta R (Ex. Part list or Process list)
5) Machine or Process Identify delta R on Machine or Process

1) In Drawing  R point 3) Check result or Items check in WI/EIS 5)Identify  R on Machine or Process

Quality Check Sheet

2) ATIS must reflect  R point 4) Control list of  R

 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(6) Conduct training on fundamental skill.
No.6 : Operator skill management
No. Evaluation item Check point Criteria
1) Training road map Have flow or road map for training operator
Have clear evaluation criteria bolt of Paper test and
2) Evaluation test
6 -Operator skill management shop floor test
3) Skill matrix Completed all member
4) Refreshment and level up Have clear training plan for refreshment and level skill

1) Have flow or road map for 2) Evaluation Test method 3) Skill matrix : Completed all member
training operator
Paper test Inspection test
(สอบภาคทฤษฎี) (สอบการใช้เครือ ่ งมือ
PAPER TEST ด)TEST
INSPECTIONวั
TOOL Skill Matrix

• FOR INCREASE KNOWLEDGE AND MAKE QUALITY AWARENESS.

• FOR OPERATOR TO UNDERSTAND PRINCIPLE OF OPERATION IS ACCORDANCE WITH THE
• FOR INCREASE KNOWLEDGE ABOUT MEASURING TOOLS TO OPERATOR
REQUIREMENTS OF CUSTOMER.
• FOR OPERATOR CAN USE MEASURING TOOLS AND PART MEASURING PART ACCURATELY
• FOR OPERATOR KNOW CORRECTLY WORKING.
AND PRECISELY.
• FOR OPERATOR TO UNDERSTAND PRODUCT AND REALIZE IN QUALITY CONTROL.
• FOR INCREASE AWARENESS TO TAKE CARE OF MEASURING TOOL.

Blind test Simulation test

(สอบ (สอบภาคปฏิบตั )ิ
ภาคปฏิ
BLIND บ ั )ิ
TESTต SIMULATION TEST

4) Have clear training plan for refreshment

• DEVELOP OPERATOR TO WORKING EFFECTIVELY AND DELIVERY QUALITY PART TO CUSTOMER.
• FOR OPERATOR CAN WORKING FOLLOW STANDARD WI CORRECLY.
• FOR OPERATOR CAN SEPARATED NG PART OUT FROM FG PART BOTH CASTING DEFECT AND MACHINING
DEFECT.
• FOR PREVENT NG PART FLOW OUT TO CUSTOMER.
and level skill
• FOR OPERATOR CAN PRODUCTION ON SHOP FLOOR BY CAN OPERATION FOLLOW STANDARD
AND CYCLE TIME.
• FOR OPERATOR CAN USE GENBA KANRI TOOL CORRECTLY.
• FOR OPERATOR CAN OPERATION ACCORDING ABNORMAL ROUTE WHEN ABNORMAL HAPPEN.
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(6) Conduct training on fundamental skill.
No.7 : Operator skill management
No. Evaluation item Check point Criteria
7 -Operator working follow Std. 5) Check operator working follow Std. Have check sheet / Plan / audit result

10 times check

5) Have check sheet / Plan /

audit result

[Plan to audit]
Sequence, Motion, Time
 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(7) Prepare Job Instruction Sheet/EIS/WIS by include low frequency
job <clearly describe key points of quality/safety>.
No.8 : WI (include low frequency job)
No. Evaluation item Check point Criteria
Complete Level#3 : Element /Quality key point / Effect if
1) WI implementation
not follow
8 WI (include low frequency job) 2) Complete item check from ATIS Not less than ATIS
3) Review and update Recording of each revision and training operator

WORK INSTRUCTION ( Q-GATE )

1) Complete Level#3 : Element /Quality key point / Effect if not follow
Issued date : July 2,2013

QC. FINAL CHECK 100% Issued by : R.Sutat / QA.

CUSTOMER : TOYOTA KANBAN NO : 42

PART NUMBER : XXXXX-XXXXX
Suitable operation Effect
PART NUMBER : XXXXX-XXXXX ,TYPE of, 2TR
: 2WD problem
Element + time วิธก
ี าร มาตรฐานการตรวจสอบ เวลาที่ ผลกระทบด้า นคุณภาพ
No. รูปภาพ ขนตอนการท
ั้ างาน
ตรวจสอบ method (Keyใช้point)
และความปลอดภ ัย ตรวจสอบ (Safety , Quality)
และความปลอดภ ัย

1.1 ตรวจหมายเลข Kanban สายตา Q:ต ้องเขีย นเป็ นตัวเลข 42 1 Sec. Q:ลูกค ้าประกอบรถผิดรุ่น

