- Business, Operations, TPM
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Chapter 8 of TPM Instructor Course.
The only way we can achieve our goal of zero quality defects is to discard the reactive, “shutting the stable door after the horse has bolted” type of approach, where we only examine quality after it has already been built into the product.
In this chapter will teach how build a system for controlling the causes of quality – in other words, establish and maintain the “zero-defect conditions” mentioned earlier. “Controlling quality through its causes” is the essence of Quality Maintenance.
Next Chapter – Education and Training
Course Content
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The Need for Quality Maintenance
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Goal of zero quality defects
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What is Quality Maintenance?
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Establish Zero-Defect Conditions in Order to Create Equipment and Production Processes that Do Not Produce Any Quality Defects
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The Basic Philosophy of Quality Maintenance
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Establishing Conditions
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The 4 Ms – the Determinants of Quality
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Raising the Quality Assurance Capability (Cp)
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Prerequisites for Promoting Quality Maintenance
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Eliminate Forced Deterioration, to Achieve Stable Equipment Subject to Natural Deterioration Only
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Ensure that All Staff, from Managers through to Operators, Are Equipment Experts
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Developing Quality Maintenance (A 10-Step Procedure)
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Carrying Out Quality Maintenance
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Step 1 Verify the Existing Situation
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Step 2 Investigate the Processes where Defects Occur
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Step 3 Investigate and Analyze 4-M Conditions
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Step 4 Plan Action to Correct Deficiencies
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Step 5 Analyze Situations where the Conditions for Building in Quality Are Unclear
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Step 6 Eliminate Flaws in 4-M Conditions
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Step 7 Finalize 4-M Conditions
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Step 8 Consolidate Checking Methods
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Step 9 Determine Standard Values for Checks
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Step 10 Revise Standards
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Results
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The Figure-of-Eight Method for Quality Maintenance
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The History of Quality Maintenance and the Emergence of the Figure-of-Eight Method
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The Figure-of-Eight Method : Basic Concepts and Development Steps
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Quality Maintenance in a Manual Operation
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Step 1 Identify Existing Situation (Clarify Quality Characteristics and Work Conditions)
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Step 2 Restore (Assess Control Level and QA Level, and Calculate Process QA Rate)
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Step 3 Analyze Causes (Investigate Relationship between QA Level and Defects (In-Process Defects and Passed-On Defects)
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Step 4 Eradicate Causes (Establish Improvement Targets)
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Step 5 Establish Conditions (Propose Improvements and Implement)
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Step 6 Improve Conditions (Check Results and Evaluate)
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Step 7 Maintain Conditions (Consolidate Gains and Sustain)
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Quality Maintenance in Manual Work Processes
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Case Study
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Step 1 Identify Existing Situation
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Step 2 Restore
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Step 3 Analyze Causes
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Step 4 Eradicate Causes
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Step 5 Establish Conditions
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Step 6 Maintain Conditions
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Step 7 Improve Conditions
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P-M Analysis in Eight Easy Steps
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Step 1 Clarify Phenomenon
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Step 2 Do Physical Analysis of Phenomenon
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Step 3 Identify Contributing Conditions
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Step 4 Study 4-M Correlations
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Step 5 Revise Optimal Conditions (Standards)
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Step 6 Investigate Measurement Methods
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Step 7 Identify Deficiencies
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Step 8 Restore, Improve and Sustain
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