The document provides an overview of quality initiatives and performance metrics at Switchgear Equipments & Electromechanical Industry and Trade Inc. It discusses their quality core values and Elimsan Way approach, which focuses on standard work, parts, production, and process assurance. Metrics are provided tracking performance of their suggestion system, supplier improvement activities, process control, and other quality programs from 2010-2012, showing improvements in areas like cost reduction, scrap reduction, productivity increases, and more.

1. Switchgear Equipments &
Electromechanical Industry and Trade Inc.
QUALITY PRESENTATION
Prepared by
Quality Ass. and Env. Manager
Taner KUZU – 29/10/2010

2. QUALITY CORE VALUES
SUPPLIER
SUPPLIER
CUSTOMER
BENEFITS

3. ELİMSAN WAY
 Standard work STANDARD QUALITY
with STANDARD WORK
 Standard part STANDARD PRODUCTION
with STANDARD PART
 Process Assurance INTERNAL CUSTOMER SATISFACTION
(Quality in place) with PROCESS ASSURANCE
 Analysis with PDCA PERMENANT SOLUTION AGAINST PROBLEMS
with PDCA
 Work with 5S LIVING and MAINTAINING in WORK DISCIPLINE
with 5S

4. Supplier monitoring & Improvement System
Receving problem
Line complain
Non-conform part report
1 sent to SUPPLIER
Corrective actions
2 followed closely
3 Regular visit to Supplier
GENCHI GENBUTSU
LINE
SATISFACTION

5. Supplier monitoring & Improvement System
Conditional acceptance Standard Deviation
SUPPLIER Not allowed Form in use
Standard part assured Standard work assured
SUPPLIER
SUPPLIER
SUPPLIER
SUPPLIER
SUPPLIER
ELİMSAN QUALITY SYSTEM
 Standard part
 Standard work

6. ISO-9001:208 Quality Management system
 SYSTEM DOCUMENTS are CONTINOUSLY UPDATED
 ALL CONTROLLED DOCUMENTS HAS EASY ACCESS FOR ALL
 PRODUCT ASSURANCE HAS BEEN STANDARDIZED with INSTRUCTIONS
 DOCUMENT MANAGEMENT FOLLOWED with MASTER LIST

7. SOLUTION SEEKING with PDCA
PROBLEM SOLVING APPROACH in ELİMSAN
HAS BEEN PENETRATED TO ALL FORMS in USE
APPROACH
PROBLEM ANALYSIS FORM CORRECTIVE ACTION FORM

8. 5S DISCIPLINE
5S RULES APPLIED
ALL PRODUCTION AREAS
ESPECIALLY in ALL QUALITY AREAS
MONITORING with 5S AUDIT MONTHLY
and DISPLAYED the RESULTS

9. 5S DISCIPLINE

10. KAIZEN (SUGGESTION) SYSTEM
EACH WORKERS INVOLVES in BETTER PRODUCTION PROCESSES
ALL KAIZENs ARE NUMBERED and
FOLLOWED with LIST
RESULTS DISPLAYS in GRAPHICS MONTHLY KAIZEN AWARDING
CEREMONY with TOP MANAGEMENT

11. WORKER ENRICHMENT SYSTEM
EACH WORKERS IMPROVES THEIR SKILLS
PER PRODUCTION PROCESSES SYSTEMATICALLY
 NOT OPERATOR, CRATFSMAN
 EASY WORKER BACK-UP
 VISUAL WORKER MANAGEMENT
 BETTER WORKER FLEXIBILITY

12. CONTINIOUS TRAINING
ALL BLUE COLLARS AS WELL AS WHITE COLLARS
ARE BEING TRAINED CONTINIOUSLY
Some trainings…
 TOTAL QUALITY MANAGEMENT
 5S DISCIPLINE
 PROCESS IMPROVEMENT with
ISO-9001:2008 QMS
 BETTER INTERNAL AUDITING
 PROBLEM SOLVING METHODS
5why, pareto, fishbone, 4W1H
 SOLVING APPROACH with PDCA
2013 planned trainings…
 SWIFTING to LEAN PRODUCTION (TOYOTA Production System)
 GOLDEN KEY - TOTAL PRODUCTIVE MAINTENANCE (TPM)

13. CORRECTIVE and PREVENTIVE ACTION SYSTEM
INTERNAL CUSTOMER
COMPLAIN
1 Corrective action request
form initiated
2 Corrective actions
followed closely with list
All countermeasures are
3 verifid by Quality Dep. and
displayed the results in graphics
INTERNAL CUSTOMER
SATISFACTION

14. LEAN MANUFACTURING
PRODUCTION UNITS DESIGN with RESPECT TO LEAN MANUFACTURING
 ONE PIECE FLOW
 FRONTAL FEEDING
 PRODUCE with KANBAN

15. IN-PROCESS CONTROL (jikotei kanketsu)
EACH PROCESS CONFORM ITS WORK with
CONTROL FORM based on IN-PROCESS QUALITY PLANs
In-process
control form
CONTROL FORMS MOVES
with PRODUCT ALONG the LINE

16. MANAGEMENT BY TARGETS (hoshin kanri)
EACH DEPARTMENTS ASSES with ITS TARGETS
DEPARTMENT TARGETS DEFINED REGULARELY FOLLOWED
By TOP MANAGEMENT with GRAPHICS

17. LOSS MONITORING with PARETO
NON-QUALITY COST SUCH AS:
 RECEIVING CONTROL
 TEST CONTROL
 FINAL CONTROL
 CUSTOMER COMPLAINS
ALL FOLLOWED with PARETO and FOCUSED on
MOST PROBLEMATIC ISSUE FIRST for EFFECTIVE IMPROVEMENTS
RECEIVING TEST CONTROL CUSTOMER COMPLAIN
INSPECTION

