7 Langkah Analisa Pencegahan Defect

7 langkah Analisa Pencegahan Defect
7 LANGKAH QUALITY MAINTENANCE | SCOPE OF

THE DOCUMENT
Semua issue quality harus diselesaikan dengan alat yang tepat.

Berikut adalah 7 langkah of Quality maintenance dan Processing Point Analysis (PPA).
4M ANALYSIS
MATERIAL METHOD MAN MACHINE
7 langkahS OF PROBLEM SOLVING 7 langkahS OF Q MAINT.
 X - MATRIX
 TWTTP / HERCA
 QUICK KAIZEN  QUICK KAIZEN
 Quality maintenance -
 STANDARD KAIZEN  STANDARD KAIZEN
 QUICK KAIZEN MATRIX
 INCOMING MATERIAL  OPL  STANDARD KAIZEN
 MAJOR KAIZEN
 TRAINING
CONTROL (8 STAGES)  SOP
 POKA YOKE / ERROR  ADVANCED KAIZEN
PROOFING
 PPA
 OPL
 VISUAL AIDS  DOE / TAGUCHI
5 QUESTIONS FOR ZERO DEFECT
2
7 LANGKAH OF QUALITY MAINTENANCE | DECISION
PROCESS
Untuk issue terkait mesin, 7 langkah of Quality Maintenance adalah alat yang dipilih.
4M ANALYSIS
MACHINE MAN, METHOD, MATERIAL

7 langkahS OF QUALITY MAINTENANCE
langkah 1 PS langkah 1
7 langkahS OF PROBLEM SOLVING

*Defect PS langkah 3
N Y
Eliminated PS langkah 4
Langkah 3 langkah4 PS langkah 5
langkah 5
7 PPA langkah
Improvement N 5QF0D
N Improvement N 5QF0D
not sustainable >80% not sustainable >80%
Y Y
OK OK
*in SPC: Cpk >= 1.33
3
7 LANGKAH OF QUALITY MAINTENANCE |
CHARATERISTICS & PERFORMANCE
Prinsip utama 7 langkah of Quality Maintenance, memindahkan inspeksi produk menjadi inspeksi proses dan
mesin.
Kunci utama : pemahaman bagaimana masing masing komponen mesin berperan dalam proses.
E
PL
AM
Performance Sub Elements Characteristics

EX
Holes in Tea Bags Paper Filter Paper Strength Mesh Density
Paper Thickness
Thread Thread Strength Thread Thickness
Welding Welding Strength Surface Interation
Welding Deepness
4
7 LANGKAH QUALITY MAINTENANCE | GATE
CHECK
2 Hal yang harus di cek sebelum melakukan 7 langkah Quality Maintenance
CHECK!
Pastikan masalah memang dari MACHINE 

Phenomena Masalah sudah jelas  critical
Lanjutkan ke 7 langkah quality maintenance
Salah mendefinsikan fenomena

Salah dalam mengambil tindak lanjut
5
7 LANGKAH OF QUALITY MAINTENANCE
7 langkahs Quality Maintenance

MACHINE
Qualit
y A
mainte Improve conditions for Zero defects
Improve conditions for Zero defects Proactive
nance
Qualit
7 A
y
mainte Maintain
Maintain conditions
conditions for
for Zero
Zero defect
defect
nance
Qualit Preventive
6 C
y
Establish conditions for Zero defect
mainte Establish conditions for Zero defect
nance
Qualit
5 D
y Reduce & eliminate all causes of
mainte Reduce & eliminate all causes of
0
chronic Defects
nance chronic Defects
*If Defect =
Qualit
4 P
y
mainte Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects
nance
Qualit
3 D Reactive
y
mainte Restore abnormal conditions
Restore abnormal conditions
nance
Qualit
2
y P
mainte Understand current situation
Understand current situation
nance
1
6
7 LANGKAH OF QUALITY MAINTENANCE | PURPOSE
AND RELEVANT TOOLS
7 langkahs of Quality Maintenance

