TPM: Quality Maintenance (Hinshitsu Hozen) Poster

1. Quality Maintenance © Operational Excellence Consulting. All rights reserved. Quality Maintenance means figuring out the equipment conditions in which defects won’t occur, setting them up as the standards, monitoring and measuring actual equipment conditions over time, and confirming the actual conditions are within the standards. § Determine standard values for checks § Create Quality Maintenance matrix § Increase reliability of checks, simplify them, and reduce number of people involved § Revise materials standards, checking standards and work standards § Identify quality (“Q”) components so that standards are kept § Monitor trends and confirm results 8. Determine Standard Values for Checks & Revise Standards § Find ways to consolidate and fix the checking methods § Carry out improvements to make checking easier 7. Consolidate Checking Methods § Expose flaws in 4M conditions § Carry out restoration or improvements § Evaluate results § Establish 4M conditions that allow good product to be achieved 6. Eliminate Flaws in 4M Conditions and Finalize § Analyze situations where the conditions for building in quality are unclear § Establish defect causes § Optimize settings, processing conditions and setup procedures § Evaluate 5. Establish Conditions that Allow Good Products to be Achieved § Create deficiencies chart and identify countermeasures § Verify state of equipment and restore/improve it 4. Plan Action to Correct Deficiencies § Check quality standards and quality characteristics § Create a flow diagram of individual processes for building in quality § Investigate defect situation and stratify defect phenomena 1. Verify the Existing Situation § Draw up a Quality Assurance (QA) matrix § Investigate individual processes where defect modes occur 2. Investigate the Processes where Defects Occur § Investigate 4M conditions in each process. The 4Ms are: • Men/Women • Materials • Machines • Methods § Identify lapses in these conditions through on-site investigation 3. Identify & Analyze 4M Conditions Identify & Analyze 4M Conditions 3 Investigate the Processes where Defects Occur 2 Verify the Existing Situation 1 Plan Action to Correct Deficiencies 4 Consolidate Checking Methods 7 Eliminate Flaws in 4M Conditions and Finalize 6 Establish Conditions that Allow Good Products to be Achieved 5 Determine Standard Values for Checks & Revise Standards 8

2. Quality Maintenance © Operational Excellence Consulting. All rights reserved. Quality Maintenance means figuring out the equipment conditions in which defects won’t occur, setting them up as the standards, monitoring and measuring actual equipment conditions over time, and confirming the actual conditions are within the standards. § Determine standard values for checks § Create Quality Maintenance matrix § Increase reliability of checks, simplify them, and reduce number of people involved § Revise materials standards, checking standards and work standards § Identify quality (“Q”) components so that standards are kept § Monitor trends and confirm results 8. Determine Standard Values for Checks & Revise Standards § Find ways to consolidate and fix the checking methods § Carry out improvements to make checking easier 7. Consolidate Checking Methods § Expose flaws in 4M conditions § Carry out restoration or improvements § Evaluate results § Establish 4M conditions that allow good product to be achieved 6. Eliminate Flaws in 4M Conditions and Finalize § Analyze situations where the conditions for building in quality are unclear § Establish defect causes § Optimize settings, processing conditions and setup procedures § Evaluate 5. Establish Conditions that Allow Good Products to be Achieved § Create deficiencies chart and identify countermeasures § Verify state of equipment and restore/improve it 4. Plan Action to Correct Deficiencies § Check quality standards and quality characteristics § Create a flow diagram of individual processes for building in quality § Investigate defect situation and stratify defect phenomena 1. Verify the Existing Situation § Draw up a Quality Assurance (QA) matrix § Investigate individual processes where defect modes occur 2. Investigate the Processes where Defects Occur 3. Identify & Analyze 4M Conditions § Investigate 4M conditions in each process. The 4Ms are: • Men/Women • Materials • Machines • Methods § Identify lapses in these conditions through on-site investigation Identify & Analyze 4M Conditions 3 Investigate the Processes where Defects Occur 2 Verify the Existing Situation 1 Plan Action to Correct Deficiencies 4 Consolidate Checking Methods 7 Eliminate Flaws in 4M Conditions and Finalize 6 Establish Conditions that Allow Good Products to be Achieved 5 Determine Standard Values for Checks & Revise Standards 8

