This document summarizes the quality management pillar activities at a company. It discusses the vision, goals, organization structure and targets of the quality management pillar. It then describes the quality management approach, including identifying defects, conducting analysis to determine root causes, and implementing improvements. Metrics such as KPIs and defects are analyzed over time. Future plans include continuing to refine processes and reduce defects.

1. CHAPTER 7 QM PILLAR MR.BALAJI 1 QM PILLAR CHAIRMAN Contents 7.1 Objective Background and aim 7.1.1 Vision and Goal 7.1.2 Targets and Master Plan 7.2 QM Approach and Concept 7.2.1 QM Defect Identification 7.2.2 QA & QM Matrix\ 7.2.3 Defect Reduction Activities 7.3 KAI Cumulative Trends 7.4 QM Results 7.5 QM Future Plan

2. Sub Title : AFTER PRE AUDIT , QM ACTIVITY FLOW Slide Title : 7 QM PILLAR Vision & Goal KMI / KPI / KAI KMI / KPI / KAI KMI / KPI / KAI Organization Chart Back Ground QM Target QM Master Plan Type of defects QA / QM Matrix Assessor Observation and Background New Addition New Addition New Addition New Addition A TPM ACTIVITY REPORT

3. Sub Title : AFTER PRE AUDIT , QM ACTIVITY FLOW Slide Title : 7 QM PILLAR A Defect reduction 4M Condition Q Component PM analysis Kaizen Samples KK Results Future Plan Case study New Kaizen added Improvement after pre assessment New addition after pre audit Assessor Comments and Countermeasures Updated New Addition New Addition TPM ACTIVITY REPORT

4. Sub Title : 7.1.1 VISION AND GOAL Slide Title : 7 QM PILLAR VISION AND GOAL VISION (KMI) GOAL (KPI) KAI Responsibility Primary / Secondary P – Enhance Productivity Q – Meet Quality C – Reduce Cost D – On time S – Environment M – High for Employees QM / PM QM / SHE QM / PM QM / PM QM / AM QM / PM TO GROW BUISSNESS WITH DIGNITY AND RESPECT INTEGRITY CUSTOMER LOYALTY CONTINUAL IMP IMPROVEMENT AND INNOVATION UNCOMPROMISING QUALITY EMPOWERMENT TO INDIVIDUALS TPM ACTIVITY REPORT

5. Sub Title : 7.1.2 QM PILLAR ORGANISATION CHART Slide Title : 7 QM PILLAR 7.1.2 - QM PILLAR ORGANISATION CHART C PILLAR CHAIRMAN MR.BALAJI New members TPM ACTIVITY REPORT

6. Sub Title : 7.1.3 - QM PILLAR Background 7.1.3 - QM PILLAR Background Slide Title : 7 QM PILLAR Assessor Comments: 1. How many people really understood on QM Concept? 2. What is the time taken for all the quality testing and what is the time reduction done need to be identified TPM ACTIVITY REPORT

7. Sub Title : 7.1.4 - QM TARGETS 7.1.4 - QM TARGETS Slide Title : 7 QM PILLAR After pre audit – new targets TPM ACTIVITY REPORT

8. Sub Title : 7.1.5 - MASTER PLAN 7.1.5 - MASTER PLAN Slide Title : 7 QM PILLAR C After pre audit – New process included - Welding TPM ACTIVITY REPORT

9. Sub Title : 7.2.1- QM PILLAR CONCEPT Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT 7.2.1- QM PILLAR CONCEPT Input Raw Materials Inspection Send back to supplier Process O/p Products Inspection Dispatch to Customer Customer Problem if any Investigation / Analysis Kaizen / Countermeasures Update 4M Conditions ok Defect Man Method Material Machine Monitor 4M Conditions DO NOT SEND A DEFECT DO NOT PRODUCE A DEFECT DO NOT ACCEPT A DEFECT Not ok ok Not ok QA Activities QM Activities Input Raw Materials Inspection

10. Sub Title : 7.2.2 - CONCEPT QC, QA, QM Slide Title : 7 QM PILLAR 7.2.2 - CONCEPT QC , QA , QM After pre audit – Zero flash improvements TPM ACTIVITY REPORT Input control Output control No control Maintaining 4M basic conditions Re-setting process conditions No control mechanism Zero defects Few defects More defects By Operator By Operator By QC inspector Continuous monitoring of 4M conditions Periodic sample inspection of products Extensive inspection of products Defect Prevention Defect Detection Defect Detection On-line Inspection On-line Inspection Off-line Inspection Quality Maintenance ( QM ) Quality Assurance ( QA ) Quality Control ( QC ) AFTER TPM BEFORE TPM