PURPOSE & RELEVANT TOOLS
MACHINE
Qualit
y A
Efficient time saving checking of the optimal conditions [Trend
timal Cond.
Improve conditions for Zero defects Proactive
checking, evolution of 5Q for 0 Defects]
nance
Qualit
7 A
y
Carrying daily inspection and scheduled inspection into effect
mainte Maintain
Maintain conditions
conditions for
for Zero
Zero defect
defect
Establish Op
based on the inspection standard sheet [Quality maintenance
nance
Qualit matrix] Preventive
6 C
y Establishment of the inspection standard sheet by taking proper
mainte Establish
Establish conditions
conditions for
for Zero
Zero defect
defect inspection items into consideration [X Matrix]
nance
Qualit
5 D
y Reduce & eliminate all causes of Restoration of the equipment based on the PPA [Checking of
is
mainte Reduce & eliminate all causes of
Cond. Analys
0
chronic
chronic Defects
Defects results by the PPA]
*If Defect =
nance
Qualit
4 P
y
mainte Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects Factor analysis of unknown causes [Process Point Analysis]
nance
Qualit
3 D Reactive
y
Restore equipment to proper working conditions for unknown
.
Current Cond
Restore abnormal conditions
nance
causes
Qualit
2
y P
Clarify relationship among Quality characteristics, equipment &
Understand current situation
nance operation method [e.g. QA Matrix, 5W1H, 5G]
1
7
7 LANGKAH OF QUALITY MAINTENANCE | WITH 7
LANGKAHS OF PPA & TOOLS
7 langkahs of Quality Maintenance

7 langkahs of Processing Point Analysis Tools
MACHINE
Qualit
y A A
5Q
5Q for
for zero
zero
Improve conditions for Zero defects PPA7 Improve conditions for 0 Defects
Improve conditions for 0 Defects defect Proactive
nance
defect
Qualit
7
y A A Quality
Quality
mainte Maintain
Maintain conditions
conditions for
for Zero
Zero defect
defect PPA6 Maintain
Maintain conditions
conditions for
for 00 defect
defect maintenance
maintenance
nance Matrix
Matrix
Qualit Preventive
6 C C
y Details check and control and check Check
Establish conditions for Zero defect
mainte Establish conditions for Zero defect PPA5
Details check and control and check Check Sheets
Sheets
matrix
matrix XX Matrix
Matrix
nance
Qualit
5 D D
y Reduce & eliminate all causes of Analyze
mainte Reduce & eliminate all causes of PPA4
Analyze function
function and
and related
related 66 Factor
Factor
Analysis
0
chronic
chronic Defects
Defects controls
controls Analysis
*If Defect =
nance
Qualit
4 P P
y
Brain
Brain Mapping
Mapping
mainte Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects PPA3 List
List system
system and
and subsystem
subsystem Diagram
Diagram
nance
Qualit
3 D P
Reactive
y
List
List process
process points
points and
and evaluate
evaluate Process
Process Point
Point
Restore abnormal conditions PPA2
nance
operative standards
operative standards Standards
Standards
Qualit
2
y P P
Trends,
Trends, Deep
Deep
Understand current situation PPA1 Analyse data
Analyse data Phenomenon
Phenomenon
nance
1
8
7 LANGKAH OF PPA | WITH TOOLS
7 langkahs of Processing Point Analysis Tools
A
5Q
5Q for
for zero
zero
PPA7 Improve
Improve conditions
conditions for
for 00 Defects
Defects defect Proactive
defect
A Quality
Quality
PPA6 Maintain
Maintain conditions
conditions for
for 00 defect
defect maintenance
maintenance
Matrix
Matrix
Preventive
C
Details
Details check
check and
and control
control and
and check
check Check
Check Sheets
Sheets
PPA5 X
matrix
matrix X Matrix
Matrix
D
Analyze
Analyze function
function and
and related
related 66 Factor
Factor
PPA4 Analysis
controls
controls Analysis
P
Brain
Brain Mapping
Mapping
PPA3 List
List system
system and
and subsystem
subsystem Diagram
Diagram
P
Reactive
List process points and evaluate Process
Process Point
PPA2 List process points and evaluate Point
operative
operative standards
standards Standards
Standards
P
Trends,
Trends, Deep
Deep
PPA1 Analyse
Analyse data
data Phenomenon
Phenomenon
9
P
Quality maintenance1 Understand