Q:ลูกค ้าประกอบเข ้า

1
1.2 ตรวจรุ่น Housing clutch ↑ Q:มาร์ควงกลม สีฟ้า 1 Sec.
Engineไม่ไ ด ้ ATIS
Q:มีแ หวนรอง 1ตัว ต ้องไม่หลวม
Q:เกิดปั ญหาน้ ามันรั่ ว
1.3 ตรวจ Filler plug สายตา&มือ S:ต ้องสวมถุงมือและปลอกแขน 4 Sec.
S:Case T/M บาดมือและแขน
ขณะทาการตรวจสอบ
Q:Pipe,oil receiver ต ้องอัด
1.4 ตรวจ Pipe,oil receiver สายตา 3 Sec. Q:เกิดปั ญหาน้ ามันรั่ ว
ลงสุดและหามมี
้ ่ งว่าง(Gap)
ชอ

Q:ใช ้ Ring gauge และ

Ring gauge Spilne gauge ตรวจสอบ
2.1 ตรวจ Input shaft & เข ้าไดOK.
้ และเข ้าไม่ไ ด ้ NG 12 Sec.
Q:ลูกค ้าประกอบเข ้า Engine
Spilne gauge S:ต ้องสวมถุงมือและปลอกแขน
และชุด Clutch ไม่ไ ด ้
2 ขณะทาการตรวจสอบ

2.2 ตรวจชุด Fork sub assy

้ วนต ้องประกอบครบ 2 ชิน
Q:ชินส่
และไม่หลุดออก
้
S:Housing clutch
บาดมือและแขน 2) Complete item check from ATIS
clutch release
สายตา&มือ
S:ต ้องสวมถุงมือและปลอกแขน
ขณะทาการตรวจสอบ
3 Sec.
(Visual check)
3.1 ตรวจ Retainer sub assy Q:เกิดปั ญหาRing synchronizer
สายตา Q:ต ้องเข ้าตาแหน่งเกีย ร์ 3 RD 3 Sec.
select control ติด ลูกค ้าเข ้าเกีย ร์ไ ม่ไ ด ้
NG.อยูตาแหนงเกย ี ร N ไมม ี Gap

3 3.2 ตรวจ Reverse restrict(ซ ้าย) ↑ Q:หัวสีเงิน,มาร์ค ส ีเขียว 2 Sec.

Q:เกิดปั ญหา Shift feeling

3.3 ตรวจ Reverse restrict(ขวา) ↑ Q:หัวสีเงิน,มาร์ค ส ีขาว 2 Sec.

4.1 ตรวจ Spline output
Q:Guage ต ้องสวมเข ้าพอดี
ไม่ฝืดและไม่ตด ิ ขัด
Spline gauge
S:ต ้องสวมถุงมือและปลอกแขน
ขณะทาการตรวจสอบ
ทีล ู ค ้าSelect ซ ้าย,ขวา ฝื ด
่ ก
3) Recording of each revision and
training operator
Q:ลูกค ้าประกอบเข ้ากับชุด
3 Sec. เพลา(pop pillar shaft)ไม่ไ ด ้
S:Extension บาดมือและแขน

Q:ต ้องอัด Oil seal ลงสุด

 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(8) Comply with "one-cycle rule" and "troubleshooting rule"(Stop,Call,Wait).
No.9 : One-cycle rule, Stop-Call-Wait rule following
No. Evaluation item Check point Criteria
1) One cycle finish Normal Operation procedure
2) Part identification/Tag condition Have clear identify on part if not complete process
- One-cycle rule
9 and 3) trouble shooting Operation procedure
Stop-Call-Wait rule following 4) Abnormality criteria Abnormal Have criteria for 4M abnormality management
condition
5) Recording Have action and record for abnormality

Normal condition : Stop (Break/ Lunch/ Going to toilet)

1) Operation procedure 2) Have clear identify on part if not complete process

 Step1 - A : Set basic rules/standards CONFIDENTIAL
A-(8) Comply with "one-cycle rule" and "troubleshooting rule"(Stop,Call,Wait).
No.9 : One-cycle rule, Stop-Call-Wait rule following
No. Evaluation item Check point Criteria
1) One cycle finish Normal Operation procedure
2) Part identification/Tag condition Have clear identify on part if not complete process
- One-cycle rule
9 and 3) trouble shooting Operation procedure
Stop-Call-Wait rule following 4) Abnormality criteria Abnormal Have criteria for 4M abnormality management
condition
5) Recording Have action and record for abnormality

Abnormal condition : Stop (Found NG part, MC alarm, Pokayoke alarm )

3) Operation of trouble shooting 5) Have action and record for

abnormal

4) Have criteria for 4M abnormality management

Step1 - B : Prevention of Defect Outflow to The Market
B-(1) Manage important process (S) and provide training. CONFIDENTIAL
No.10 : Critical part management
No. Evaluation item Check point Criteria
1) Drawing Confirm delta S point
2) ATIS Must reflect delta S point
10 -Critical part management 3) Items check in WI/EIS Identification delta S point
4) Control list Have control list of delta S (Ex. Part list or Process list)
5) Machine or Process Identify delta S on Machine or Process

