仕入先名 作成日2020年 6月 日

80期 品 質 改 善 計 画 書
承認 確認 作成
(2019年7月期～2020年6月期)

1．78期と79期品質クレーム推移＆対比（登録･発生･調査） ※異議受託になるまでカウントとして下さい。 2．78期と79期クレーム結果総括

【発生先別グラフ】

【総括】

3．79期クレーム詳細（2019年7月期～2020年6月期）
発生先 クレーム内容 責任場所(発生工程) 責任場所(流出工程) 発生原因 流出原因
№ 月度 管理№ 品番 発生対策 流出対策
区分 詳細名 重点不具合 その他 内外製 会社名 内外製 会社名 4M 詳細 4M 詳細

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24
25

26

27

28
4．反省・课题 5．課題及び弊社品質目標達成に向けた活動方針

6.改善計画/実績表
計画/実績
クレーム件数 対象(品番,工程)
№ 重点不具合 具体的取り組み(方策) 目標値 責任者 寄与度 ※別紙要 年 2020年 2021年 結果
月 7月 8月 9月 10月 11月 12月 1月 2月 3月 4月 5月 6月
計画
実績
計画
実績
計画
実績
計画
実績
流出累積目標
メーカークレームの流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
計画
実績
計画
実績
流出累積目標
重点不具合の流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
計画
実績
流出累積目標
重点不具合の流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
計画
実績
流出累積目標
重点不具合の流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
流出累積目標
不具合の流出クレーム目標と実績 流出累計実績
評価
計画
実績
計画
実績
流出累積目標
不具合の流出クレーム目標と実績 流出累計実績
評価
 Supplier Prepared on 2022. Oct
Approve Review Prepare

FY82 Quality Improvement Plan (2022.July～2023.June)

PT. Schlemmer
Automotive Indonesia Adnan K. Ruliyanto
Hermawan
Eko
Siswanto

ddd
1．FY81 to FY82 complaints progress & comparison (registration, occurrence, investigation) ※Cases without disputes 2． FY82 complaint results summary
3
FY81 Costumers Defect Type
Defect types Occurrence Causes Out-Flow Causes

2
Small Burr Short Shot
0.25 0.25 Others
0.25
1
YC-Parts Suply Unit YC-Niimi Plant Others Abnormality
0.5 0.5 0.5 0.5
Improper inspection methods
0.75
0
Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Bubble Dented
0.25 0.25
Period Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Total
FY81 0 0 0 0 0 0 0 0 0 0 0 0 0
FY82(Complaint) 0 0 0 0 0 0 0 2 1 0 1 4 Statistics of defect types Statistics of occurrence causes Statistics of out-flow causes
FY82(Information) 0 0 0 0 0 0 0 0 0 0 0 0 【Summary】 Statistics of customers
Improper management of abnormalities and others issue
Target 1 1 1 1 1 1 1 1 1 1 1 0 10 (such as material issue and mold lifetime) were causing to 1. Unreasonable inspection method and requirements lead to
The reported complaints 4 cases such as serious defect is the occurrence of defects
The complaints are informed by YC-Niimi Plant & YC- missing inspection;
short shot which is 1 case reported and 3 appearance
Parts Supply Unit 2. Wrong judgement of operators due to small burrs condition
defect were meets the requirement of the inspection instruction

3.2．FY81 complaint details（2021.July～2022.June）

Occurrence place Complaint content Responsible place (occurrence process) Responsible place (outflow process) Occurrence cause(s) Outflow cause(s)
№ Month Management № PN Occurrence countermeasure Outflow countermeasure
Detailed
Type
name
Major defects Other Inhouse & Outsourcing Company name Inhouse & Outsourcing Company name 4M Detail 4M Detail

