6TOOL GUIDE 21st. Feb. 2004 100 PPM India Pvt Ltd 1. 6TOOL ? 100 PPM QUALITY PROCESS OS&D* Sequential Inspection Main Process Control Time Check Quality Audit Review Meeting 1 2 3 4 5 6 Perfect Check System Cultivating Team Skill Implement 6TOOL *OS&D : Over, Shortage & Defect 100 PPM 2. 6TOOL-1 / OS&D Activity A system to improve quality ponents found defective by monitoring , analyzing & acting on actual real time data & material supplied by suppliers. OS&D Image Establish full inspection system Establish quality information system - Real information system . Real data . Real material - Computerized OS&D management Establish vendor appraisal system - Quality contract (agreement of target quality) - I&P System Innovation Flow *I&P : Incentive & Penalty FACTORY SUPPLIERS Improvement Activities Defect Found Real & Quick Information Improved Material Innovation Activities Attach tag after finding a defect on the line Place collection box for defectives in the line Collect rejection & analysis of same from IQC members Display rejection due to supplier Request for urgent delivery in exchange of total rejection. Supplier must receive real information and have improvement meeting (once/week) => Q-manager attend Receive improved material & follow-up 100 PPM 2. 6TOOL-1 / OS&D Activity (RULE) PRODUCTION PURCHASE IQC MATERIAL SUPPLIER Activities - Find defective parts -Attach tag . Supplier defect : Red . Transportation : Blue . Work defect : Yellow - Store defective parts - Issue OS&D NCR (once/day) - Provide additional parts in lieu of defected q’ty . Emergency delivery - Hold improvement M/T with supplier . Sunrise M/T - Collect the defective parts (once/day) - Analyze and evaluate the cause of rejection. . Classify the reason their types like internal work error or transportation or vendor - Record and manage current defect status and feed back - Display the defective parts - O