Understand Current
Current Situation
Situation
Quality maintenance PPA langkah

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1
 Objective and Target

Cakupan:  Process and Examples
 lDiagnostic Check
QUALITY MAINTENANCE LANGKAH 1 | UNDERSTAND CURRENT
SITUATION
langkah 1 DIAGNOSTIC CHECKLIST
Quality maintenance langkah 1 Diagnostic Checklist …
CHECK!
Used QA Matrix/PFMEA for Project selection  Established Project Plan with milestones 
Highlighted Problem clearly with sketches  Identified Phenomena using 5W1H with 5G 
Established Project tracking KPI  Used technical tools like High Speed Camera 
Established Target on Project tracking KPI  Used Sketches to explain Phenomena 
Assembled diverse Team with AM/PM & QC  Identified link Q characteristics & Operation 
Accessed team skills and displayed  NEXT: Go to Quality maintenance langkah 2
11
P
Quality maintenance2 Restore

Restore abnormal
abnormal conditions
conditions
PPA langkah
Quality maintenance langkah 7
7
PPA langkah
6
PPA langkah
5
PPA langkah
4
PPA langkah
3
PPA langkah
2
PPA langkah
1
 Objective and langkah Expectations

Covers:  Process and Examples
 langkah Diagnostic Check
QUALITY MAINTENANCE LANGKAH 2 | RESTORE ABNORMAL
CONDITIONS
WHAT
LangkahIF2DEFECT ELIMINATEDsemua pada standard yang ada.
adalah mengembalikan
Jika dengan proses pengembalian ini, defect bias dihilangkan (minimal 3 bulan), atau Cpk is >=1.33,
lanjutkan ke langkah 5
Jika defect masih ditemukan setelah langkah 2, lakukan Point Analysis (PPA).
4M ANALYSIS
MACHINE



7 langkahS OF QUALITY
N Y
*Defect Eliminated Lanjutkan
MAINTENANCE
QM S3 QM S4 Quality maintenance langkah 5 Quality maintenance langkah 5 …

7 PPA langkah Quality maintenance langkah 6
N Y
Improvement 5QF0D
not sustainable >80%
Y
STOP
13
QUALITY MAINTENANCE LANGKAH 2 | RESTORE
ABNORMAL CONDITIONS (RAC)
Quality Quality Quality Quality Quality Quality Quality
WHAT IF DEFECT IS NOT ELIMINATED
maintenance maintenance maintenance maintenance maintenance maintenance maintenance
langkah 1 langkah 2 langkah 3 langkah 4 langkah 5 langkah 6 langkah 7
If after Quality maintenance langkah 2 problem/Defect is eliminated or Cpk is >=1.33 Go to Quality
maintenance langkah 5 Directly.
If after Quality maintenance langkah 2 problem/Defect is NOT eliminated then open Point Analysis (PPA).
4M ANALYSIS
MACHINE
7 langkahS OF QUALITY MAINTENANCE
Quality
maintenance
Quality1 

langkah
maintenance
langkah 2
 N *Defect
Eliminated
Y
Move to PPA …
Quality Quality
mainten mainten Quality
ance S3 langkahs
ance S4 maintenance
7 PPA Quality
langkah 5
maintenance
Quality
langkah 6
maintenance
langkah 7
Improvement N 5QF0D
N
not sustainable >80%
Y
STOP
14
QUALITY MAINTENANCE LANGKAH 2 | RESTORE ABNORMAL
CONDITIONS (RAC)
langkah DIAGNOSTIC CHECKLIST
Quality maintenance langkah 2 Diagnostic Checklist …
CHECK!
Phenomena is well understood by the team  Developed Before and After pictures 
RAC on Lack of parameters & Maintenance  Check result on KPI Chart after RAC 
RAC on Unstable parameters  Applied Decision Process to go to PPA or not 
NEXT Go to Quality maintenance langkah 3 (In case
RAC on m/c improper/wrong parameters  Defect  0)
RAC = Restore Abnormal Conditions
15
P P
Quality Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects PPA1 Analyse
Analyse Data
Data
maintenance3

