KITAB
KNOWLEDGE INNOVATION TECHNOLOGY ATTITUDE BEHAVIOUR
eNewsletterof TPM CLUB INDIA NOVEMBER 2012 ISSUE - 03
ZERO DEFECT – IS IT EXPENSIVE?
Following are the three questions which are coming to mind when we start talking about Zero defect.
1. Is zero defects impossible? 2. Is zero defects a myth or reality? 3. What is the cost of doing it? Many companies have resigned to the concept that
towards ZERO defect is shown in figure 1.
achieving ZERO defect is not possible. Some value is kept
Raw Material Quality
only the variations over and above this are discussed in the meetings. While, they do discuss the reduction of defects, seldom the discussion is towards ZERO.
ze Tow ro a de rd fe s ct
in the mind which is considered as acceptable and it is
Going back to the 3 questions, from a TPM perspective, it
Inconsistent process Quality
Abnormalities in the machines
is not impossible, definitely not a myth and is not expensive. It is real and it is possible to achieve if the basic
Machine Quality
Figure 1: Path towards ZERO Defect.
concepts of man, machine, material and method (4M condition) is understood and followed to the core. Not a easy one; but not difficult either. The attempt and focus is
REMOVING ABNORMALITIES IN THE MACHINES
the key. There are many abnormalities present in the machines To achieve ZERO defect, it is very important to select the
which have not been attended to in the TPM way. In
right tools and techniques, its application together with
general, these are not noticed or they are seen through or
the monitoring of critical parameters for sustenance of
left unattended even when seen. One or some of these
the results achieved play a great role. Of course, people's
would be creating that defect. There are 7 types of
involvement in the whole process is a vital success factor.
abnormalities in the machines that needs to be
How to prevent defects?
addressed which will lead to the occurrence of defects. Maintaining the optimal condition of the machine parts
It is not possible to achieve ZERO defect status overnight
(as in Table in 2) and monitoring them will lead to
nor it is a short term activity. The steps taken towards it
prevention of forced deterioration from occurring on the
should be firmly grounded and activities taken forward. A
machine parts. With this, at least 70 % of the defects
good strategically drawn out process, meticulously
would be prevented.
followed will lead to the goal. The generalized path KNOWLEDGE
INNOVATION
TECHNOLOGY
ATTITUDE
BEHAVIOUR
KITABeNewsletter
of TPM CLUB INDIA NOVEMBER 2012 ISSUE - 03
Table – 1: 7 Types of abnormalities
1 2 3 4 5
6
Minor flaw
Table 2: Optimal conditions to be maintained for
1 2 3 4 5
Un necessary and non urgent items
Unfulfilled basic condition
7
In accessible places
Un safe places
Contaminating sources Quality defect sources
REMOVING INCONSISTENCY IN PROCESS QUALITY
6 7 8 9
Station Material Shape Surface
Assembly Function Installation Operation
Environment
malfunction / natural deterioration will determine the
The next to be considered would be “Inconsistent process quality”. With the forced deterioration prevented on the machine, the processing and maintenance of the process parameters would become the most important factor ie., the process parameters going out of specification would create the defects. When these are addressed through Quality Assurance Matrix (QA matrix) and establishing of 4M (Man, Machine, Material and Method) condition, another 15% of
generation of the defect. By addressing this, defects due to machine quality are taken care of. ENSURING RAW MATERIAL QUALITY The balance 5% would be due to the variation in the raw material condition. If this is addressed, the concept of achievement of ZERO DEFECT will move away from Myth to Reality.
defect generation would be prevented.
Status of Indian Companies
ENSURING MACHINE QUALITY
Many Indian companies are at varied levels of TPM
Of the balance 15 %, 10% could be attributed to the “Machine Quality”. By machine quality we mean the quality of the components which make up the machine. Not all the
implementation over a period of time. They have achieved very good results in Quality parameters. Results of some of the companies are given below.
components, but there are few components whose
Quality related achievements of companies through TPM practise SL
COMPANY
1
Sundram Fasteners Ltd. Padi Sundaram Indusrtries Ltd. Madurai
3 4
2
5 6 7
QUALITY PARAMETER
SL
Rejection / rework
Customer complaints
In process rejection improved by 83%
Zero
8
Reduced from 50000 PPM to 300 PPM
Reduced from 3500 PPM to 65 PPM.
9
Bajaj Auto Ltd. Chakan
Reduced by 98%
Zero
Dattatreya Textiles, Madurai TVS Motors Hosur
Reduced by 94%
-
11
Pre delivery inspection defects reduced by 99%
Reduced by 95%
12
Reduced to less than 1/15th
Reduced to less than 1/18th
13
Tata Iron & Steel Co. Ltd Wire Rod Mill ISPAT Kamleshwar
Quality Rate Increased to 99%
10
COMPANY
Rejection / rework
Customer complaints
IOCL, Barauni
Internal sample failure (LPG) reduced to 4 from 160
Zero
Munjal Showa Ltd. Manesar Plant Sona Okegawa Precision Forgings Ltd Gurgaon Raychem RPG Pvt. Ltd Vasai plant Endurance Technologies (Casting) Mahindra & Mahindra Limited, FES, Nagpur Plant
Line rejection reduced to Reduced to 0.2 per month 425 PPM from 11850 PPM from 3
14 Asahi India Glass
Limited, Auto Glass Div, Bawal Plant
For Further Details, Please Contact: Ms Preethi Peter CII Institute of Quality, Near Bharat Nagara, 2nd Phase, Vishwaneedam Post, Magadi Main Road, Bangalore - 560 091
QUALITY PARAMETER
Defects reduced by 77.7%
Reduced by 94.4%
In-process defects reduced to Zero
Zero
In-house Rejection reduced by 90%
Customer Complaint reduced by 87.5%
Reduction in rejection Machines - 96.7% and Reduction in rework Machines - 96.7%
-
Reduced to one-tenth
Reduced to one twentieth
Ph: 080-65667804/23289391/7960 Email:
[email protected] Website: www.tpmclubindia.org
Fax: 080-23289388