10

11
 12

13

14

15

16

17

18

19

20

21

22

23

3.3．FY82 complaint details（2022.July～2023.June）

Occurrence place Complaint content Responsible place (occurrence process) Responsible place (outflow process) Occurrence cause(s) Outflow cause(s)
№ Month Management № PN Occurrence countermeasure Outflow countermeasure Defect Type
Detailed
Type
name
Major defects Other Inhouse & Outsourcing Company name Inhouse & Outsourcing Company name 4M Detail 4M Detail

Material PA66 D225-HA-PRET producing lot

of gas and residue or material debris plastic Inspector detect the ejector mark condition but
1. Optimize injection parameter setting.
debris from previous runs with plastics of lower misjugde the condition of the dented from 1. Train all inspectors on techniques;
YC-Niimi 2. Reducing the numbers of mold preventive
1 February, 2023 K-2302-006 7176-0920-50 矢崎工場
Plant - Dented 社内 Schlemmer Automotive Indonesia 社内 Schlemmer Automotive Indonesia Material melting point. This can cause degradation in
maintenance to ensure gas vent were not
Man ejector mark due to dented from ejector process 2. Include defect point into inspection
parts near the walls. The degraded plastics tend was not detailed include into inspection instruction
clogged.
to stick to the mold. This causes difficulty with instruction
part release from the mold

During production, when the machine alarmed

for abnormality, the on-duty group leader
checked the mold and found the gate was
1. Train the group leader on abnormality
clogged, so he cleared up the mold. However, The inspection procedure manual is difficult to
handling process. 1. Revision of inspection instruction and
YC-Part when he was about to clean the mold, he put the understand (requires detailed instructions for
2 February, 2023 K-2302-013 7171-6335-30 矢崎工場
Supply Unit
ショートショット Short-Shot 社内 Schlemmer Automotive Indonesia 社内 Schlemmer Automotive Indonesia Man
defective parts on the workbench; after
2. Reduce cushion machine automatic Method each procedure, such as the order and parts of
include customer compliant.
supervision tolerance to prevent material 2. Re-training of inspection workers.
cleaning, he forgot to place the defective parts the inspection)
clogged during production.
into the NG part bin, so the defective parts were
mixed in the carton box of good parts and thus
flowed to the next process for final inspection.

The material produces a lot of residue and gas

Reducing the numbers of mold preventive The inspection instruction was not specifically 1. Revision of work instruction and include
YC-Niimi which results in the presence of gas and residue
3 March, 2023 K-2303-045 7276-2032-5W 矢崎工場
Plant
- Bubble 社内 Schlemmer Automotive Indonesia 社内 Schlemmer Automotive Indonesia Material
produced from the processed material causing
maintenance from 10,000 shot to 5,000 shot to Method on mentioning the detail of the bubble condition customer compliant.
ensure gas vent were not clogged and lead to misjudge from inspector 2. Re-training of inspection workers.
gas vent clogged

1. Add point check to inspection instruction

mentioning no hairline condition in entire
In production process we found the flashing surface in product
defect in product. The burrs was parting line 2. Retraining inspection instruction for
1. Update working instruction Mold Inspection worker noticed the hairline condition
burrs due to mold wear.We do optimize the inspection worker & QC patrol
maintenance instruction instruction - Injection but did not mention as abnormality issue due to
parameter injection condition to avoid putting 3. Refresh training abnormality handling
to Adding monitoring entire mold condition inspection instruction did not mention hairline
YC-Part too much pressure on the parting line. After problem to all worker to inform if found new
4 May, 2023 K-2305-033 7171-6334-30 矢崎工場
Supply Unit
- Small Burs 社内 Schlemmer Automotive Indonesia 社内 Schlemmer Automotive Indonesia Machine
changing the parameter condition, string
check when mold accumulation shots near 80% Man problem and taught hairline problem there not
type of defect or potentially defect to superior
from mold lifetime history causing serious problem to the product
occurred from the sprue part of the runner. as mention as in working instruction
2. Adding specific point to check parting line and being mention in inspection instruction.
When the mold was opened after injection QNSLMZD-Z08 Annex 1 Process abnormality
condition every 50,000 shots
process, the thread of the string was left in the handling to injection worker
mold. 4. Creating work instructions for the sorting
process and including how to prevent the
hairline from falling back into the product.
4．Reflection / Subject 5．Subject and activity policy for achieving our quality goals
4M Reflection point Subject point
1. Zero outflow of major defects;
※ The detection ability of full inspection personnel for defect Quality goals 2. External complaints decreased by 45%
detection is high but when abnormality occur, personnel lack of ※ Group leader abnormality handling ability improvement; 3. 0 times of non-compliance with quality impact;
Man 4. 0 times of intentional test failure for inspectors;
sense of reporting; ※ Ability improvement of full inspection personnel;
※ Group Leader incompliance abnormality handling;

