University of Marconi - Milwaukee. Quality 101. May /10/2001 1

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Theodora Thomasine May
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1 Quality 101 University of Marconi - Milwaukee May /10/2001 1

2 What You Will Learn Today Why Quality is important How we calculate Defects Per Unit What is a defect? How defect data is captured Reports and charts available to help you pinpoint and fix problems. What I can do to improve quality. Hands on example 01/10/2001 2

3 Why Quality is Important If you have a positive experience with a product, how many people do you tell? What if that experience was negative? In the automotive industry a satisfied customer tells 8 to 10 people a dissatisfied customer tells 16 to 18 people Satisfied customers = repeat business and potential new business Dissatisfied customers = lost business and no new business 01/10/2001 3

4 Why Quality is Important Market research shows that companies with excellent quality Earn prices 8% higher than those with poorer quality. Averaged 30% return on investment (ROI) compared to 10% for a company with poorer quality Excellent quality does not always cost more because by doing things right the first time we reduce scrap, rework and warranty costs. Impacts productivity, line balance, on time delivery, costs 01/10/2001 4

5 Defects per Unit Total # of Defects Found # of Cabinets Inspected 01/10/2001 5

6 What s a Defect? Doesn t conform to our visual standard for painted surfaces M.10.IT1-13 Doesn t conform to our standard for unpainted surfaces M.10.IT1-14 Doesn t conform to our welding standard M.09.WT7.02 Doesn t conform to our assembly workmanship standard M.10.IT1-15 Doesn t pass a functional test Doesn t match the Manufacturing Instructions Doesn t match the drawing (dimensions, features) Doesn t match the Bill of Material 01/10/2001 6

7 How is Defect Information Captured? Successive Checks Production Inspection Final Quality Inspection All information is captured on the traveler or the audit form and recorded in a Microsoft Access database. 01/10/2001 7

8 Defect Reports and Charts Weekly DPU Defects by Station Defects by Category Defects by Specific Traveler Line Item Detail by shift, inspector, line item, station, assembler 01/10/2001 8

9 Weekly DPU MESA 1/2/2001 To 2/7/2001 DPU = 74 / 102 = '01 2 '01 3 '01 4 '01 5 '01 6 '01 Week Number 01/10/ DPU

10 Defects by Station MESA Defects by Station Week Number 01/10/ Defects

11 Defects by Category Week Ending: 2/10/2001 MESA Defect Category Paint 15 Missing 7 Mispositioned 3 Loose HDW 25 Inoperative 4 Incorrect 3 Appearance /10/

12 Defects by Traveler Line Item Station Number 3 MESA FROM: 1/1/2001 TO: 2/10/2001 Pareto of Number of Defects per Process ID Number of Defects Defects Traveler Line Item 01/10/

13 What I Can do to Improve Quality Verify the work from the previous operation prior to starting your work (Successive Checks). Report the defects you find on the traveler (don t just repair them). Use Manufacturing Instructions, routings and drawings. Keep your work area clean and organized (5S). Be a problem solver (PROFormance, Team Based Problem Solving). Verify your work prior to sending it on. Completely fill out the traveler so that you can receive feedback on the quality of your work. 01/10/

14 Detail Report Exercise Calculate DPU 15 Defects = 3.0 Defects per Unit 5 cabinets What are the two most common defects by defect code? Main chamber paint defects (4) Loose wind latch (4) 01/10/

15 Ser# Audit QA Prod Code Key Description Comments Shift Station Emp # JJ AB 2.1 P Main chamber inspected for paint and forming defects paint touch up 1 5 EM JJ AB 3.15 L Wind latches and hardware windlatch was loose 1 3 GR JJ AB 3.17 M Apply no-oxide to ground wires missing 1 3 GR RL DK 2.8 M Intrusion alarm brackets, switches bracket missing star washer 2 2 TR RL DK 3.15 L Wind latches and hardware windlatch was loose 2 3 SZ RL DK 3.17 A Apply no-oxide to ground wires excess 2 3 SZ RL DK 2.1 P Main chamber inspected for paint and forming defects paint touch up 2 5 GT RL DK 3.15 L Wind latches and hardware windlatch was loose 2 3 SZ RL DK 2.1 P Main chamber inspected for paint and forming defects paint touch up 2 5 GT RL DK 3.15 L Wind latches and hardware windlatch was loose 2 3 SZ RL DK 2.8 A Intrusion alarm brackets, switches bent bracket 2 2 TR JJ AB 2.1 P Main chamber inspected for paint and forming defects paint touch up 1 5 EM JJ AB 3.17 M Apply no-oxide to ground wires missing 1 3 GR JJ AB 4.5 M Inserts installed top & bottom of main frame missing silicon on the insert 1 1 NT JJ AB 2.29 L Screens are attached and tightened all screws were loose 1 2 EM 01/10/

NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).

NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM). SECTION 417-01: Exterior Lighting 2009 Mustang Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 05/23/2008 Reversing Lamps Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent Vehicle