1) In Drawing  S point 3) Check result or Items check in WI/EIS 5)Identify  S on Machine or Process

Quality Check Sheet

S S

2) ATIS must reflect  S point 4) Control list of  S

ATIS

S
Step1 - B : Prevention of Defect Outflow to The Market
B-(1) Manage important process (S) and provide training. CONFIDENTIAL
No.11 : Capability to control critical part/process and frequency of critical part/process
confirmation
No. Evaluation item Check point Criteria
Critical part/process and TOYOTA certify result : SSAS / CPPP Passed/completed all TOYOTA require topics or No
11
frequency -Confirmation(PESS, SSAS, CPPP,..) critical process

Conduct SSAS activities and good maintain

SSAS : is a kind of system to aim for part supplier

Jiritsuka enhancement in critical processes -Available ASD, PML,
especially during mass production stage.
AOMS
(Audit Organization Management Sheet) TCA.
Method : Supplier audit all lines by certified -Has change with plan
auditors as Toyota certifying criteria.

Toyota

Related UPMS -Complete audit with

• Provide Tools document (Unified Process Management Sheet) satisfied result.
• Certify Auditors Sampling audit

Supplier
1st Tier: TCA
- SSAS Process Audit
• Train Manual in Thailand
- Questionnaire
• Certify Audit
SMCS -Score 100% with 24
- Supplier
Etc. (Sustainability Management Check Sheet) TDEM confirm.
2 Tier
nd

/Lower : SCA Audit Process

TCA or SCA do self audit process.(every line of critical process)
 Step1 - B : Prevention of Defect Outflow to The Market
B-(2) Establish abnormality handling procedure for non-conformance
outflow from manufacturing process. CONFIDENTIAL
No.12
No. : Identification
Evaluation item & separationCheck
of abnormal/NC
point part Criteria

Identification & separation of 1) Non-conformance part Operation procedure

12
abnormal/NC part
2) Identification status Have clear identify on part for separation

1) Operation procedure (Non-conformance part) 2) Identification status on part/ Tag

Identify tag with part

Mark identify Tag NG

NG shooter
 Step1 - B : Prevention of Defect Outflow to The Market
B-(3) Establish a procedure to check the quality of repair Part and
repair skill training. CONFIDENTIAL
No.13 : Repairing skill evaluation method
No. Evaluation item Check point Criteria

1) Part repair Operation procedure

2) Judgment Criteria Can Repair, Can't repair

-Repairing skill evaluation 3) Repairing standard There is STD/EIS/WI for repairing

13
method 4) operator skill Identification operator skill for repairing
5) Mark on part Identify mark on part (After repaired)

6) Confirmation part after repaired Item check problem (Effect from repair point)

1) Operation procedure 2) Judgment Criteria : Can Repair, Can't repair

[Repair Flow Route]

 Step1 - B : Prevention of Defect Outflow to The Market
B-(3) Establish a procedure to check the quality of repair Part and
repair skill training. CONFIDENTIAL
No.13 : Repairing skill evaluation method
No. Evaluation item Check point Criteria

1) Part repair Operation procedure

2) Judgment Criteria Can Repair, Can't repair

-Repairing skill evaluation 3) Repairing standard There is STD/EIS/WI for repairing

13
method 4) operator skill Identification operator skill for repairing
5) Mark on part Identify mark on part (After repaired)

6) Confirmation part after repaired Item check problem (Effect from repair point)

3) There is STD/EIS/WI for repairing 4) Identification operator skill for repairing 6) Item check problem
(Effect from repair point)

5) Identify mark on part (After repaired)

 Step1 - B : Prevention of Defect Outflow to The Market
B-(4) Manage hengaten at the time of engineering change (ECI).
No.14 : PCR and ECI management CONFIDENTIAL
No. Evaluation item Check point Criteria
Operation procedure (with clear identify lead time for
1) Process / Engineering change
14 PCR and ECI management each process)
2) follow up the progress Log book or visualization board

1) Operation procedure (with clear identify lead time for

2) Log book or visualization board
each process)

The change status of each process

28
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(1) Confirm the assurance level of Functional defects through in-process
inspection and complete part inspection , QA-N (Out flow prevention only)
No.15: Quality assurance level
No. Evaluation item Check point Criteria
1) New issue or new item Check on ATIS, control plan

2) FMEA or QA network Actual with updated

15 - Quality assurance level
3) QA Rank, RPN score ( ) Evaluation correctly with standards of QA Rank, RPN score
4) Action C/M RPN score is down, QA network is up

1) Check on ATIS, control plan 2) FMEA/QA-Network Actual with updated

[ATIS] [Process Flow / Control Plan]

[FMEA Matrix for inspection

[New Issue or new item need to review]
method confirmation]]