11. Sub Title : 7.2.3 – STATUS BEFORE / AFTER TPM IMPLEMENTATION Slide Title : 7 QM PILLAR 7.2.3 – STATUS BEFORE / AFTER TPM IMPLEMENTATION S. No. DESCRIPTION BEFORE TPM IMPLEMENTION AFTER TPM IMPLEMENTION BENCH MARK PRESENT STATUS TARGET UPTO 2005 ( QC CONCEPT ) 2006 - 2009 ( QA CONCEPT ) 2010 - 2011 ( QM CONCEPT ) 1 Customer complaint More, No Clear Structure For Approach Few, Clear Structure For Approach No 2 Quality Defects 3 Control Mechanism No Approach Reactive Approach Pro active Approach 4 Understanding of Defects No understanding Defect Phenomena Action plan for eliminating chronic defects. 5 Defects Identifications QC Inspector Plant Supervisor Plant Operator 6 Quality skill QC Department Supervisor Operator 7 Quality depends on Inspector Functional heads Operator 8 Inspection OFF-Line OFF-Line With Quick Measurement ON -Line OFF-LINE MEASUREMENT ON-LINE MEASUREMENT TPM ACTIVITY REPORT

12. 7.2.4 - Step 1 : Preparation of QA matrix Sub Title : 7.2.4 - Step 1 : Preparation of QA matrix Slide Title : 7 QM PILLAR Đ Đ TPM ACTIVITY REPORT Seriousness Past Occurrence Đ Develop into major defects Δ Frequent Ψ Reprocessing possible @ Occasional Ø Not occurred

13. 7.2.5 - Step 2 : Prepare production – input condition analysis table Sub Title : 7.2.5 - Step 2 : Prepare production – input condition analysis table Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT Target LSL USL Adjustment C – Type First-Off Inspection Stabilisation First Piece of setting. W/O Adj. A – Type ACTION TAKEN by the operator. Adjustment of the equipment / tools / jigs / fixtures to achieve stabilisation . Measurement & Adjustment 1/3 of Tolerance Caused during change over Due to inadequate setup procedures and lack of skills in fixturing & setting of equipments, tools, measuring instruments, etc. and also wrong selection of the above. Stabilization Mass production B – Type UCL LCL ACTION NOT TAKEN by the operator. No adjustments made. Setting Defect - Abnormal Accepted - Normal Target = (LSL+USL) / 2 Defect - Abnormal Chance / Chronic Causes Identify root cause using PM analysis. Tolerance Assignable / Sporadic Causes Identify root cause using Why-Why analysis.

14. Sub Title : 7.2.5.1 - TYPE OF DEFECTS 7.2.5.1 - TYPE OF DEFECTS Slide Title : 7 QM PILLAR After pre audit – defect type added TPM ACTIVITY REPORT

15. Sub Title : 7.2.5.2 - UNDERSTANDING OF QUALITY DEFECT 7.2.5.2 - UNDERSTANDING OF QUALITY DEFECT Slide Title : 7 QM PILLAR After pre audit – Zero flash improvements TPM ACTIVITY REPORT

16. 7.2.5.3 - DEFECT REDUCTION ACTIVITIES Sub Title : 7.2.5.3 DEFECT REDUCTION ACTIVITIES Activities 4M Condition set for Major Defects Why – Why Analysis done Counter measures Plan One Point Lesson Training Kaizens 4M Conditions Revisions plan Visual Control Poke - Yoke DEFECTWISE IND PRODUCT SCRAP PPM PARETO ANALYSIS : AVG JAN 2011 – SEP 2011 Split up of IND product Scrap Split up of high wall thickness A type High wall thickness due to A type defect Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT

17. 7.2.6 - Step 3: Prepare Problem chart Sub Title : 7.2.6 - Step 3: Prepare Problem chart Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT S.No. Details of Case Study Tools Used 1 Wall thickness variation in TT tub. PM Analysis 2 Gate point shift on Jumbo crates Why ? Why ? Analysis 3 Blow holes on TT tub. Why ? Why ? Analysis 4 Warpage on Rad tub. Why ? Why ? Analysis

18. 7.2.7 - Step 4: Evaluate seriousness of problems ( FMEA 1) Sub Title : 7.2.7 - Step 4: Evaluate seriousness of problems ( FMEA 1) Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT

