Documente Academic
Documente Profesional
Documente Cultură
SUPPLIER Thai Kansai Paint Co., Ltd LOCATION Samutprakarn Thailand SUPPLIER ATTENDEEDS H. Nagaoka san, M. Minami san, M. Miyazaki san, H. Noguchi san, K. Yamashita san, KP (Japan) : A.Tsuge san, H. Sanada san RESULTS ITEMS
A : RAW MATERIAL
PRODUCT Paints DATE August 03. 2005 9:00-17:00 TOYOTA ATTENDEES TMT-QA : Siriluck P san, Songwit K san Chutinat N san TMC-QCD : M. Sugiura
POINTS(%) 55/60 (92) 56/65 (93) 56/60 (93) 167/180 (92.7) 135/155 (86) 138/160 (86) 125/155 (80.6)
COMMENTS Please carry out personal computer control as planned. Two or three stacking of the palette of raw material is not good.
Songwit
AVG.(%) C : INSPECTION PROCESS
D : EDUCATION
TOTAL
Should leave the record of manufacturing abnormalities. Management in a transition figure of equipment conditions. The description to batch ticket is required in the loading actual weight measurement of raw material. 398/470 (85.6) The exit of finished product warehouse is opening. Furthermore, please carry out the reduction activities of cratering. 44/50 (88) Need the reduction of paint variation of color inspection panel. 46/50 (92) Trend control of inspection date of finished products is required. 48/50 (96) It is by waterborn paint introduction about reinforcement of 138/150 temperature/humidity control of spray booth. (92) Consider introduction of colormeter CM-512m3 (under TMC use). 23/25 (92) In order to improve color adjustment technology, please consider training by KP (Japan). 24/25 (96) 25/25 (100) 72/75 (96) 36/40 (90) The quality check in initial control period needs to be substantial. 34/40 (85) 36/40 (90) 106/120 881/995 (88.5)
ORIENTATION of IMPROVEMENT 1) More visual control and fool-proof required. (batch ticket, R.M. PC control) 2) Trend control (Manufacturing abnormalities, equipment conditions, finished products date) 3) Prevention of dusts and comtamination (R.M and finished product warehouse) 4) Enrichment of equipment (spray booth temp./humidity control, colormeter) 5) Improved quality (cratering, spray variation of color panel) NEXT FOLLOW SCHEDULE Periodical follow of improvement activities towards new paint introduction (1time/half a year). TARGET and ACTUAL RESULT 100 90 80 70 60 50
88.5
Target
85%
03/08/05
A. RAW MATERIAL
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3
Although it talks with a supplier and being decided, there is no inspection standard.
0
With no standard
It talks with a supplier and The maintenance situation manages by the inspection of a raw-material receiving standard.
inspection standard
50% or more of real Less than 50% of real Only supplier data check Nothing inspection ratios inspection ratios It is actually inspecting 100%. Since the transportation of an import (Japan) in Thailand is not good, getting wet with water, breken, etc. are checked. There is data as regulation It is kept although it is not With no storage
Data is kept as regulation. Storage and management and it is arranged well. as regulation. of raw-material receiving inspection record It is kept for every kind of raw material. It manages with Lot No. Keeping during four years. It is acting as the regular Tendency management is monitor by original not performed but a cause Only judgment of management width as is investigated at the time abnormalities tendency management. of abnormalities. Tendency control is carried out in graph every day. Tendency control is requested also from a Japanese raw-material maker (local maker is made). The check method is There is regulation, it It is not carried out indefinite, although there It carries out, when carries out periodically and periodically, although there is regulation and being necessity arises. the check method is clear. is regulation. carried out periodically.
