Contact Us
Please feel free to contact us via the form below.
Loading...
KAIZEN at a Thai manufacturing site that can be achieved by introducing
31/03/2022
Nobuhiro OishiManaging Director
LINE QC SPECIALIST, "a comprehensive monitoring and management system for preventing the production of defective products in the process," which I have explained several times. In this system, software monitors and manages operation procedures, equipment (machines), and measuring instruments so that products are always manufactured within the specifications (within mass production standards) and safely in accordance with in-house manufacturing rules.
This time, I will explain what you can understand from analyzing the data obtained by actually introducing LINE QC SPECIALIST , and that by analyzing the data, what specific improvements can be made at sites.
① In the process of the production line, we sorted all the products at the points where defective products could occur, but the process capability was higher than expected. Assuming that there is an outflow of defective products, it is most likely that the product is not from a normal process, but from a "temporary interim placement" or a setup product during machine adjustment.
The necessary action is not to sort all the products, but to thoroughly manage the setup product quality control at the start of mass production.
② Analysis of machine setup by LINE QC SPECIALIST revealed that the process capability of the same machine can vary significantly depending on the difference between the workers performing the setup. The difference in process capability became clear not only by the setup but also by the frequency of performing detailed adjustment work. By using this index from LINE QC SPECIALIST, the accuracy of the machine itself and the degree of effort of each worker can be visualized. (It can also be used for employee salary assessment)
③ Regarding certain parts such as the runout accuracy of the machine itself, if the holders and inserts used is corrected, the accuracy may increase dramatically. Where should it be corrected? LINE QC SPECIALIST can acquire data that can determine this.
④ Since the production line has different capabilities in each process, the measurement frequency should be determined according to each process capability, but many companies measure at a uniform frequency. By using LINE QC SPECIALIST to reduce unnecessary and excessive frequency of measurements, productivity can be improved.
If the measurement frequency for each measurement point is changed, one of the concerns is forgetting to measure. LINE QC SPECALIST also performs measurement frequency management by system, so it gives out alerts if the measurement frequency is changed or if the worker forgets to do the measuring. Since the system manages the required measurements, you can rest assured that the required measurement frequency according to the process capability is managed.
KAIZEN by LINE QC SPECIALIST data analysis report [Specific example]
*This report can be downloaded as PDF data from following link LINE QC SPECIALIST
The process capability varies depending on the coordinator of the manufacturing machine and the method of fine adjustment during manufacturing. Let us refer to one worker as Mr. A and not disclose the real name for his honor. Mr.A and Mr.NOPPORN are in the exact same section and are responsible for 5 machines of exactly the same type.
The analysis data of LINE QC SPECIALIST is set so that the cell turns yellow as a warning when the process capability of the finished product does not reach CP/CPK 1.0. The machines that Mr. A is in charge of had 5 yellow cells (Fig. 1), and the machines that Mr. NOPPORN is in charge of had 2 yellow cells (Fig. 2). The data clearly show that the quality is better when Mr. NOPPORN adjusts the machines.
▲ Figure 1—A: In the case of Mr. A
▲ Figure 1-B: In the case of Mr. A
▲ Figure 2-A: In the case of Mr. NOPPORN
▲ Figure 2-B: In the case of Mr. NOPPORN
If the conditions are not the same, it yields a mis-judgement, but if the conditions are exactly the same, evaluation of employees can be done at the same time while performing quality control. It is possible to train Mr. A on how to do it and how to improve the process capability while showing him the data.
▲ Figure 3: In the case of MACHINE NO.7
▲ Figure 4: In the case of MACHINE NO.25
The above two sheets (Fig. 3 and Fig. 4) summarize the process capability by each machine. MACHINE No. 7 is in poor condition and there are six places where CP.CPK does not reach 1.0. On the other hand, MACHINE No.25 has only one place under the same conditions. Where to draw a line based on process capability is up to each company and determined by the process capability of each company's facilities, etc.
If the same product is handled by the same worker under the same conditions, the accuracy and accuracy difference of the machines can be compared. In addition, by analyzing the place where the process capability is low, it is possible to judge the place of "It becomes such data because this place has a problem". It can be used for machine maintenance priority, repair location priority, machine use, non-use judgment, changing point management, and others.
▲ Figure 5: Summary
Figure 5 is summary of the analytical data.
■ If one month's worth of data can be obtained and aggregated/analyzed, various issues will be observed. By solving theses issues one by one, quality improvement can be done continuously.
■ When something happens, long-term data (rather than small lot data) can be used to determine if the equipment/tools are bad.
■By distinguishing a cause of an issue between workers and management-related problems, the speed of improvement can be increased
This LINE QC SPECIALIST will be a great support as a mechanism to prevent (no production of) defective products while actually manufacturing products on the production line. I am convinced that this system can produce even greater effects by utilizing the vast amount of data acquired over a long period of time and connecting it to quality improvement after the work is completed. One of the Nano Precision Group companies, "FORTUNE CROSS", will actually utilize LINE QC SPECIALIST to improve process capability. Please come visit FORTUNE CROSS at any time.