※ Improve the skills of equipment management personnel and injection

Machine ※ Lack of concern to mold that near lifetime usage;
molding shift leaders; 1.Defect occurrence subjects
（mold） ※ Insufficient mold maintenance capacity;
※ Increase the number of mold maintenance personnel;
※ Confirm the implementation effect of abnormality countermeasures every day;
※ Confirm the implementation and management of change points every day;
※Material were not stable, causing lot of gas and residue during
Material None
process;
2.Defect out-flow subjects
※ Inadequate preparation of inspection methods and inspection contents of inspection instructions;
Method ※ The inspection method in the inspection instruction is improper; ※ The product inspection method shall be confirmed at the operation site; 3.Common subjects
※ Improper management of internal abnormalities and change points
Management reflection point Management subject point 4.Occurrence activity policy
※ Organize manufacturing, quality assurance and development personnel to hold weekly quality meetings (review the past quality problems and this week's quality situation);
※ The inspection speed of workers is too fast; ※ The inspection instructions shall be reviewed by the related engineer after 5.Out-flow activity policy
※ Inspection instructions are unreasonable; being formulated; ※ Irregularly conduct intentional test on inspectors;
※ The inspection methods and contents of the inspection instructions are feasible and effective;
6.Common activity policy
※ Effectiveness of internal defect improvement

6.Improvement plan/performance table

Number of Plan/Actual
complaints Object (part number, process)
№ Key defect Specific countermeasures (strategies) Target value Person in charge Year 2022 2023 Result
Contribution ※Attach a separate sheet
degree Month Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun
Plan
Actual
Plan
Actual
Plan
Actual
1
Plan
Actual
Plan
Actual
Plan
Actual
Cum. Target
OEM Complaint Outflow Target and Actual Performance Cum. Actual
Evaluation
Plan
Actual
Plan
Actual
2
Plan
Actual
Plan
Actual
Cum. Target
Major Defects Outflow Target and Actual Performance Cum. Actual
Evaluation
Plan 0 0 0 0
Number of non-compliance by operators & Group Leader; Viviani All PNs; Injection process
Actual 0 0 0 0
Plan 0 0 0 0
3 Short shot Number of improper implementation of inspection method; 0 Hermawan 25% All PNs; Injection process
Actual 0 0 0 0
Plan
Actual
Cum. Target 0 0 0 0
Major Defects Outflow Target and Actual Performance Cum. Actual 0 0 0 0
Evaluation ○ ○ ○ ○
Plan
Actual
Plan
4
Actual
Plan
Actual
Cum. Target
Major Defects Outflow Target and Actual Performance Cum. Actual
Evaluation
Plan
Actual
Plan
Actual
5
Plan
Actual
Plan
Actual
Cum. Target 1 1 1 1
Defect Outflow Target and Actual Performance Cum. Actual 0 1 0 1
Evaluation ○ ○ ○
Plan 1 1 1 1
Number of non-compliance by operators & Group Leader; Viviani All PNs; All processes
Actual 0 1 0 1
Plan 1 1 1 1
Number of improper implementation of inspection method; Hermawan All PNs; All processes
Actual 0 1 0 1
6 Other 0 35%
Plan