19. 7.2.8 - Step 5 : Use PM Analysis to track down causes of problems Grasping Quality defect phenomena Sub Title : 7.2.8 Step 5 : Use PM Analysis to track down causes of problems Grasping Quality defect phenomena Slide Title : 7 QM PILLAR PHENOMENA MECHANISM ANALYSIS FOR WALL THICKNESS TPM ACTIVITY REPORT

20. 7.2.8.1 - STEP 5 – PHENOMENA MECHANISM ANALYSIS FOR WALLTHICKNESS Sub Title : 7.2.8.1 - STEP 5 – PHENOMENA MECHANISM ANALYSIS FOR WALL THICKNESS Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT

21. 7.2.9 – STEP 6: Assess impact of the countermeasures taken (FMEA 2) Sub Title : 7.2.9 – STEP 6: Assess impact of the countermeasures taken (FMEA 2) Slide Title : 7 QM PILLAR FMEA OF VARIATION OF WALLTHICKNESS IN TT TPM ACTIVITY REPORT

22. Sub Title : 7.2.9.1 - QM MATRIX 7.2.9.1 - QM MATRIX Slide Title : 7 QM PILLAR After pre audit – QM Matrix revised for SSR part TPM ACTIVITY REPORT

23. 7.2.9.2 - “ Q” COMPONENTS IN INJECTION MOLDING MACHINES Slide Title : 7 QM PILLAR Sub Title : 7.2.9.2 DEFECT REDUCTION ACTIVITIES After pre audit – Mold manifold heater - Q Component added TPM ACTIVITY REPORT

24. 7.2.9.3 - “ Q” COMPONENTS IN INJECTION MOLDING MACHINES Slide Title : 7 QM PILLAR Sub Title : 7.2.9.3 DEFECT REDUCTION ACTIVITIES TOTAL Q COMPONENT – 8 NOS MOLD Heater After pre audit – Q component added TPM ACTIVITY REPORT

25. 7.2.9.4 - DEFECT REDUCTION ACTIVITIES Sub Title : 7.2.9.4 DEFECT REDUCTION ACTIVITIES Slide Title : 7 QM PILLAR 360-370kgf.cm2 60- 80% 180 - 220 o C 180 – 200 kg/cm 2 4 – 5 mm 250 – 300 kg.cm2 120-150kgf.cm2 CONTROL VALUES Flash Shrink Shortfill Shrinkage Shortfill FLASH FLASH CONTROL QUALITY Pressure Q 7 SpeedInject Injection speed mmi Q 6 Temp of material Barrel Heater Q 5 PRESSURE Injection pressure Q 4 SIZE Nozzle ID Q 3 Plattern moving Moving plattern open / close Gauge Q 2 Core pressure Mold Core in / out gauge Q 1 CONTROL PARAMETERS COMPONENT NAME Progress Injection speed Mold locking gauge Mold locking gauge 12 to 15 ohms Flash Temperature Q 8 Mold Heater After pre audit – Q 8 added TPM ACTIVITY REPORT

26. Sub Title : 7.2.10 - STEP 7 – IMPLEMENT IMPROVEMENTS Slide Title : 7 QM PILLAR 7.2.10 - STEP 7 – IMPLEMENT IMPROVEMENTS TPM ACTIVITY REPORT Valve seal Changed Focus on seal by QM Pillar Oil to Inj mode Oil Retraction

27. Slide Title : 7 QM PILLAR Sub Title : 7.2.10.1 - QM KAIZEN 7.2.10.1 - QM KAIZEN After pre audit – Kaizen added TPM ACTIVITY REPORT

28. 7.2.10.2 - DEFECT REDUCTION - OPL SAMPLE Slide Title : 7 QM PILLAR Sub Title : 7.2.10.2 DEFECT REDUCTION ACTIVITIES After pre audit – OPL added TPM ACTIVITY REPORT

29. Sub Title : 7.2.11 - Step 8: Review production – input conditions Table for Wall thickness Slide Title : 7 QM PILLAR 7.2.11 - Step 8: Review production – input conditions Table for Wall thickness TPM ACTIVITY REPORT Quality test is performed Quality test of R/D product is performed every shift Optimum blend ratio implemented. 1300 Optimum material blend ratio, Plant D Material Machine Method (man) Defect mode Sub process Main process Thickness variation Material mix, parametrs Input condition Additive dosage As per Standard Standard need improvement ? Standard need x Std Impossible to follow