29
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(1) Confirm the assurance level of Functional defects through in-process
inspection and complete part inspection , QA-N (Out flow prevention only)
No.15: Quality assurance level
No. Evaluation item Check point Criteria
1) New issue or new item Check on ATIS, control plan

2) FMEA or QA network Actual with updated

15 - Quality assurance level
3) QA, RPN score ( ) Evaluation correctly with standards of QA Rank, RPN score
4) Action C/M RPN score is down, QA network rank is up

3) Evaluation correctly with standards of QA Rank, RPN score 4) RPN score is down, QA network rank is up

FMEA = RPN

Severity (S) X Occurrence (O) X Detection (D)

[FMEA Revise]
Target
QA-Network
= QA RANK

30
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(2) Pokayoke management (important item for outflow prevention only)
No.16: POKAYOKE management
No. Evaluation item Check point Criteria
1) POKAYOKE map Visualization POKAYOKE layout on board

2) Pokayoke point on machine Identification Pokayoke point on machine

16 - POKAYOKE management 3) Daily check sheet
4) Sign status of leader
5) Dummy test function
Complete all items check as POKAYOKE map
Have sign confirm and checking Pokayoke status by
leader
Master dummy with calibration tag

1) Visualization POKAYOKE layout on board 2) Identification Pokayoke point on machine

Pokayoke layout visual and control

Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(2) Pokayoke management (important item for outflow prevention only)
No.16: POKAYOKE management
No. Evaluation item Check point Criteria
1) POKAYOKE map Visualization POKAYOKE layout on board

2) Pokayoke point on machine Identification Pokayoke point on machine

16 - POKAYOKE management 3) Daily check sheet Complete all items check as POKAYOKE map
Have sign confirm and checking Pokayoke status by
4) Sign status of leader
leader
5) Dummy test function Master dummy with calibration tag (Functional part)

3) Complete all items check

as POKAYOKE map 4) Have sign
confirm and
checking Pokayoke
status by leader

5) Master dummy
with calibration tag

MASTER LEAK TEST

Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(3) Maintain/Update standard which related to quality e.g. drawings,
inspection standards, boundary sample
No.17: Boundary Sample / NG sample or part key point
No. Evaluation item Check point Criteria
Actual boundary sample ro NG sample or document of
1) Boundary sample or NG sample
part key point
- Boundary Sample /
17
NG Sample or part key point 2) Issued date Identification issued date (Current year)

3) Expire date Identification expire date/Review date (Current year)

1) Actual boundary sample or NG sample or document of part 3) Identification expire date (Current year)
key point

DWG. ATIS Boundary

sample 2) Identification issued date (Current year)

Revise/update
when changing

Keep latest version & 5S

Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(4) Manage measuring tool and critical equipment
No.18: Measurement tools control / Parameter confirmation / MC maintenance or
Daily check
No. Evaluation item Check point Criteria
1) Tool list Tool list control with calibration plan
- Measurement tools control /
Parameter confirmation /
2) Calibration tag Calibration tag on tools (Not over due date)
18 MC maintenance or
Daily check 3) Daily check sheet Data record (Correct information)
4) Sign status of leader Leader's signature (All items)
แผนสอบเทียบเครื่องมือประจาปี
01/07/2008 RUN No.
1) Tool list controlEquipment
withCalibration
calibration
Yearly Schedule plan
Issue Form : 20/12/99

2) Calibration tag on toolsหมายเหตุ

ปี 2014 ( 2557 ) ปี 2015 ( 2558 ) สถานทีส่ อบเทียบ

ลาดับ รหัส ชือ่ เครือ่ งมือ ผูผ้ ลิต / ยีห่ อ้ รุ่น /หมายเลข ผูถ้ อื ครอง ความถี่ Tolerance ค่าความละเอียด วัน ที่ส อบเทียบ JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC วัน ที่ค รบกาหนด JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC วัน ที่ค รบกาหนด CAL. Place Remark
16-31

16-28

16-31

16-30

16-31

16-30

16-31

16-31

16-30

16-31

16-30

16-31

16-31

16-28

16-31

16-30

16-31

16-30

16-31

16-31

16-30

16-31

16-30

16-31
ภายใน ภายนอก
1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15

1-15
Item Code No. Name Manufacturer Model/S-N Location Frequency Accept Resolution Cal. Date Due. Date Due. Date