Nothing
There are a plan and a actually record. Last year 28 maker enforcement. Self-valuation is also made a supplier in advance. The shelf life after All raw materials prescribe The rule of disposal is not Only specific raw material manufacturing is specified the term of validity after stipulated although there is specified. Expiration Nothing to all raw materials. delivery. Expiration are some which are disposal stipulates. Expiration disposal disposal stipulates. specified. stipulates. The shelf life after 100% manufacture prescribes. Expiration is a prior check 15 days ago. Expiration indicates by a yellow card and moves to somewhere else. Reexamination O.K. is the extension of term of the first half. There is a disposal rule and recurrence prevention is also carried out. Recurrence prevention is inadequate although there is a disposal rule. Nothing
Regulation of the shelf life of raw material Regulation of the disposal rule of expiration
Acceptance
- 1/12 -
(A-2/13)
A. RAW MATERIAL
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0
It is the storage which took It is the storage which took into consideration into consideration Although an improvement preventing of rain water and preventing rain water and Rain water and mixing of a required is considered, it is mixing of a foreign mixing of a foreign foreign substance is not the level which a substance to material substance to material anxious. problem produces. packing bag etc. A storage packing bag etc. A storage place is clean. place is disorderly. Two or three stacking of the palette of raw material is not good. There is a problem quality sides, such as a tear of a paper bag, 4S is carried out every day and is OK. It is good to have shown regulation of entering in the photograph of the cleaning at warehousing. A brand display and a Although division and an classification display are Although division and an indication are given, they With no division and no precision and the state indication are given, they are visually display where it is made orderly are disorderly. incomprehensible. and a mistake cannot happen easily. It manages on the board in a warehouse. It is manual control (it is not personal computer control) now. A storage place is distinguished on a floor (3rd floor : raw material of FIFO, 2nd floor: pigments and a part of resin, 1st floor : resin). Those with fool-proof by an automatic reading system. The directions document in a place, and the check of raw material. It is extraction by memory of a worker.
10
The double-check in an extraction check and two tags (green & orange). Those with a system, it carries out. It does not carry out, although there is a system. With no system
11
First-out materiala are kept on the 3rd floor. It checks by two persons. It is better to display by first-out card.
12
Distinction of under uninspecting and inspection, an acceptable product, and rejected goods of raw material (a space, display, etc.).
It is the system which is not mixed from clarification of a space, and a display.
Those with a possibility that it will be mixed if a worker is not careful, Mixture or indefiniteness although it is distinguishable once. After inspection OK, green seals stick (paper bag : every palette, a drum and a can : every can).During inspection, drums and cans keep in an outer temporary tent to a temporary space, paper bags keep in a temporary space in a warehouse. Rejected goods display a red card and move to somewhere else.
- 2/12 -
(A-3/13)
B. MANUFACTURING PROCESS
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
A picture and a photograph are used, and the point is clear and intelligible.
3
The contents are complicated although a settlement is good.
1
Inadequate in the contents of directions, although it is. Nothing
Working instruction sheets using a picture or a photograph is each process and according to equipment.
A rule is clear and is kept. There is the change column. It is put up for the position which is easy to view.
With no rule
It is not notified.
Near is notified for every process. However, a part is in the distant place for a while. A instruction sheet and recognition suit and are observed. It is not observeed although a instruction sheet and recognition are correct. Recognition differs from a instruction sheet and is not observed.
A worker and an engineer create working instruction shhet together. It is intelligible and there is the check column (there is With no check column, nothing and good, if there although it is intelligible. is a check sheet The contents of batch ticket independently). There is no description of the tolerance of the loading amount (additive agents : 1%, others : 2%). There is the double-check column of loading raw material. The double-check by the Only a person's in charge person in charge and a check Last check method of batch supevisor
Batch tickt
With no check
The definition of abnormalities and who do The contents of the unusual what, or it is a judgment etc. and is intelligible. disposal instruction sheet
Although the definition of abnormalities and who do what or there is judgment etc., its contents is complicated.
The definition of abnormalities is not detailed. There are its displays at plant. - 3/12 -
(B-4/13)
B. MANUFACTURING PROCESS
No * A B Unusual disposal instruction sheet Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
An unusual disposal person is decided and it is educated about a definition and the disposal method of abnormalities.
3
Education is inadequate although the unusual disposal person is decided.
0
With no setup of an unusual disposal person.
Abnormality manual prescribes. Judgment is production engineer. An item and the contents
Past record management of are clear and the past record is left behind. unusual generating
It has not left the record. A change factor is grasped and it is reflected to conditions.
The past record is not left behind although an item and the contents are clear.
An item and the contents are indefinite and a past record is also nothing.
10
Since equipment differs from Japan, it carries out uniquely. It is recorded on a check sheet and the required item is managed in the numerical value or the graph.
11
12
There is a rule and the Correspondence at the time record which is carrying out the quality identification of equipment condition based on it is also kept.
With no rule
change
13
Cleaning of equipment, daily and a scheduled inspection, and record Loading process
There is no standard.
It carries out every three months using a check sheet. Record is kept for three years. Automatic reading, record, the system by two or more more persons to doublecheck Description of survey data, With description of survey With no record only with a the double-check by one data, and no doublecheck person check
14
Although it is a double-check by two persons, it is not description of an actual weight measurement. Note: * Mark (Check place) A;Office B; Work-site - 4/12 -
(B-5/13)
B. MANUFACTURING PROCESS
No * A B Check item State of a loading and a measurement place Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Only a required quantity has a required thing.
