Factory management formulas are so worth collecting

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An overall goal


Guarantee quality and quantity (quantity), meet deadlines and comply with regulations (regulations), and always approach zero defects.  


Two key points


The first thing must be done, and there are few problems with spot inspections in place.

Process abnormalities should be paid attention to, problems should be eliminated and remanufactured.



Three no policy


Do not accept defective products.

Do not manufacture defective products.

Do not let go of defective products.



Four practices 


Refer to the requirements of the homework instruction book to understand the essentials of your position.

Refer to specifications and standards.

No first inspection (first inspection) has been done. 

Reconfirm when you are done.


Five concepts


Meet customer requirements, there is no discount on quality.

Quality is not tested, but guaranteed by design, manufacturing, and habits. 

The effect of active self-inspection is better than countless passive inspections. 

Do it all at once, and any repairs and rework will affect the quality. 

Almost, probably, seems to be the worst enemy of quality.


Six don't let go


The reason can't be found-------don't let it go 

I can't tell the responsibility-------don't let it go 

Corrective measures are not implemented---do not let go

Corrective measures are not verified---do not let go 

Effective measures are not included---do not let go


Seven kinds of waste 


Waste of waiting, handling, moving, excessive production, inventory, substandard products, and processing.
Eight steps to solve the problem 


Clarify the problem    

Decompose the problem    

Set goals  

Grasp the true cause      

Formulate countermeasures    

Implement countermeasures

Evaluation results and process         

Consolidate results


Nine steps for quality exception handling 


Discover the problem 

Selected items-Quality-SPC  

Track down the cause               

Analyze data 

Propose a plan              

Select object 

Drafting action           

Comparison of results 

standardization

 


5W2H rule


What---what's the problem?(Main problem) 

Why---Why do you want to do this (goal) Clarify the goal and eliminate unnecessary steps 

Where---Where is it/Where is it done (location) 

When---What time is the best, when to start/end (time) selection order 

Who----Who will execute and who is responsible (person) 

How----How to complete, is there any other way (method) to simplify the work? 

How much---To what extent is it completed and how much is the cost (degree, cost)



4M1E 


Man

Machine

Material

Method

Environment


VIQ technique


Value Analysis techniques


Value Engineering techniques 


Industrial Engineering techniques 


Quality Control techniques



Quality control circle activities


5-10 colleagues in the same place form a small group together. In view of the problems in the workplace, the members brainstorm ideas, use VIQ techniques, turn the PDCA management cycle, implement independent management, and fully participate in and implement it.


QC Seven Techniques and Formulas


Check the received data   

Control and prevent mutation  

Straight square display distribution

Bola grasps the point 

Spread to find related       

Don't look for differences

Characteristics find the reason



8D technique


Organize a group

Problem description

Emergency treatment

Expand horizontally

Bad containment

Status analysis

Preliminary reasons and temporary countermeasures

Root cause and permanent countermeasures

The effect is confirmed, unfolded horizontally

Implementation of foolproof measures

Standardization, documentation, curing



Three Present Five Principles 


Sanxian：

On-site

Present object

Status quo





Five principles：

A Figure out the occurrence (phenomenon, content of complaint, number of occurrences), and grasp the facts (confirmation results of parts, cause analysis, and quality status of the parts currently in production)

B Identify the cause (path of occurrence, problem reproduction test, analysis of 5 WHY)

C Appropriate corresponding strategies (countermeasure content, effect prediction)

D Confirm the effect (confirm the actual performance of the countermeasure)

E Feedback on the source (to be implemented into the content of system and organization standardization