8 STEP QUALITY CONTROL Plan 1 Defining quality

8 STEP QUALITY CONTROL Plan 1. Defining quality problem 2. Determining causes of problem 3. Identifying major causes 4. Design improvement Plan Do 5. Conduct improvement Check 6. Check improvement result 7. Create standardization Action 8. Defining next problem 1 / 16

POSSIBLE PROBLEMS ELECTED • Behind output target • repair • Reprocess, • Reshipment, • Recheck • Machine damage • Unclear or difficult work instruction • Unqualified input or raw material • Excessive inventory • Sudden work 2 / 16

QUALITY CONTROL TECHNIQUE/TOOL • • • FLOWCHART 7 QUALITY CONTROL TOOL 7 MANAGEMENT TOOL STATISTICAL PROCESS CONTROL (SPC) VALUE ANALYSIS/VALUE ENGINEERING (VA/VE) • MULTIVARIATE ANALYSIS • DESIGN OF EXPERIMENT 3 / 16

Sample of Flow chart Mother Board Production process Incoming Material - PCB &- Component Fail QC Pass Return to Vendor A Auto Insertion Fail QC repair Pass Manual Insertion Fail QC repair Pass Board yang by pass auto test Solder & Cleaning Fail QC repair Fail Auto Test Repairman Pass Send Pass Touch Up QC Fail repair Pass A 4 / 16

7 QUALITY CONTROL TOOL 1. Checklist 2. Stratification 3. Graph and Map Control UCL LCL 4. Pareto Diagram 5. Cause-Effect Diagram 6. Histogram 7. Scatter diagram 5 / 16

Sample of Data sheet for Defect/ product failure detect Product Name : Number checked : Notification : Unit Name : Period : Factory Name : Department/Section : Collector : SUM TYPE OF DEFECT SUB TOTAL GORESAN //// //// // 32 RETAK //// /// 23 GELEMBUNG 48 KELENGKAPAN //// //// //// LAIN-LAIN //// Total NUMBER OF PRODUCT REJECTED 4 8 115 86 6 / 16

Sample of Stratification : 7 / 16

Sample of Pareto Diagram Masalah MOUNT 14" Period 13 -19 Des. 1996 134 120 75% 100 60 Percentage 54% 80 31% 40 20 Lain-lain (11 items) Eve/Flare Crack Heater/Alu mina B/G Crack 0 Heater Suporter Frequency 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 85% Category 8 / 16

Sample of Line Chart of IST defect 250 200 150 TEW 100 TEW 1 MIB 50 31 28 24 21 18 15 12 1/9 1/6 1/3 0 January 1997 9 / 16

Sample of Bar Chart Menunjukkan berapa tinggi masing-masing bagian, relatif terhadap yang lain. Sumbu datar dapat berupa kategori atau waktu. 10 / 16

Contoh Grafik Lingkaran Explain the amount of each section compared to others 11 / 16

Sample of cause-effect diagram Analisa : Hasil ketik Banyak Salah - 25 Feb. 1997 Dibuat oleh : Tim A, VCR. MANUSIA KEAHLIAN LOTUS METODA BEBERAPA VERSI KONDISI FISIK WS 4 SAKIT BAHASA ASING PROGRAM KOMPUTER KESUNGGU HAN PEMAHAMAN BID. KERJA MENGETIK SYMPHONI YANG MENGETIK KETELITIAN SUASANA HATI WAKTU PEMBUAT NASKAH PAGI SIANG WAKTU PROGRAM MALAM RUANGAN BISING SANTAI MUSIK DEKORASI SUASANA TEGANG LINGKUNGAN MESIN KETIK UKURAN HASIL KETIKAN BANYAK SALAH TULISAN MANUAL LISTRIK SUHU SORE SIBUK DIKETIK ORANG LAIN KETELITI AN KERTAS DISKET MANUAL NON LISTRIK SALAH TIDAK JELAS PROGRAM KENA VIRUS KONSEP KOMPUTER BANYAK RUSAK MATERIAL INGGRIS INDONESIA PERANCIS JERMAN BAHASA 12 / 16

Sample of Histogram 13 / 16

Scatter Diagram • DEFINITION : A graph to show relationship between two variable • BENEFIT: Ê Identify the correlation of two variables, and the significance of it Ë To determine the relationship found in cause-effect diagram 14 / 16

Sample of 7 tool : Scatter Diagram 15 / 16

7 MANAGEMENT TOOLS 1. Interrelationship Diagram 2. Affinity Diagram or KJ Method 3. Tree Diagram / Systematic Diagram 4. Matrix Diagram 5. Prioritization Matrices 6. Process Decision Program Chart (PDPC) 7. . Arrow Diagram / Activity Network Diagram 16 / 16