3
There is every one time and a little complicated.
0
It is complicated and may makes a mistake.
15
Loading process
16
Prevention correspondence of mixing the foreign substance and dust at the time of a raw-material loading. Washing of a raw-material loading container and a measurement can Incorrect filling prevention at a filling (canned) process.
17
The process which the measure against mixing a The process depending Those with mixing on a worker's foreign subsutance was possibility consciousness made and was anxious about mixing. A tank washes regulation. Lids are four division (loading side). Cleaning at the time of carrying into a factory from a warehouse is carried out. Piping is not nitrogen gas washing. There is a instruction sheet It is not kept although there There is also no instruction and it is kept. is a instruction sheet. sheet and it is dirty. There is a privention instruction sheet of mixing a foreign subsutance and it carries out at the process. The exclusive plastic cup is used and it is thrown away. However, there is no instruction sheet. The double-check by the fool-proof system and a worker. The check by a worker With no check by a worker
18
Filling process
Tank No is entered in the tag of green. There is a tank No also in a batch ticket. Although there are There is no prevention prevention corresondences corresondence of mixing of mixing the foreign the foreign substance and substance and contamination contamination, it is inadequate. Oscillating sieve + filter filtration is carried out. The entrance slot is covered with the poly sheet. All cans are washed. Further examination of covering filled up space. A place is decided and the A place is decided and the display (product No, display (product No, A place is unknown, 4S product name, address, product name, address, state is bad. quantity) is clarified, 4S quantity) is indefinite, 4S state is good. state is somewhat bad. Those with prevention correspondence of mixing the foreign substance and contamination An exit is an open state. The 2nd floor is covered with the poly sheet. A kind and classification are control on a board.
19
Prevention of mixing the foreign substance and contamination at a filling (canned) process.
20
21
Distinction of under unThose with a possibility that inspecting and inspection, It is the system which is it will be mixed if a worker not mixed from clarification an acceptable product, and is not careful, although it is rejected goods of finished of a space, and a display. distinguishable once. product (a space, display, After Inspection O.K. it is filled. Rejected goods move to another warehouse. etc.).
- 5/12 -
Mixture or indefiniteness
(B-6/13)
B. MANUFACTURING PROCESS
No * A B Finished product Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Those with a system, it carries out.
3
It does not carry out, although there is a system.
0
With no system
22
A warehouse keeps only one lot. Personal computer control. A green card (first-out) is displayed. A cleaning schedule is decided and 4S state is good. A zone person in charge is set up and carried out. Although the cleaning schedule is decided, 4S state is inadequate.
4S state is bad.
23
24
The deployment situation to It is developed. the manufacturing process of manufacturing quality chart.
It is not developed.
25
There is no standard.
26
With no view
Although there is no notice of an important process, the common important item of each process is put up on a board. A check item is clear and carries out using a check sheet. It is carried out although the check item is indefinite.
27
28
Improvement target of product quality (Inside of a manufacturing process, inspection process, following process).
Paint residue reduction activities are carried out (target: 0.8mg/16kg, results: 0.4-0.5mg/16kg).
(B-7/13)
B. MANUFACTURING PROCESS
No * A B Manufacturing process whole Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0
29
The true cause is pursued and it is coped with including whether correspondence with a Correspondence at the time design post and Production Engineering of fault generating post is required.
Their related posts, such as technical, are put in and examined. Tendency management is performed and an acceptance result is reflected. With no reflection of tendency management and an acceptance result
N.A.
30
Others
31
Only the present process control (4S, electrostatic dress wear, etc.)
Paint residue reduction activities are carried out (target: 0.8mg/16kg, results: 0.4-0.5mg/16kg). Improvement matter: SUS-izing of a tank, a glove is changed into rubber from cotton, a palette is changed into resin from a wood, A bag filter is changed into a Cuno filter. Those with a measure towards outflow prevention. Those with a positive measure also to Although there is a measure towards outflow prevention, the cause investigation at the time of
32
Measure to cratering
The cratering check of each process and submaterials is carried out. Note: * Mark (Check place) A;Office B; Work-site
- 7/12 -
(B-8/13)
C. INSPECTION PROCESS
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
There is the shelf life and it
3
With no periodical maintenance, although there is the shelf life.
0
Those with apparatus in which the shelf life went out.