30. 7.2.11.1 - 4M CONDITION EXAMPLE Slide Title : 7 QM PILLAR Sub Title : 7.2.11.1 DEFECT REDUCTION ACTIVITIES After pre audit – PART added in 4M Condition TPM ACTIVITY REPORT 190 ± 10 kgf/cm2

31. Sub Title : 7.2.12 - Step 9: Consolidate and confirm checkpoints Quality Check Matrix Slide Title : 7 QM PILLAR 7.2.12 - Step 9: Consolidate and confirm checkpoints Quality Check Matrix Batch formation Retain the inspection Thickness Seal Every Shift Checking interval Right level of Mixing Standard PPCP Check Item Raw materials Equipment part TPM ACTIVITY REPORT

32. Sub Title : 7.2.12.1 DEFECT REDUCTION ACTIVITIES Slide Title : 7 QM PILLAR 7.2.12.1 - TT Tub : QM Check sheet TT Tub : QM Check sheet TPM ACTIVITY REPORT Quality Component Control Conditions Condition Checking Method Checking Standard TT TUB Injection Pressure Gauge Injection Pressure to with stand up to full cycle Thickness Fall rate should be in permissible limits (180 - 200 kg/cm2)

33. Sub Title : 7.2.12 DEFECT REDUCTION ACTIVITIES Slide Title : 7 QM PILLAR TPM ACTIVITY REPORT 7.2.12 STEP 10 – Quality Component for wall thickness Data are entered in Plant operating log Result Laboratory Checking method Setting Speed and Pressure Checking Standard Per Shift Checking interval Quality Component : Seal, MB Mixing

34. Sub Title : 7.2.12 DEFECT REDUCTION ACTIVITIES Slide Title : 7 QM PILLAR Question & Answers Pre audit Assessor Comments TPM ACTIVITY REPORT

35. Sub Title : 7.3 KAI CUMULATIVE TREND Slide Title : 7 QM PILLAR KAI CUMULATIVE TREND KAI CUMULATIVE TREND C TPM ACTIVITY REPORT WHY – WHY ANALYSIS Nos OPL DONE Nos TRAININGS CONDUCTED Nos POKE YOKE Nos COUNTERMEASURES Nos KAIZENS Nos

36. Sub Title : 7.3.1 KAIZEN SAMPLE SHEETS Slide Title : 7 QM PILLAR 85 QM KAIZEN IMPLEMENTED After Pre audit – kaizen updated TPM ACTIVITY REPORT

37. Sub Title : 7.4 QM RESULTS Slide Title : 7 QM PILLAR P.1.1.12 – CRATE PRODUCTS SCRAP PPM Better FROM 4365 PPM TO 98 PPM BM – 4365 (JUN 07 ) TPM ACTIVITY REPORT

38. Sub Title : 7.4 QM RESULTS Slide Title : 7 QM PILLAR P.1.1.13 – FURNITURE PRODUCTS SCRAP PPM FROM 15002 PPM TO 501 PPM BM – 15002 (JUN 07 ) Better TPM ACTIVITY REPORT

39. Sub Title : 7.4 QM RESULTS Slide Title : 7 QM PILLAR P.1.1.14 – INDUSTRIAL PRODUCTS SCRAP Better % FROM 1% TO 0.26% BM – 15002 (JUN 07 ) TPM ACTIVITY REPORT

40. Sub Title : 7.4 QM RESULTS Slide Title : 7 QM PILLAR P.1.1.15 – FURNITURE REWORK % Better FROM 12% TO 2.52% BM – 12 (JUN 07 ) TPM ACTIVITY REPORT

41. Sub Title : 7.5 QM RESULTS Slide Title : 7 QM PILLAR C 3.1.1 – INPROCESS SCRAP % Better FROM 3.9% TO 0.64% BM – 3.9% (JUN 07 ) TPM ACTIVITY REPORT

42. Sub Title : 7.5 QM FUTURE PLAN FUTURE PLAN Slide Title : 7 QM PILLAR C TPM ACTIVITY REPORT Sl No Activity Target Date 1 2 3 4 5 To achieve 85 PPM in Crate Product Scrap To achieve 350 PPM in Furniture Product Scrap To achieve 0.15% in Industrial Product Scrap To achieve 1.55% in Furniture Rework To achieve 0.4% in in process Scrap Dec 2011 Jan 2012 Feb 2012 Mar 2012 Feb 2012

43. CHAPTER 8 DM – PILLAR Presentation By Mr. Ramesh Kumar