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 3 | FACTOR ANAYSIS OF CHRONIC
DEFECTS
Quality maintenance langkah 3 (PPA langkah 1) Diagnostic Checklist …
CHECK!
Defect Not eliminated after Restoration  Problem is of Chronic nature 

Team has right skill set for PPA methodology  New data analysed in depth 
NEXT Go to Quality maintenance langkah 3 (PPA langkah 2)
17
P P
Quality List
List process
process points
points and
and evaluate
evaluate
Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects PPA2
operative
maintenance3 operative standards
standards

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 3 | FACTOR
ANAYSIS OF CHRONIC DEFECTS
CHECK!
Process Point identified and sketched  Process Point Operating Principle identified 
Sketch showing Process Point Operation  Process Point Operating Standards identified 
NEXT Go to Quality maintenance langkah 3 (PPA langkah 3)
19
P P
Quality Factor
Factor analysis
analysis of
of chronic
chronic Defects
Defects PPA3 List
List system
system and
and subsystem
subsystem
maintenance3

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 3 | FACTOR
ANAYSIS OF CHRONIC DEFECTS
CHECK!
System(s) and Sub System(s) identified  Closed Sub system involved in transformation 
NEXT Go to Quality maintenance langkah 4 (PPA
Followed correct Sequence (Sys-Sub Sys-PP)  langkah 4)
21
D D
Quality Reduce
Reduce && eliminate
eliminate all
all causes
causes of
of Analyze
Analyze function
function and
and related
related
PPA4
maintenance4 chronic Defects
chronic Defects controls
controls

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 4 | ELIMINATE
CAUSES OF CHRONIC DEFECTS
langkah DAIGNOSTIC CHECKLIST
CHECK!
6 Factor sheet for all Systems & Sub Systems  Sketches and Drawings used 
NEXT Go to Quality maintenance langkah 5 (PPA
Noted all FUNCTIONAL deviations  langkah 5)
23
C C
Details
Details check
check and
and control
control and
and check
check
Quality Establish
Establish conditions
conditions for
for Zero
Zero defect
defect PPA5
matrix
maintenance5 matrix

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 5 | ESTABLISH
CONDITIONS FOR ZERO DEFECT
langkah
langkahDAIGNOSTIC
PPAQuality 1 langkah 2CHECLIST
PPAQuality PPAQuality
langkah 3 PPAQuality
langkah 7
maintenance maintenance maintenance maintenance maintenance maintenance maintenance
langkah 1 langkah 2 langkah 3 langkah 4 langkah 5 langkah 6 langkah 7
CHECK!
Evaluated Detailed checks and Controls  Linked System/Sub System components 

Countermeasure taken against each NOK  All relevant parameters linked 
Know Why for each NOK condition  X Matrix available on time with easy access 
Inspection/Control matrix developed  Line crew understands X Matrix in full 
NEXT: Go to Quality maintenance langkah 6 (PPA
Sketches used defects and Phenomena  langkah 6)
25
A A
Quality
Maintain
Maintain conditions
conditions for
for Zero
Zero defect
defect PPA6 Maintain
Maintain conditions
conditions for
for 00 defect
defect
maintenance6

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 6 |
MAINTAIN CONDITIONS FOR ZERO DEFECT
CHECK!
Quality maintenance Matrix is developed  Responsibilities assigned for Checks 

