Quality Management Overview
Quality management is Quality Control, which starts with two abbreviations and is called QC.
People may belong to different departments. Everyone may think that quality management is to determine whether a product is good or bad, and it is an inspection job. Many people may think this way. But quality management in the true sense is not that, but the work of all employees and the improvement of the quality of all work.
Only with the consent of the buyer can an enterprise obtain certain benefits. To this end, we cannot lack indispensable production and sales technology, technology to ensure product quality, etc. To be precise, "a system of means to economically manufacture products with quality suitable for customers' requirements." Therefore, as mentioned above, it is necessary to pursue the efficiency improvement of all work and the improvement of effective work, so to solve various problems that occur at work, it is necessary to constantly explore new and more effective methods. Such activities are called "problem solving", and various techniques and techniques are being developed as solutions. You will learn the basics of this technique and the concept of quality management in this lecture, focusing on "Quality Management in Manufacturing". As mentioned above, transaction work also has many similarities.
{Development of quality management}
***No defective products allowed to leave the factory***→ ***Quality assurance relying on inspection***
***Do not produce defective products***→ ***Quality assurance relying on engineering management***
***Do not plan for defective products***→ ***Quality relying on source management Guaranteed***
Then we will learn step by step.
[Edit this paragraph] 1. What is quality?
There is probably no one who can answer this simple yet very difficult question. The reference book I looked through said: "The evaluation objects and inherent properties are used to determine whether the products or parts meet the purpose of use and the customer's agreement." For hardware parts, it is the aperture, bending height, etc.
[Edit this paragraph] 2. Excellent quality
If the so-called quality concept (project) is created and evaluated, it must be used as the basis for evaluation. This is generally called a specification. If it meets the specifications, it will be evaluated as "excellent quality". If it meets the requirements within the minimum limit, it is also a good teacher and helpful friend, and it is not expected to be the highest level.
[Edit this paragraph] 3. Quality is the company’s comprehensive strength
It is absolutely impossible to produce good quality solely by relying on manufacturing capabilities. So when it comes to quality here, it’s the company’s comprehensive capability. For example, if there is a discrepancy between the fabricated sales information and the schedule requested by customers, it will be impossible to make correct production plans. Therefore, it is a dream within a dream to create a situation where production is forced and unskilled people collectively try to produce good quality. Also, in terms of technology, if you do not prepare suitable jigs, check the jigs, etc., good quality will be absurd and empty, and defective products will only pile up like a mountain. Therefore, all company employees, including personnel, must move towards good goals. This is the company's comprehensive capabilities.
[Edit this paragraph] 4. The so-called quality deviation
Since it is a product, even if it is made by the same mechanical method, it will not be completely accurate even if it is precisely measured. Same, there will be differences. The verbal description of this distinction and difference is called deviation.
[Edit this paragraph] 5. The so-called tolerance
Leaving aside the origin of the name, when manufacturing products, there must be specifications called tolerances. For example, if ordinary copy paper is cut to a width of 3cm, then let's think about it, 3cm is 3.00000...cm, not 2.99 or 3.10. So we need the so-called tolerance - the allowable range.
Moreover, in today's world, it is not an era where one part is simply combined with another part. What is now pursued is the interoperability between parts. Otherwise, we cannot talk about production, and our cultural life cannot be established.
Just like this, designers mark various tolerances on drawings based on experience, etc., but we ignore the tolerances and think that "as long as it fits in, there will be no problem, and as long as it can move, there will be no problem." It is not a good thing to interpret tolerances arbitrarily , I hope everyone can understand the tolerances so simply.
[Edit this paragraph] 6. What is standardized 4M?
Consider how production works?
"Production of Hardware and Injection Molded Parts" "Production Situation of Assembly Products"
A. With machine A. With machine type and without machine type
B. There are materials B. There are parts and materials
C. There are molds C. There are jigs and inspection tools
D. There are people D. There are more people's work
This A, B, C, and D replace their English names with institutions, materials, methods, and people as Machine, Material, Method, and Man respectively. Their respective English prefixes are called 4M. They are deeply understood in the industry around the world. 4M is an indispensable and important factor in producing stable quality. Every company pays great attention to its management method and is further exploring it.
