18.1 Cost of Poor Quality

Cost of Poor Quality ( 2014-15 )
Month
Apr.,07
May.,07
Jun.,07
Jul.,07
Aug.,07
Sep.,07
Oct.,07
Nov.,07
Dec.,07
Jan.,08
Feb.,08
Mar.,08
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Feb.,08
Mar.,08
Dispatch Value
Cost Of Poor
Quality
COPQ % of sales
Cost of Poor Quality Trend ( 2007~08 )
% of sales
12.00
10.00
8.00
6.00
4.00
2.00
0.00
Apr.,07
May.,07
Jun.,07
Jul.,07
Aug.,07
Sep.,07
Month
Prepared By :-
Oct.,07
Nov.,07
Dec.,07
Jan.,08
Prepared By :-
Cost of Poor Quality

Apr.,07
May.,07
Jun.,07
Jul.,07
Aug.,07
Sep.,07
Oct.,07
Nov.,07
Dec.,07
Jan.,08
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Inhouse Rejection
Value
Customer Returned
Rejection value
(including
transportation and any
penalty by customer)
Inhouse Rework value
(part replaced+reprocessing
cost+manpower cost)
Rework cost at
customer end (if any)
Travelling Cost for
review and analysis
Cost of Poor Quallity
Dispatch Value
COPQ % of sales
Feb.,08
Mar.,08
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Sr. No.
Indicator
Data
Source
Metric
Base
Line
Goal
5S Score
Supplier
32%
60%
Customer Quality PPM

(Talbros)
Tallbros
PPM
1000
Customer Quality PPM

(Overall customer)
Supplier
PPM
4356
2178
Supplier in house PPMQuality (scrap+ Rework)
Supplier
PPM
7054
3527
Breakdown
Supplier
Hrs/month
72
30
Productivity
Supplier
Sale/Salary
13.89
14.4
Inventory Turns
Supplier
Turns
12.37
13.6
Delivery schedule
adherence (Overall)
Supplier
97.9
97.9
Accident frequency rate /

MONTH
Supplier
Nos./ Month
10
Mfg Excellence Score

(Quarterly)
QGS Audit
36%
60%
11
No. of QW Kaizens
Supplier
Nos./ Month
16
12
Visual Management
QGS Audit
Level
13
Vendor Performance
rating-QHT
Talbros
14
Delivery PerformanceQHT
Talbros
15-Apr 15-May 15-Jun
15-Jul
15-Aug 15-Sep
15-Oct 15-Nov 15-Dec 16-Jan
32%
32%
32%
32%
32%
32%
32%
32%
32%
32%
364
6857
9671
5523
12934
7580
199
98
272
758
431
3434
504.199
1457
2050
555
368
1855
546
5462
4398
5477
3695.3
1245
1852
1996
2700
3101
3677
96.5
139.5
219.4
170
170
155
166
149
159
62
14.6
15.8
15.7
14.3
15.8
15.9
12.7
13.7
12.2
15.23
17.35
32.28
9.3
11.78
22.6
12.8
20
18
107
98
108
96
91
97
95
88
88
100
36%
36%
36%
36%
36%
36%
36%
36%
36%
36%
100
52
100
89
100
99
87
90
96
100
90
100
87
100
100
98
89
73
93
86
16-Feb 16-Mar
16-Apr
44%
44%
44%
156
248
185
723
543
458
3254
3165
2956
78
49
120
11.7
11.9
12.35
13.5
15.8
12.1
99
100
100
44%
44%
44%
99
100
76
100
% SCORE
A MJ JuA S ON D J F MApr'16
5# # # # # # # # # # # # #
Ta# # # # # # # # # # # # #
PPM
Target
5'S Score
70%
PPM
Target
60%
50%
40%
PPM
Target
30%
20%
10%
0%
Apr'1 May' Jun'1 Jul'15 Aug' Sep' Oct'1 Nov' Dec' Jan'1 Feb'1 Mar' Apr'1
5
15 5
15 15 5
15 15 6
6
16 6
Customer Quality PPM (Talbros)

PPM
14000
12934
12000
9671
10000
8000
7580
6857
5523
6000
4000
2000364
199
98
272
248
185
0
5
15 5
15 15 5
15 15 6
6
16 6
Axis Title
Customer Quality PPM (Overall customer)

4000
3434
3500
3000
2050
2500
1855
2000
1457
1500
758
555
546
543 458
1000
504.199
431
368
500
0
5
15 5
15 15 5
15 15 6
6
16 6
Apr'15
May'15
Jun'15
Jul'15
Aug'15
Sep'15
Oct'15
Nov'15
Dec'15
Jan'16
Feb'16
364
6857
9671
5523
12934
7580
199
98
272
156
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
Apr'15
May'15
Jun'15
Jul'15
Aug'15
Sep'15
Oct'15
Nov'15
Dec'15
Jan'16
Feb'16
758
431
3434
504.199
1457
2050
555
368
1855
546
723
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
Apr'15
May'15
Jun'15
Jul'15
Aug'15
Sep'15
Oct'15
Nov'15
Dec'15
Jan'16
Feb'16
5462
4398
5477
3695.3
1245
1852
1996
2700
3101
3677
3254
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
Apr'16
248
185
1000
1000
Mar'16
Apr'16
543
458
1000
1000
Mar'16
Apr'16
3165
2956
1000
1000
Supplier in house PPM-Quality

AxisTitle
Mar'16
6000
5000
4000
3000
2000
1000
0
5477
5462
4398
3695.3
1245
1852 1996
2700
MONTH
3101
3677
3165 2956
(scrap+ Rework)
scrap+ Rework)

18.1 Cost of Poor Quality

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18.1 Cost of Poor Quality

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Cost of Poor Quality ( 2014-15 )

Cost of Poor Quality Trend ( 2007~08 )

Cost of Poor Quality

Customer Quality PPM

Customer Quality PPM

Supplier in house PPMQuality (scrap+ Rework)

Accident frequency rate /

Mfg Excellence Score

15-Apr 15-May 15-Jun

15-Oct 15-Nov 15-Dec 16-Jan

Customer Quality PPM (Talbros)

Customer Quality PPM (Overall customer)

Supplier in house PPM-Quality

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