Zero Defect

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