Quality Assaurance

1. Minda Huf Limited Date
QUALITY
QUALITY IS THE TOTALITY OF FEATURES & CHARACTERISTICS
OF A PRODUCT, PROCESS OR A SERVICE THAT BEARS ON ITS
ABILITY TO SATISFY STATED & IMPLIED NEEDS. (AS PER
ISO:8402 APPLICABLE TO ISO:9000:1994 SERIES)
QUALITY IMPROVEMENT
-THE ACTIONS TAKEN TO INCREASE THE VALUE TO THE
CUSTOMER BY IMPROVING THE EFFECTIVENESS AND
EFFICIENCY OF PROCESSES AND ACTIVITIES THROUGH OUT
THE QUALITY LOOP.
PROCESS OF SYSTEMATIC & PLANNED ACTIONS TO
CONTINUOUSLY IMPROVE THE QUALITY PERFORMANCE
INDICATORS.

2. Minda Huf Limited Date
NEED OF QUALITY IMPROVEMENT
• COMPETITION IN AUTOMOTIVE & OTHER SECTORS.
• GLOBALISATION.
• INCREASING CUSTOMERS EXPECTATIONS.
• WASTE REDUCTION IN SUPPLY CHAIN
• REDUCTION IN INVENTORY LEVELS
• PRODUCTIVITY IMPROVEMENT
• FOUNDATION FOR AUTOMATION
• PART OF TQM JOURNEY
• CHANGE IN COSTING PATTERN (NO ALLOWANCE FOR
REJECTION)

3. Minda Huf Limited Date
HOW TO MEASURE QUALITY
• CUSTOMER REJECTION PPM
- LOT REJECTION (CUSTOMER)
- LINE REJECTION (CUSTOMER)
- WARRANTY REJECTION
• INPROCESS REJECTION PPM (INCLUDING HANDLING)
- ASSEMBLY LINE REJECTION
- COMPONENT SHOP REJECTION
• BOUGHT OUT PARTS REJECTION PPM.
• RELIABILITY OF THE PRODUCT
• DURABILITY OF THE PRODUCT
• FIRST TIME TO FAILURE
• MEAN TIME BETWEEN FAILURES ETC.

4. Minda Huf Limited Date
TOOLS & TECHNIQUES AVAILABLE FOR
QUALITY IMPROVEMENT
• SEVEN QC TOOLS
- CHECK SHEETS - CONTROL CHARTS
- ISHIKAWA DIAGRAM -PARETO DIAGRAM
- SCATTER DIAGRAM - STRATIFICATION
- HISTOGRAM
• REVIEW OF FMEA’S
• DESIGN REVIEWS
• DESIGN OF EXPERIMENTS
• BENCHMARKING
• LIFE ENHANCEMENT
• POKA-YOKE (MISTAKEPROOFING) ETC.

5. Minda Huf Limited Date
TYPES OF QUALITY IMPROVEMENT
REACTIVE
PROACTIVE

6. Minda Huf Limited Date
STEPS FOR CONTINUOUS QUALITY
IMPROVEMENT (REACTIVE)
• DATA COLLECTION
• DATA ANALYSIS (PARETO)
• ROOT CAUSE ANALYSIS OF TOP 20 % PROBLEMS CONTRIBUTING 80 % OF
TOTAL REJECTION.
• COUNTERMEASURES
- CONTAINMENT ACTION
- CORRECTION
- CORRECTIVE ACTION
- CORRECTIVE ACTION IMPACT(HORIZONTAL DEPLOYMENT)
• IMPLEMENTATION OF ACTIONS
• EFFECTIVENESS VERIFICATION OF ACTIONS
• PRIORITISATION OF NEXT PROBLEMS.

7. Minda Huf Limited Date
STEPS FOR CONTINUOUS QUALITY
IMPROVEMENT (PROACTIVE)
•FMEA REVIEW – INITIATING ACTION ON
NEXT REDUCED RPN LIMITS.
•PERIODIC DESIGN REVIEW FOR
- ADDITIONAL FEATURES
- MISTAKE- PROOFING
- SPECS. LIMIT TIGHTENING
- MATERIAL IMPROVEMENT ETC.

8. Minda Huf Limited Date
STEPS FOR CONTINUOUS QUALITY
IMPROVEMENT (PROACTIVE)
•HORIZONTAL ACTION DEPLOYMENT BASED ON
TGWs(THINGS GONE WRONG)& TGRs (THINGS
GONE RIGHT)
• IMPROVEMENT IDEAS THROUGH KAIZEN
METHODOLOGY ETC.