1 QAF2-SV-001 VERNIER CALIPER MITUTOYO 6735665 วิฑูรย์ 1 YEAR ±0.05 0.02 mm 18/07/2014 18/07/2015 x SAB

2 QAF2-SV-002 VERNIER CALIPER MITUTOYO 12080741 วิฑูรย์ 1 YEAR ±0.06 0.02 mm 18/07/2014 18/07/2015 x SAB

3 QAF2-SV-003 VERNIER CALIPER MITUTOYO 12080741 พรเทพ 1 YEAR ±0.06 0.02 mm 18/07/2014 18/07/2015 x SAB

4 QAF2-SV-004 VERNIER CALIPER MITUTOYO 6735665 ธีรพงษ์ 1 YEAR ±0.06 0.02 mm 18/07/2014 18/07/2015 x SAB

34
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(4) Manage measuring tool and critical equipment
No.18: Measurement tools control / Parameter confirmation / MC maintenance or
Daily check
No. Evaluation item Check point Criteria
1) Tool list Tool list control with calibration plan
- Measurement tools control /
Parameter confirmation /
2) Calibration tag Calibration tag on tools
18 MC maintenance or
Daily check 3) Daily check sheet Data record (Correct information)
4) Sign status of leader Leader's signature (All items)

3) Data record (Correct information)

4) Leader's signature (All items)
Summit Auto Body Indusrty Co.,LTD.
่ อวัด
ใบตรวจเชคเค็ รืองมื ชือเ่ครืองมือวัด
่ :VERNLERCALIPER(DIGITAL) ขนำด: ่ :
หมำยเลขเครืองมือวัด เดอนื :
รูปภำพ ลดำบทีั ่ ่
จุดทีต้องตรวจสอบ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 ปำกกำวัดนอก(ไม่บิดเบยวี ้ ,แนบสนิท)
2 ปำกกำวัดใน(ไม่บิดเบยวี ้ ,แนบสนิท)
3 ก้ำนวัดลึก(ไม่หัก)
4 ปำกกำวัดลดำบขัั น้ (รำบเร ียบ)
5 ชุดเลอน่ื (เลอนสะดวก
่ื )
6 ขีดสเกลหลัก(คมชัด)
7 จอแสดงผล(ไม่แตกคมชัด)
8 สกรูล็อก(ปรับหมุนสะดวก)
9 สติกเ๊ กอร(ไม่หลุดลอก
์ )
10 ่ี อนนไำปใช้
ควำมเทยงตรงก่

่ ชค็
พนักงำนหรือเจำหน้ำที
้ ตรวจเ
APPROVED CHECKED ISSUED หมำยเหตุ: 35
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(5) Manage material /process defect
No.19: Identification of NG or suspect NG part
No. Evaluation item Check point Criteria
1) Material / process defect Rule/Operation procedure
- Identification of NG or 2) Defect area Identification defect area (Ex. Red,Yellow boxes)
19 suspect NG part
3) Problem record NG problem record

4) Action C/M There is status of countermeasure

2) Identification defect area

1) Rule/Operation procedure
(Ex. Red,Yellow boxes)

สีเหลือง สาหรับชิน
้ งาน
สีแดง สาหรับชิน
้ งาน NG
ที่รอการตรวจสอบ
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(5) Manage material /process defect
No.19: Identification of NG or suspect NG part
No. Evaluation item Check point Criteria
1) Material / process defect Rule/Operation procedure
- Identification of NG or 2) Defect area Identification defect area (Ex. Red,Yellow boxes)
19 suspect NG part
3) Problem record NG problem record

4) Action C/M There is status of countermeasure

4) There is status of countermeasure

3) NG problem record
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(6) Stock Control (Including logistics)
No.20: FIFO (First in First out)
No. Evaluation item Check point Criteria
1) Materials store Have enough area by confirm with Max-Min stock control

2) WIP (Work in process) Keep in STD(Quantity)

20 - FIFO (First in First out)
3) FG store Have enough area by confirm with Max-Min stock control
4) Logistic routing Logistic flow is not complicate (TP Route)

1) Have Factory
enough Mat’l store Process (WIP) FG store
area by
confirm
with
Logistic Logistic 4) Logistic flow
Max-Min
Stock is not complicate
control M/C#1 M/C#2 M/C#3 3) Have
enough
area by
confirm
with
Max-Min
Stock
control

Keep the STD

Keep the STD

2) Keep in STD
Step2 - C : Establish a structure for preventing defect outflow
to following process CONFIDENTIAL
C-(7) Manage Quality of supply chain
No.21: Incoming part/component inspection
No. Evaluation item Check point Criteria

- Incoming part/ 1) Part inspection standard/WI/EIS There is inspection standard of each part
21
component inspection
2) Inspection result Data updated = Frequency on inspection standard

Factory

Receiving

1) There is inspection standard of each part 2) Data updated = Frequency on inspection standard
Step2 - C : Establish a structure for preventing defects
outflow to following processes CONFIDENTIAL
C-(7) Manage Quality of supply chain.
No.22 : Conduct Evaluation system & Status monitoring for sub-supplier
No. Evaluation item Check point Criteria
1) Supplier Evaluation There is evaluation criteria for all supplier
-Conduct Evaluation system &
2) Result visualization Easy to get data and know status
22 Status monitoring for sub-
supplier 3) Problem investigation Supplier problem report
4) Audit plan and audit result There are plan for audit supplier and result