18. CUSTOMER SATISFACTION SYSTEM
Customer
Complain
1 3 Actions followed by Quality
Dep. closely and displayed
Complains are entered the results in graphics
into Follow-up list
2
Every complain fill into
the form and issue
CUSTOMER
SATISFACTION

19. CUSTOMER CONVEY FOLLOW UP
Customer
Convey
1
Complain and suggestions 2 All conveys are analysed
Collected through form with report
3 Feedback to customer
CUSTOMER
SATISFACTION

20. SUSTAINABLE QUALITY
1 Based on production unit for CB and LBS ,
Samples are taken randomly and tested with QA-R&D team
Follow up list
Durability test record form
2 Results are investigated and
finalized in KAİZEN manner
Special durability test case
(Our Laboratory* has just entitled for durability
test as well from TURKAK
(*) Lightning impulse, Temperature rise test,
Partial discharge, Power frequency is already in our scope since 2008 ,

21. Switchgear Equipments &
Electromechanical Industry and Trade Inc.
IMPROVEMENTS in FIGURES’2012
Prepared by
Quality Ass. and Env. Manager
Taner KUZU – 11/08/2011

22. SUGGESTION
KAIZEN
SYSTEM
Kick off:
Suggestion system initiated at 01/08/2010
Target and current figures:
Kaizen target Accepted Kaizen Status
2010 140 301 Doubled the target
2011 220 276 Target reached
2012 190 173 Almost reached
ITEM PROFIT PICTURES
COST: 1.280 K$ profit
SCRAP: %39 scrap down in two parts
PRODUCTIVITY: 204 min. faster production
QUALITY: 135 quality kaizen implemented
WORK SAFETY: 59 kaizen implemented
WORKER HEALTH: 33 kaizen implemented

23. SUPPLIER GENCHI
IMPROVEMENT GENBUTSU
Kick off:
Supplier QUALITY SYSTEM AUDIT initiated at 10/05/2010
Target and current figures:
2010: 7
2011: 38 suppliers audited in terms of product, process, delivery assurance
and quality system with 4 pages assessment form
Monitoring the Defining the suppliers
supplier performance With full collaboration of supplier , ''To do list'' for
that should be improved improvements is summarized during the audit.
with PARETO. and planning the visit
Payback:
Reject Ratio decresed
6 times in 1 year

24. PROCESS JIKOTEI
CONTROL KANKETSU
Kick off:
Process control initiated at 01/01/2011 for all units
Target and current figures:
Decrease the product failures and improve the process quality
90 100 90 99
100100
98 98 97
96 97
95 96 96
85 94 95 85 94
93 94 93 Seri 2
81 91 91
90 Seri 2 90 90 Seri 1 90
80 89 80 88
77 88 87
86 Seri 1 85
85 75 84
75 83 82
81 80
80 80 79
70 78 70
76 75
74 65
65 69 70
70 70
60
60 57 66
63
62 55 60
55 60 57
57 50
50
DECEMBER 2010 JULY 2012
47 51
52 45 50
45 50
46
40 44
40 40
35
40 37
35 38
33
31 30
30 28 30
25 28
25 30
25 28
21 20
20 20
20 15 18
20 12
15
15 12 10
14 7 10
6
9 9 9 9 9 5 5
10 8 8 4 4 4 4
7 7 7 10 5 3 2
5 1 1 1 1 1 1 1 1 1 1 1 1
4 4
5 3 3 3 3 3 3 0 0
11
13
16
15
10
17
E7
3
6
8
E5
E8
9
1
4
E9
E6
1
2
5
P3
0
4
0 0
EL
EL
EL
EL
E2
E1
E1
EM
E1
E1
EM
EL
EL
EL
EL
EL
EL
M
M
M
M
M
K
ME2 - EL7 - EL5 - EL4 - EL6 - EL11 - EL9 - EL16 - EL10 - EL3 - EL17 - EL2 - ME15 - ME6 - ME4 - KP3 - EL13 - EL14 - EL15 - ME7 - KP6 - EM4 - ME22 - ME14 - ME11 - ME10 - EL1 - ME12 - ME8 - KP1 - ME18 - M
M
M
M
M
Final control defect that flows out from process failures
Payback:
Process failures for Metal Enclosed Switchgears decresed 8 times in 6
months.

25. PROCESS JIKOTEI
CONTROL KANKETSU
SWITCHGEAR
CIRCUIT BREAKER

26. DEFECT FREE ZERO
PRODUCT DEFECT
Kick off:
Zero Defect Product project initiated at 01/05/2010 for all units.
Target and current activities:
Produce defect free product at the level of %80 minimum.
Regular preventive activity
meetings between quality
and production team
Daily monitoring the
line performance
with GRAPHICS.
Payback:
Average defect free product ratio
increased 2 times , from %45 to %90.
Now 9 product out of 10 is DEFECT FREE

27. COST SCRAP
EFFICIENCY IMPROVEMENT
Kick off:
Since February’2010, epoxy process problems have been taken into
consideration with PDCA problem solving methodology.
Target and current activities:
2011 Second half %5 and reached after improving process and initiating one
POKA YOKE solution in the line.
POKA YOKE INITIATED
If the resistance in the mould broken,
system automatically detects
Payback:
Average 45,5 K$ scrap cost down. (Gain SF6 gases, disassambling cost, epoxy

28. Focus on the BEST as a TEAM