AM/PM teams are trained on Quality maintenance
Visuals are used on Quality maintenance Matrix  Matrix 
Parameters are coming from X Matrix  AM/PM Checklists updated respectively 
Checks are established to guarantee 0 Defect  Machine ledger updated respectively 
NEXT: Go to Quality maintenance langkah 7 (PPA langkah 7)
27
A A
Quality Improve
Improve conditions
conditions for
for Zero
Zero defects
defects PPA7 Improve
Improve conditions
conditions for
for 00 Defects
Defects
maintenance7

langkah 7 7
langkah 6 6
langkah 5 5
langkah 4 4
langkah 3 3
langkah 2 2
langkah 1 1

QUALITY MAINTENANCE LANGKAH 7 |
IMPROVE CONDITIONS FOR ZERO DEFECT
CHECK!
Applied 5 Q for Zero Defect (Machine)  B/C Ratio Calculated 

Applied 5QF0D at every Sub System (Process)  Evaluated Skills Radar Chart of Team 
Checked 5QF0D improvement after Actions  Overall Project Methodology Complaint 
KPI Results achieved (Defect = 0/Cpk >=1.33)  Communicated results & updated QA Matrix 
NEXT: CELEBRATE!
29

7 Langkah Analisa Pencegahan Defect

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7 langkah Analisa Pencegahan Defect

7 LANGKAH QUALITY MAINTENANCE | SCOPE OF

Semua issue quality harus diselesaikan dengan alat yang tepat.

MATERIAL METHOD MAN MACHINE

7 langkahS OF PROBLEM SOLVING 7 langkahS OF Q MAINT.

5 QUESTIONS FOR ZERO DEFECT

MACHINE MAN, METHOD, MATERIAL

7 langkahS OF PROBLEM SOLVING

*in SPC: Cpk >= 1.33

Performance Sub Elements Characteristics

Holes in Tea Bags Paper Filter Paper Strength Mesh Density

Thread Thread Strength Thread Thickness

Welding Welding Strength Surface Interation

2 Hal yang harus di cek sebelum melakukan 7 langkah Quality Maintenance

Pastikan masalah memang dari MACHINE 

Salah mendefinsikan fenomena

7 langkahs Quality Maintenance

*in SPC: Cpk >= 1.33

7 langkahs of Quality Maintenance

*in SPC: Cpk >= 1.33

7 langkahs of Quality Maintenance

*in SPC: Cpk >= 1.33

7 langkahs of Processing Point Analysis Tools

Quality maintenance1 Understand

Quality maintenance PPA langkah

 Objective and Target

langkah 1 DIAGNOSTIC CHECKLIST

Quality maintenance langkah 1 Diagnostic Checklist …

Quality maintenance2 Restore

 Objective and langkah Expectations

QM S3 QM S4 Quality maintenance langkah 5 Quality maintenance langkah 5 …

*in SPC: Cpk >= 1.33

*in SPC: Cpk >= 1.33

Quality maintenance langkah 2 Diagnostic Checklist …

RAC = Restore Abnormal Conditions

Quality maintenance PPA langkah

 Objective and langkah Expectations

langkah DIAGNOSTIC CHECKLIST

Quality maintenance langkah 3 (PPA langkah 1) Diagnostic Checklist …

Defect Not eliminated after Restoration  Problem is of Chronic nature 

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 3 (PPA langkah 2) Diagnostic Checklist …

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 3 (PPA langkah 3) Diagnostic Checklist …

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 4 (PPA langkah 4) Diagnostic Checklist …

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 5 (PPA langkah 5) Diagnostic Checklist …

Evaluated Detailed checks and Controls  Linked System/Sub System components 

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 6 (PPA langkah 6) Diagnostic Checklist …

Quality maintenance Matrix is developed  Responsibilities assigned for Checks 

Quality maintenance PPA langkah

 Objective and langkah Expectations

Quality maintenance langkah 7 (PPA langkah 7) Diagnostic Checklist …

Applied 5 Q for Zero Defect (Machine)  B/C Ratio Calculated 

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