1) There is evaluation criteria for all supplier 3) Supplier problem report

Supplier car

Supplier investigate root cause and take countermeasure

2) Easy to get data and know status 4) There are plan for audit supplier and result

Supplier Claim Result ลำดับ

(No.)
Supplier Part / Model Problem Progress Mth.
Supplier audit plan 2018
Jun Jul
Year2018
Aug Sep Oct
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
ผูรับผิดชอบ
้
(PIC)
Day
Tensioner
YDK3 12-Jun-18 Plan
Yamaha Motor Parts Manufacturing Follow up defect of Year 2018 (
1 Sudarat
(Thailand) Co., Ltd. Tensioner NCR & Debit note )
YD25 12-Jun-18 Actual

Follow up countermeasure 16-Jul-18 Plan

Tensioner
2 A.I.Foundry&Manufacturing Co.,Ltd. problem Remain rough surface ( Sudarat
GDT1
Customer claim ) 16-Jul-18 Actual

Follow up problem position 0.8 15-Aug-19 Plan

3 Aapico Hitech Public Company Limited Guide P/B NR Pranda
over spec ( over spec customer ) 15-Aug-19 Actual
Follow up problem oxide and 17-Aug-19 Plan
4 C S P Casting (Thailand) Co.,Ltd Lever M/B Sudarat
perpendicular Actual
Guide P/B NR Follow up problem Distance over 5-Sep-18 Plan
5 Thai Ikeda Manufacturing Co., Ltd. Pranda
ZR spec 2.75 ±0.3 5-Sep-18 Actual
Follow up problem GDG3 Die 14-Sep-18 Plan
6 Aapico Hitech Public Company Limited Guide P/B GD Pranda
broken ( Can't delivery to TAT ) 14-Sep-18 Actual

Follow up countermeasure 17-Oct-18 Plan

Lever M/B
7 Thai Kikuwa Industries Co., Ltd. (TKI) problem Hole step ( Customer Sudarat
YD25
claim ) 17-Oct-18 Actual
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(1) Establish a quality information sharing system (inform to each Mfg.
concern process and visualize of information & countermeasure).
No.23 : Quality information sharing system
No. Evaluation item Check point Criteria
1) Conduct Asakai meeting Have meeting area
2) Quality information Share quality info. to all concern (Ex.Prod,MT,PC)
-Quality information sharing 3) KPIs control KPIs in meeting match with policy (Main,Sub,Process KPIs)
23
system
4) Problems analysis Easy to get data and know cause of problem
5) C/M status Display C/M status and follow up

1) Have meeting area 3) KPIs in meeting match with policy (Main,Sub,Process KPIs)

Management Control Board

Main KPI

Sub KPI

Process KPI

2) Share quality info. to all concern (Ex.Prod,MT,PC) Activity

Prod. QC

PC
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(1) Establish a quality information sharing system (inform to each Mfg.
concern process and visualize of information & countermeasure).
No.23 : Quality information sharing system
No. Evaluation item Check point Criteria
1) Conduct Asakai meeting Have meeting area
2) Quality information Share quality info. to all concern (Ex.Prod,MT,PC)
-Quality information sharing 3) KPIs control KPIs in meeting match with policy (Main,Sub,Process KPIs)
23
system
4) Problems analysis Easy to get data and know cause of problem
5) C/M status Display C/M status and follow up

4) Easy to get data and know cause of problem

Problem Description Investigation timeline Root cause / Audit/
Yokoten
Customer claim (Receiving) Tracking Countermeasure FMEA
review

5) Display C/M status and

follow up
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(2) Take early action and countermeasure against defects detected
at quality gate (E.g. Quickly feedback).
No.24 : Investigation sheet submission
No. Evaluation item Check point Criteria
-Investigation sheet
24 1) QC tools (e-QIS : PIRR & defect claim) 100% completed replied C/M on time
submission.

Base on e-QIS reply

1)100% completed replied C/M on time

43
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(2) Take early action and countermeasure against defects detected
at quality gate (E.g. Quickly feedback).
No.25 : Traceability
No. Evaluation item Check point Criteria
1) Traceability rule Rule/Operation procedure
25 Traceability
2) Traceability method Can traceability on part or Tag

1) Rule/Operation procedure 2) Traceability method

Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(3) Sustain fundamental skill (how to confirm skill of team member,
refresh skill).
No.26 : OP skill refreshment (concern production operation)
No. Evaluation item Check point Criteria
1) Skill refreshment Clarify the skill that need to refreshment
26 OP skill refreshment 2) Evaluation test method Evaluation criteria & record
3) Refreshment training plan Have plan to refreshment OP skill