In order to help everyone realize this, let's do an experiment.
As mentioned just now, cut ordinary copy paper into a width of 3cm. Then there will be a difference of 3cm in width between two adjacent people. This difference is not only due to the difference in people, but also the difference in the methods of the two adjacent people. But what about cutting with a ruler and knife? Here we assume that the material "paper" is a certain situation. Of course, if it is thick paper, the situation will change. It is stipulated that "machine" means a knife and "method" means using a ruler. Will the differences between people be reduced?
Such regulations are called "standardization". At the same time, if you want to produce high-quality products, you must truly manage people, machines, methods, and materials as "variable factors." This kind of management is "Project management" will be discussed later.
[Edit this paragraph] 7. What is sampling inspection?
You can often see this in our daily life. Sampling inspection is in use.
For example, when buying peanuts, you will eat one or two, peel them off and take a look. This is a typical sampling inspection. Everyone may have experienced something like this. This idea was introduced into the industry during the World War when soldiers on the front lines needed weapons. However, in the munitions industry at that time, parts were sent to the assembly factory after being fully inspected to see if the assembled guns were acceptable. The bullets must be fired, whether they are heading towards the target, etc., and must be fully inspected before being released. Moreover, the troops accepted must be strictly inspected, but they cannot meet the number required by the front line. In this case, random inspections are considered. .
*Isn’t it possible to have a certain number of bullets that are slightly different from the target?
*It is ideal to be able to shoot down the enemy at 1Km. Yes, some of them were shot down at 800 meters, isn't it possible?
*So we decided to send such weapons to the front line.
* Guns. Random hair is not allowed. The quality of such important parts must be strictly confirmed. For the quality of unimportant parts, it is decided to conduct random inspections to reduce inspection time and inspection costs.
*Everyone thinks it is a good company. Parts and products produced on the assembly line can also be shortened and inspection time can be reduced. The military industry considers this method by sending these parts and products to the frontline as soon as possible, and published "MIL-STD-" based on theoretical values ????of statistics. The sampling specification of 105" has been continuously improved and adopted by many companies. However, sampling inspection is a random inspection after all, and there is no guarantee that 100% of the LOT will be good products, and there will definitely be defective products among them. In these 5 to 10 years, The concept of quality has improved, but there is a problem with the concept that there must be defective products.
So each of us consumers probably only buys one part.
But if the one you buy has poor performance, it will be 100% defective for that person, which is unacceptable to us, and for its manufacturer, it may be such a bad product among 1,000pcs. Good product.
If two or more people buy such defective products, they will say that the company's quality is not good. This causes the company to have a business crisis. Nowadays, many companies have business crises due to this. Therefore, more and more operators believe that the era of relying on random inspections to ensure quality is over.
Although the specificity varies greatly depending on the product. Basically, the times are changing, so we need to keep up with the changes of the times. However, the reality cannot change the sampling inspection method as a guarantee method. When there is no choice, the requirement to establish a system that does not produce defects is becoming more and more important. strong.
This also leads to project management.
[Edit this paragraph] 8. What is standardization and standard data?
All company information in the company is called standard information, but generally it refers to production-related information. When a company produces a product or component, the issue of cost is another matter. What must be done first is what are the customer's requirements? This requirement is the "drawing" and "specimen book". The next step is to meet this requirement and what specifications the company can deliver when it meets it is the "inspection standard book". Then there is the order in which to produce in order to meet the specifications, which station to evaluate the quality, and whether the jig needs to be evaluated. The other thing is to explore a system that does not produce defects and determine the order of data, that is, the "QC schedule". Use this engineering table as the basis, and explain its operations with diagrams and text. Eliminating the differences among people in 4M and making them work according to a certain "standardization" is the "work instruction book". But I think our company has a very weak understanding of the importance of work instructions.