Physical-properties inspection
With no control
The temperature and humidity of a testing laboratory is controlled by 20+-2 degree C and 65+-10%RH (the width of humidity is somewhat large). It is by waterborn paint introduction about reinforcement of temperature/humidity control of spray booth. A picture and a photograph are used, and the point is clear and The contents are complicated although a settlement is good. Inadequate in the contents Nothing of directions, although it is.
Not entry of only a number but those of O.K. and NG with judgment.
With no sheet
Directions method of the spray conditions of color panel for color inspection
A body is REA auto and a bumper is hand air. Need the reduction of paint variation of color inspection panel. It is carried out in the decided environment and is visible like the Although carried out in the decided environment, it is not visible like the With no regulation about environment
Colormeter uses CR-300 and Exrite RH68. Please consider introduction of colormeter CM-512m3 (under TMC use). Color inspection and color arrangement check is carried out in the same Although color inspection and color arrangement check is different Environment of color inspection and color arrangement check is
Note: * Mark (Check place) A;Office B; Work-site The system whose correspondence can perform tendency management about a control item, and is possible before becoming a problem.
- 8/12 -
It is not utilizing.
(C-9/13)
ers
C. INSPECTION PROCESS
8
No
* A B
Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0
There is a system which can be prevented rightly (unless it is O.K., neither Outflow prevention of under the following process shift inspection or an inspection nor shipment can be NG product performed).
Others
10
With no regulation
- 9/12 -
(C-10/13)
D. EDUCATION
No * A B Check item Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5
Each one of educational plans are made and it is obligation about periodical attendance.
3
Participation is judgment of an individual although the educational opportunity is carried out periodically.
0
An educational plan is nothing. A lecture is taken at worker's hope.
Each one of attendance lists of all are fixed, and an educational plan is promoted along with this.
With no practical use, although each one of attendance lists of all are fixed.
Worker education
The education which includes a reason (why is the work necessity?) at the time of education was performed, and the degreeof-comprehension-up is aimed at.
QC education is considered as all staff indispensable education, and is carried out. Please carry out QC education to all the staff. There is a system checked for every step. It cannot step up without O.K. of a supervisor.
Although education is carrying out, the check for Only educational every step is un-carrying implementation out (only in case of the last check).
5 rnks estimate. Only two persons require a B rank level by color adjustment. In order to improve color adjustment technology, please consider training by KP (Japan). Note: * Mark (Check place) A;Office B; Work-site - 10/12 -
(D-11/13)
3
It uses, when the necessity that the persons concerned are correspondence comes out.
0
Existence of SQAM is not known.
SQAM relation
In addition to the inspection data which Toyota is demanding, Item specially carried out to there is a check item an initial stage control independently carried out period. within a process, and the period is also clear. Three lots are carrying out FMEA examination. It is specified by letter, and the contents are also concrete and it is easy to understand them.
Although there is regulation, it is not enough grasped even to a business person in charge.
There is no regulation.
There are a point of the quality identification for every process, frequency, The contents of manufacturing quality chart record, etc., and it is intelligible. Technical posts enters and creates. It is specified by letter and information deployment is carried out at its required post timely.
System
Recurrence prevention, widespread implementation, the structure and enforcement situation that carries out and follows up prevention before it happens.
There is a mechanism in which a left item is carried out and it carries out certainly.
Although there is no structure, recurrence prevention is certainly carried out at the time of problem generating.
There is no structure and There is no structure and recurrence prevention is recurrence prevention etc. also the dependence on a is not carried out. person in charge.
- 11/12 Although there is regulation, it is not enough grasped even to a business person in charge. There is no regulation.
Conditions of jurisdiction change to the manufacture from the trial production of a new product.
It is specified by letter, and the contents are also concrete and it is easy to understand them.
(E-12/13)
tem
* B A
Conditions of jurisdiction Check item change to the manufacture from the trial production of a new product.
Marks (the blank without a comment presupposes that a setup is possible by discretion of a marker) 5 4 3 1 0
Three lots are checked by Cross Functional Team. There is a system carried out periodically. There is There is a system carried actual results carried out out periodically. along with it this year also. Although there is no system carried out periodically, there is actual It is to carry out if needed. It is not carrying out. results in the current fiscal year.
System
It carries out twice per year periodically. It is late for a plan for a while, and it will carry out next manth this year. There is a measure by a quality control group etc. and it is reported periodically. Although there is a measure by a quality control group etc., there is little enforcement.
With no measure
- 12/12 -
(E-13/13)