9. Minda Huf Limited Date
MONTH TOTAL
PRODUC
TS
DESPATC
HED
(NOS.)
TOTAL
REJECTI
ON
RECEIVE
D/
(NOS/PPM
.)
LOT
REJECTI
ON
RECEIVE
D
(NOS./PP
M
LINE
REJECTI
ON
RECEIVE
D
(NOS./PP
M
WARRAN
TY
REJECTIO
N
RECEIVE
D
(NOS./PP
M
REJECTIO
N RECD.
DUE TO
OTHER
REASONS
(NOS./PPM)
TOTAL
PPM
FOR
THE
QUART
ER
CUMUL
ATIVE
PPM
MONT
HLY
REM
ARK
S
JAN-03
FEB-03
MAR-03
APR-03
MAY-03
JUNE-03
FINISHED GOOD REJECTION DATA- ALL CUSTOMERS AND PRODUCTS INCLUSIVE

10. Minda Huf Limited Date
Apr-02 59671
May-02 10159
Jun-02 22105
Jul-02 1209
Aug-02 18878
Sep-02 13549
Oct-02 6947
Nov-02 6171
Dec-02 13479
Jan-03 6761
Feb-03 8070
Mar-03 10294
Apr-03 18266
MONTHLY PPM TREND
0
10000
20000
30000
40000
50000
60000
70000
Apr-02 May-
02
Jun-
02
Jul-02 Aug-
02
Sep-
02
Oct-02 Nov-
02
Dec-
02
Jan-
03
Feb-
03
Mar-
03
Apr-03
MONTHS
PPM

11. Minda Huf Limited Date
LOT PPM LINE PPM WARRANTY PPM COMPANY PPM
Feb-02 10 9637 5000 14647
Mar-02 0 658 2800 3458
Apr-02 0 11200 3200 14400
May-02 0 4622 3100 7722
Jun-02 3933 6975 2825 13734
Jul-02 4085 4000 2500 10585 1968
Aug-02 0 4021 2400 6421 264
Sep-02 0 3500 3000 6500 7007
Oct-02 0 4000 3115 7115
Nov-02 0 3200 2800 6000
Dec-02 0 3400 2800 6200
Jan-03 0 3000 2400 5400
Feb-03 0 2500 2100 4600
Mar-03 0 2400 2000 4400
Apr-03 0 2000 1500 3500
PPM TRENDS
Feb-02 Mar-02 Apr-02 May-02 Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02 Dec-02 Jan-03 Feb-03 Mar-03 Apr-03
MONTHS
PPM
COMPANY PPM LOT PPM LINEPPM WARRANTY PPM

12. Minda Huf Limited Date
BREAK UP OF LINE REJECTION CUSTOMERWISE
H
1%
G
2%
F
3%E
6%
D
8%
C
11%
B
31%
I
1% J
2%
K
1%
A
34%
++

13. Minda Huf Limited Date
CUTOMERWISE BREAKUP OF TOTAL WARRANTY
F
1%
H
1%
I
4%
G
1%
C
6%
D
1%
B
13%
K
12%
A
61%

14. Minda Huf Limited Date
BREAKUP OF LOT REJECTION
36%
6%
6%
28%
4%
6%
4%
10%

15. Minda Huf Limited Date
PRODUCTWISE DISTRIBUTION OF LINE REJECTION
A
76%
B
6%
C
4%
D
4%
E
3%
F
4% G
3%

16. Minda Huf Limited Date
DEFECTWISE DISTRIBUTION OF LINE REJECTION
WITHOUT PAINTED
MATERIAL
INWARDED BY
MISTAKE
18%
WITHOUT KEY
1%
PRINTING RING
COMES OUT
46%
PAINTING DEFECT
29%
MIXED LOT
6%

17. Minda Huf Limited Date
SL NO DEFECT OBSERVED COUNTERMEASURE ACTION TAKEN RESP TGT Compl EFFECTIVENESS
MONITORING
POKAYOKE/PROCES
S IMPROVEMENT
REMARKS
COUNTERMEASURE ACTION SUMMARY

18. Minda Huf Limited Date
POKA YOKE/ PROCESS IMPROVEMENT LIST
SL NO DEFECT PART NAME PART NO CUSTOMER POKA YOKE/IMPROVEMENT IMPL. DATE EFFECTIVENESS MONITORING

19. Minda Huf Limited Date
PPM TREND VENDOR (A)
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
DEC'02 JAN'03 FEB'03 MAR'03 APR'03 MAY'03

20. Minda Huf Limited Date