For example, consider a speech-conduction game. And please experience it, to what extent will your words be conveyed to the last person? When a defect occurs, someone often says "because the operator has changed" during a meeting. It is precisely because the operator changes frequently that it is necessary to improve this information. Based on this information, it is necessary to guide the operator and perform his or her work. Although we are taught by the same person, the teaching methods will become simpler and simpler. Although this is understandable, our company, which has a lot of manual work, does it correctly. To what extent you can teach, this is the most important, and it is also the most important task of lengthening. Therefore, the enrichment of the work instructions must be implemented more seriously.
Other bad records, records of working conditions, etc. are also standard data.
[Edit this paragraph] 9. The work of the squad leader
The important task of the squad leader is to always have problem awareness and desire for improvement in the production line he manages, and to accurately grasp the status of his own production line , improve its problem points. If you are limited in your ability to improve a problem, you must report the problem to your superiors and seek instructions. Your top priority should be to use this method to manage the production line. An example of the specific record describing the method has been introduced previously as the basic idea. If the work is done correctly, there will be no defective products. As a monitor, if you think otherwise, you are not qualified to be a monitor.
(1) Frequently inspect the production line to monitor whether the operators are working correctly.
(2) If an erroneous operation is discovered, correct it immediately, confirm the produced products, and accurately report the fact to the superior.
(3) If you find an abnormal situation and are unable to solve it yourself, handle it according to the above method.
(4) If the operator finds something unusual, let him or her develop the habit of reporting.
(5) A defective summary sheet must be given to the operator at the quality confirmation station so that he or she can record the number of defects per day.
(6) Collect the daily statistics of this DATA and consider implementing improvement measures.
*To do this, the squad leader must personally confirm the number of defects and re-educate the workers who caused the defects.
*At the same time, listen to the opinions of the operators correctly. If fixtures are needed, report to the boss and rely on them.
(7) Be aware that newcomers and agency operators know nothing about the assignment.
(8) Therefore, the homework instructions should clearly convey what you want him to do and provide guidance based on standard materials.
(9) After the guidance, the monitor will personally confirm the result of the assignment and judge whether it is good or not. If the result is not good, re-instruction will be given. Repeat this process.
[Edit this paragraph] 10. The operator’s work
The operator works according to the content written in the standard information represented by the "operation instruction book", records the data, and records the data according to the The boss's instructions are to complete the work meticulously, that's all. Among them, I would like to specifically record the distinction between color, sound, feeling, touch, etc. that is different from the usual and the report to the boss. The five senses of the human being are very sensitive, and they will definitely know if the quality is different from the usual. Therefore, if discovered and reported promptly and correctly, defective products that can be handled correctly will not flow into subsequent processes.
[Edit this paragraph] 11. Quality is created in engineering
What is engineering management?
First of all, it should be understood that quality is created in engineering. Everyone can understand that many problems cannot be discovered by QC random inspection. It is impossible to understand engineering management without understanding this issue. It is natural to have quality goals when producing products, and achieving those goals is a manufacturing job. Therefore, the quality is affected by the manufacturing process, so the smaller the impact, the better. This method of thinking is engineering management, and its backbone is 4M management. The management methods are divided into management of factors that affect quality and management of product and quality characteristics (result management). The center of this type of management activity in manufacturing engineering: "Engineering Management".
To what extent can this project management really be achieved? It is the key to reducing defective losses and improving production efficiency. At the same time, there is the language that quality is created in engineering.
In engineering management, QC engineering drawings, generally referred to as QC drawings, are often effectively used. The contents that must be recorded include what should be confirmed as quality characteristics in each manufacturing process, what should be confirmed as factors affecting quality, etc.