1) Clarify the skill that need to refreshment Skill maintain การร ักษาสภาพทักษะ

1. Ready to work พร้อมทางาน 3. Sustain sensory

- Daily health check ตรวจสอบสุขภาพประจาว ัน ร ักษาทักษะการส ัมผัส
2. Keep STDW scan
ทาตามมาตรฐาน Q - Skill refreshment
ทวนสอบท ักษะ
Skip item ข้ามขัน
้ ตอน Skip area ข้ามบางพื้นที่
Skip
Appearance Assembly Fitting
Check

Inspection time Wrong method

เวลาตรวจสอบ ผิดวิธีการ

X O สิง่ ภายนอก
- Defect simulation
การประกอบ การเข้ารูป
Appropriate time : 10 sec
ของเสียปลอม
5sec 10 sec

X
Wrong sequence
O แค่มอง
Visual only มองและส ัมผัtouch
Visual and ส
X O
ผิดลาดับ

X O
 Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(3) Sustain fundamental skill (how to confirm skill of team member,
refresh skill).
No.26 : OP skill refreshment (concern production operation)
No. Evaluation item Check point Criteria
1) Skill refreshment Clarify the skill that need to refreshment
26 OP skill refreshment 2) Evaluation test method Evaluation criteria & record
3) Refreshment training plan Have plan to refreshment OP skill

2) Evaluation criteria & record

spection
Can remember : Std. Memory Paper test / Interview STEP# 5
Memorize >80%
Sequence Follow up 100% Follow up by Controller
STEP# 4
RK
Can do : Checking operation Motion Follow up >95 % (Crrent takt time)

ACTICE OJT Time Within current takt time

1. Standardize work follow up
OB ELEMENT
Correct
Actual judgement
working @ TT.>>
1.0Sensory calibration 100%
- STW Follow up

ACTICE OJT >> Defect knowledge

mim (on line training) - 10 Time checking & Eva
OB ELEMENT 1. Standardize working 2. Reliability test Eva
# Judgement point & Sensory testing # Monitoring Board
2. Quality 3. Sonsory test check Eva
# Paper
G IN THE test (Work Seq.) # Motion & Time Accuracy check & Tuning by Controller Everyday
CESS - Judgement for acceptance 4. Refreshment skill Eva
G IN THE
CESS (NEW STEP # 3 or rejection
- Sensory inspection
5. Rotation plan

IN PROCESS Theory & Practical working - Prevention

for current takt time 3. Health & Safety
1. Theory & Practical training in 4. Inspection / Measuring device

#23) Have plan to refreshment OP skill

class room
2. Job training outside
Observationof
5. Maintenance
(Controller)
equipment
bytools
Supervisors
and

ng @ Takt time inspection line for getting - STDW follow

6. Information up 100%
/ communication Follow up & Evaluation
orking more process skills in - 10 Time checking & Eva
On line training
elements which will be - Reliability test Eva
r acceptance in the inspection - Sensory test check Eva
process at TT. 1.0 min. - Refreshment skill Eva
ction 2. Experiment working at - Rotation plan
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(4) (4) Standardized Work management by Supervisors (Controller).
No.27 : Confirm work operation of supervisors in order to keep STDW
No. Evaluation item Check point Criteria
1) Leader role Identification leader role
-Confirm work operation of
2) Training plan Have training plan
27 supervisors in order to keep
STDW 3) Evaluation method There is evaluation and result
4) Skill matrix Display leader skill

1) Identification leader role 3) There is evaluation and result for leader

Evaiuation for SV,FR,LL,AL Central Plant
เกณฑ์การให้คะแนน -
สรุปผลรวมทั้งหมด
ASSY 1 ASSY 2
WEEK 1
ลาดับ หัวขอในการตรวจเช็
้ ค EL1 SMALL LHD VENZA R1A T-BAS DOOR
1.ลงหัวขอการต่
้ อกะครบถวนหรื
้ อไม่
1. การต่อกะ 2.ยอดการผล ิตต ิดบวก-ลบครบหรือไม่
3.มีของเสีย อธิบายรายละเอีย ด-สาเหตุการเกด
ิ หรือไม่
สรุปผลคะแนนการตรวจเช็ค

1.แจงยอดการผล
้ ิต ผลต ิดบวก-ลบ
2. การประชุมเชา้ 2.นาชนงานมาแจ
ิ้ งพนั
้ กงานกรณี มข
ี องเสีย
3.แจงข่
้ าวสารทั่ วไป
สรุปผลคะแนนการตรวจเช็ค
2) Training plan for leader การควบคุมจุด 1.ต ิดTag Henkaten จุดทีเ
่ ปลีย
่ นหรือไม่
3. เปลีย
่ นแปลง 2.ผูกผาพั
้ นคอหรือไม่
แผนการตรวจเช็ค 3.ลงขอมู
้ ลเอกสารบอร์ดหนาไลน์
้ ครบหรือไม่
หัวขอการการตรวจเช็
้ ค
สรุปผลคะแนนการตรวจเช็ค
6. การตรวจสอบเครือ่ งมือ -เครือ่ งจัก ร