3. Quality Maintenance © Operational Excellence Consulting. All rights reserved. Quality Maintenance means figuring out the equipment conditions in which defects won’t occur, setting them up as the standards, monitoring and measuring actual equipment conditions over time, and confirming the actual conditions are within the standards. § Determine standard values for checks § Create Quality Maintenance matrix § Increase reliability of checks, simplify them, and reduce number of people involved § Revise materials standards, checking standards and work standards § Identify quality (“Q”) components so that standards are kept § Monitor trends and confirm results 8. Determine Standard Values for Checks & Revise Standards § Find ways to consolidate and fix the checking methods § Carry out improvements to make checking easier 7. Consolidate Checking Methods § Expose flaws in 4M conditions § Carry out restoration or improvements § Evaluate results § Establish 4M conditions that allow good product to be achieved 6. Eliminate Flaws in 4M Conditions and Finalize § Analyze situations where the conditions for building in quality are unclear § Establish defect causes § Optimize settings, processing conditions and setup procedures § Evaluate 5. Establish Conditions that Allow Good Products to be Achieved § Create deficiencies chart and identify countermeasures § Verify state of equipment and restore/improve it 4. Plan Action to Correct Deficiencies § Check quality standards and quality characteristics § Create a flow diagram of individual processes for building in quality § Investigate defect situation and stratify defect phenomena 1. Verify the Existing Situation § Draw up a Quality Assurance (QA) matrix § Investigate individual processes where defect modes occur 2. Investigate the Processes where Defects Occur 3. Identify & Analyze 4M Conditions Identify & Analyze 4M Conditions 3 Investigate the Processes where Defects Occur 2 Verify the Existing Situation 1 Plan Action to Correct Deficiencies 4 Consolidate Checking Methods 7 Eliminate Flaws in 4M Conditions and Finalize 6 Establish Conditions that Allow Good Products to be Achieved 5 Determine Standard Values for Checks & Revise Standards 8 § Investigate 4M conditions in each process. The 4Ms are: • Men/Women • Materials • Machines • Methods § Identify lapses in these conditions through on-site investigation

4. Quality Maintenance © Operational Excellence Consulting. All rights reserved. Quality Maintenance means figuring out the equipment conditions in which defects won’t occur, setting them up as the standards, monitoring and measuring actual equipment conditions over time, and confirming the actual conditions are within the standards. § Determine standard values for checks § Create Quality Maintenance matrix § Increase reliability of checks, simplify them, and reduce number of people involved § Revise materials standards, checking standards and work standards § Identify quality (“Q”) components so that standards are kept § Monitor trends and confirm results 8. Determine Standard Values for Checks & Revise Standards § Find ways to consolidate and fix the checking methods § Carry out improvements to make checking easier 7. Consolidate Checking Methods § Expose flaws in 4M conditions § Carry out restoration or improvements § Evaluate results § Establish 4M conditions that allow good product to be achieved 6. Eliminate Flaws in 4M Conditions and Finalize § Analyze situations where the conditions for building in quality are unclear § Establish defect causes § Optimize settings, processing conditions and setup procedures § Evaluate 5. Establish Conditions that Allow Good Products to be Achieved § Create deficiencies chart and identify countermeasures § Verify state of equipment and restore/improve it 4. Plan Action to Correct Deficiencies § Check quality standards and quality characteristics § Create a flow diagram of individual processes for building in quality § Investigate defect situation and stratify defect phenomena 1. Verify the Existing Situation § Draw up a Quality Assurance (QA) matrix § Investigate individual processes where defect modes occur 2. Investigate the Processes where Defects Occur 3. Identify & Analyze 4M Conditions § Investigate 4M conditions in each process. The 4Ms are: • Men/Women • Materials • Machines • Methods § Identify lapses in these conditions through on-site investigation Identify & Analyze 4M Conditions 3 Investigate the Processes where Defects Occur 2 Verify the Existing Situation 1 Plan Action to Correct Deficiencies 4 Consolidate Checking Methods 7 Eliminate Flaws in 4M Conditions and Finalize 6 Establish Conditions that Allow Good Products to be Achieved 5 Determine Standard Values for Checks & Revise Standards 8

5. © Operational Excellence Consulting. All rights reserved. 5 Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg

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