Therefore, it is necessary to clarify in advance what is recorded in the QC drawing and what affects the quality in each manufacturing process during the process analysis. The accumulation of experience learned from similar products in the past is also very important. In this high level of knowledge, it is necessary to clearly define the work that the workers at each station are expected to do. However, with limited analytical equipment, I think there are still many problems that cannot be analyzed and solved, which can only be solved with the advanced application skills of technicians.
[Edit this paragraph] 12. Seven application methods of QC
On the basis of quality improvement activities, the organization and utilization of DATA is very important. The value of its DATA tells me something, we won’t turn a blind eye! It is necessary for us to take a look at the situation of DATA. The method is called "seven application methods", which are as follows:
(1) Grasp the key points of the Pareto chart
( 2) Check and record in the inspection record sheet
(3) Grasp the histogram distribution
(4) Grasp the associated values ??of the distribution graph
(5 ) Management of management drawing projects
(6) Visualization of graph data (visual management)
(7) Tracing of characteristics due to drawings
Detailed information about each type of calligraphy will be learned in the next intermediate level study.
[Edit this paragraph] 13. Calligraphy and views on histograms
Each of the seven tools above has its own advantages. I think it is best to use them separately according to the purpose of use. However, to investigate the quality status, it is necessary to investigate its volatility. So what is the most basic method? How many DATA are there? Organizing in this way is called a histogram.
The views are as follows:
(1) The position of the center
(2) The fluctuation state
(3) The shape of the distribution
( 4) Is there any outlier value
(5) Bad speculation
To make a histogram, at least 30 PCS of DATA are required. If the number is small, even making this histogram is meaningless. . Because the shape of this value histogram does vary greatly, as this histogram, through calculation, the mean and standard deviation can be obtained. The method of deriving this deviation and average value and utilizing it will be explained in the intermediate level. It has high utilization value.
14. Ten principles of supplier quality management
Traditional incoming material quality management is mainly for IQC internal management, and externally it is a passive relationship. Due to the pursuit of quality To improve and win-win situation, IQC incoming material quality management will be transformed into supplier's source quality management. Enterprises do not passively deal with suppliers, but must actively guide, change, manage, and maintain the quality relationship between them.
○ Buyers can dispatch full-time factory personnel to important suppliers, or conduct frequent quality inspections on suppliers.
○ Buyers conduct quality testing or on-site inspections of supplied goods regularly or irregularly.
○ Buyers can reduce their over-reliance on individual large suppliers and diversify procurement risks.
○ The buyer shall formulate the acceptance standards for each purchased part and the acceptance handover procedures with suppliers.
○ For the selected suppliers, the company will enter into a long-term supply cooperation agreement with them, which specifically stipulates the rights and obligations of both parties, and
mutually beneficial conditions for both parties.
○ Buyers can set up SJQE at suppliers. SJQE plays the role of customers to promote supplier quality.
○ Purchasers regularly or irregularly rate suppliers and formulate and implement reward and punishment measures.
○ Suppliers are re-evaluated every year and those that do not meet the requirements are eliminated. , and then replenish qualified suppliers from the candidate team.
○ Purchasers conduct quality control and management of upstream suppliers of key materials.
○ Control any changes in process parameters or design of supplier materials that require the purchaser’s confirmation and approval.
15. Feedback and handling of abnormal quality
① If you can judge by yourself, directly notify the operator or workshop to deal with it immediately;
② If you cannot judge by yourself, Then submit the bad sample to the supervisor for confirmation, and then notify the correction or processing;
③ Abnormal situations should be truthfully recorded;
④ Confirm the corrective or improvement measures, and track the results of the treatment ;
⑤ Clear status identification should be made for inspection of semi-finished products and finished products, and relevant departments should be supervised for isolation and storage.