4) Display leader skill

3. การควบคุมจุดเปลีย่ นแปลง

11.การฝึ กอบรมพนั กงานใหม่

8. การควบคุมยอดการผลิต

การควบคุม 1.การตอบเอกสาร IPD ส่งตามกาหนดหรือไม่

10. การควบคุมสิง่ ผิดปกติ

LINE
12. การชีแ้ นะการทางาน
ั งิ านตามกฏ
4. การควบคุมคุณภาพ

5. การจัดการของเสีย

4. คุณภาพ 2.ตอบปั ญหาลงในสมุดชมพูครบถวนหรื

้ อไม่
2. การประชุมเช ้า

REMARK
9. การทา 5 ส
7. การปฏิบต
1. การต่อกะ

3.การลงกราฟDefect ครบถวนหรื
้ อไม่
WEEK สรุปผลคะแนนการตรวจเช็ค
มิถุนายน กันยายน ธันวาคม
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 การจัดการ 1.ตรวจเช็คการลงสมุดชมพูกับใบ Fตรงกันหรือไม่
IMV R2D
5. ของเสีย 2.ตรวจเช็คใบ F ชมพูลงรายละเอีย ดครบหรือไม่
IMV H
EFC I/P RHD 3.ตอบปั ญหาการแกไขDefect
้ ในสมุดชมพูหรือไม่
EFC I/PLHD
HIACE สรุปผลคะแนนการตรวจเช็ค
050 A การตรวจสอบ 1.ตรวจเช็คใบเช็คชีททีบ
T-BAS ่ อร์ด Conveyorครบหรือไม่
640 WIRE SEAT 6. เครืองมื
่ อ/ 2.มีการขยั บหรือโยกทีห
่ ลักจิ๊กหรือไม่
884 A
EFC WIRE DOOR เครืองจั
่ กร 3.ตรวจเช็คการลงบันทึกการแจงซ่
้ อมครบหรือไม่
IMV EL1 สรุปผลคะแนนการตรวจเช็ค
IMV L2F
EFC SMALL WIRE ปฎิบัต ิงาน 1.ว ิธีก ารจับใส่เขย่ าดง
ึ ทีเ่ ครือ
่ งCPG,KENSAKถู ก ตองหรื
้ อ ไม่
EFC E/G RHD
EFC E/G LHD
640A LHD
640A RHD
7. ตามกฎ 2.LAYสายไฟเขาใน
้
่ ครูท
3.มีใ บพั กชัว
[ Leader Skill ]
่ C
F-RONหรือไม่
ี่ onveyorครบหรือไม่
สรุปผลคะแนนการตรวจเช็ค
Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(5) Leave management of Team Member and establish backup system
(develop multi-skill personnel).
No.28 : 4M change control (Man, M/C, Method, Material)
No. Evaluation item Check point Criteria

1) 4M control items Classify 4M control items

2) 4M Board/Assignment board
-4M change control (Man, 3) Visualization
28
M/C, Method, Material) 4) Changing point record
5) Countermeasure status
6) Skill visualization
Board control
Updated => know current condition
Recording changing point
Recording C/M of changing point
Can know skill of each operator

1) Classify 4M control items

2) 4M change control/Assignment board

3) Update changing point on board

Step3 - D : Sustain Standardized Work and skills CONFIDENTIAL
D-(5) Leave management of Team Member and establish backup system
(develop multi-skill personnel).
No.28 : 4M change control (Man, M/C, Method, Material)
No. Evaluation item Check point Criteria

1) 4M control items Classify 4M control items

2) 4M Board/Assignment board
-4M change control (Man, 3) Visualization
28
M/C, Method, Material) 4) Changing point record
5) Countermeasure status
6) Skill visualization
Board control
Updated => know current condition
Recording changing point
Recording C/M of changing point
Can know skill of each operator

4) Record of changing point 6) Skill visualization and Multi-skill development

TM multi skill development การพัฒนาทักษะหลากหลายด้านของ TM

49

5) Recording C/M of changing point

Process 6,7 need more back up skill

 Others CONFIDENTIAL
No.29 : Activity progress & result
Check point :
- Achievement of requirement : All activity progress on plan with good result
=> SSAS document submission on time (UPMS + AOMS)

AOMS -Available ASD, PML, UPMS -Complete audit with

TCA. (Unified Process Management Sheet) satisfied result.
(Audit Organization Management Sheet)
-Has change with plan

 Monthly evaluation submission (ESPI)

Submit before 10th of each month
 Others CONFIDENTIAL

No.30 : Strengthen Product chemical management

Check point :
1) All request chemical management activity was submitted on plan Ex. IMDS
submission , substance survey , chemical AA submission(E-SPI)
2) Overall chemical management score pass criteria based on chemical AA
submission(E-SPI)

51
Quality Shop Floor Management