1. Basic introduction to quality
1. What is quality
2. Six indicators of quality
3. Trends in quality development
4. On-site personnel’s views on quality
2. Discussion of on-site quality problems and improvement strategies
1. Common quality problems on site
< p> 2. Cause analysis of on-site quality problems3. Improvement measures for on-site quality problems
4. Practical drills
3. How to effectively implement process control
1. Steps of process control
2. Basis for process control
3. Methods of process control
4. Process anomalies Processing
5. Work-in-progress (WIP) control
6. Process quality analysis
4. How to use quality techniques to discover quality problems
1. Checklist: Collect quality data
2. Plato: Find the focus of the problem
3. Factor diagram: Master the causes of abnormalities
4. Control charts: Exploring potential problems
5. Histograms: Finding variations
6. Use of other quality techniques
7. Practical drill
5. Techniques for process improvement
1. Focus of process improvement
2. Objects of process improvement (4M)
< p> 3. Steps for process improvement (QC Story)4. Design of fool-proof production operations
5. Establishment of work standard documents
6 . Implementation of work instruction
7. Implementation of process quality audit
8. Application of six standard deviations
Lecturer introduction:
Lecturer Expert——Mr. Chen Jinhe (Taiwan)
Current position: Deputy General Manager, Senior Consultant, and Professional Lecturer of Fuyou Enterprise Management Consulting Co., Ltd.
Education: Department of Industrial Engineering, Feng Chia University, Taiwan (graduated in 1979)
Experience: 25 years of practical experience in manufacturing and consulting companies
Anchuan Electronics Co., Ltd. Co., Ltd. Quality Control Section Chief
IE Supervisor of Sanguang Weida Co., Ltd.
Electronic Production Management Supervisor of Industrial Technology Research Institute
Huazhi Information Management Consulting Company Manager, General Manager
General Manager of FiberHome Headhunting Company
Director of Quality Assurance Section of Measurement Center of Industrial Technology Research Institute
General Manager of Tianlu Management Consulting Company
p>Deputy General Manager of Dingpei Co., Ltd.
Executive Vice President of Suzhou Huajie Electronics Co., Ltd.
Deputy General Manager of Kangke Electronics Co., Ltd.
< p> Certificate: Passed the Quality Control Technician ExamPassed the ISO 9001/Laboratory Quality System Certification Chief Assessor Exam
Qualified Mid-Level Management Training (MTP) Lecturer
IECQ QC-080000 HSPM (ROHS) director review training
Specialty projects:
Enterprise physical reconstruction, factory overall operation process system planning, production management system,
Quality management system, IE industrial engineering establishment and improvement, R&D management system, ERP system design and planning,
Objective management and performance appraisal, human resources management system, salary and bonus system establishment,
p>
Training to improve the management capabilities of mid-level cadres.
Coaching and in-house training on behalf of clients:
Volkswagen Computer, Honsheng Rubber, Yongfeng Yu Paper, ABIT Computer, Ruixuan Technology, Lijie Computer,
Blue Sky Computers, Qihong Electronics, Nanya PCB Factory, Xiamen Liangji, Xiamen Mengfali Technology, Anta (China) Shoes, Yongchun Hongtai Paper, Jiangsu Tanghuang Group... and more than 100 companies;
Carry out Establishment of enterprise operation management system, process improvement, establishment of standard working hours and work improvement,
Enterprise e-based assessment and planning, and management ability improvement training for mid-level cadres.
Job Responsibilities
Main job responsibilities:
1. Regularly organize quality analysis meetings to coordinate and solve various quality problems
2 .Responsible for the establishment, operation and improvement of the company's quality management system
3. Responsible for organizing new product testing and review work
4. Responsible for organizing and handling quality incidents
5. Responsible for the approval of sample/new product confirmation reports and batch test reports
6. Responsible for the preparation of the department’s fund use plan and cost control
7. Handle other quality-related matters Management work
1. Assist department managers to make trial production and mass production decisions for new products
2. Assist department managers to review and approve sample/new product confirmation reports, batch test reports, and unqualified incoming material reports
3. Assist department managers in making final product release decisions
4. Examine and approve the quarterly assessment and annual assessment reports of subordinate division-level departments
5. Work with department managers to make suggestions on the introduction of new products to the company