JP3092647U - Quality control work table - Google Patents

Abstract

(57) [Summary] [Problem] To realize a quality management system aiming for zero defects. SOLUTION: In order to realize the (Y) method, a quality plan sheet (Y table A) for filling in contents relating to required quality, management resources and management means in the process, a method for assuring the product itself, Product Process Simultaneous Warranty Table (Y Table B) in which warranty methods are entered in parallel, criteria for cause items,
A cause verification table (Y table C) that fills in the contents of the grounds, actual measurement, consistency and improvement, and the progress of the discovery of the failure, confirmation of the method, estimation of the state when the failure occurred, inference of the cause, determination of the cause and countermeasures, Using Y table A, B, C, and cause analysis table (Y table D) for entering revisions of the standard book, a series of quality improvement work is performed within the range of the process for the planned period.

Description

[Detailed description of the device]

[0001]

[Technical field to which the device belongs]

  The present invention relates to a quality control work table used in a quality management system.

[0002]

[Prior art]

  In the field, in the daily production activities, the launch of new products, the reorganization of the process for rationalization, Due to the relocation of personnel, etc., the quality demanded by customers is being pushed further. Like that Under such circumstances, if a defective product is leaked, a complaint will result and a large loss will result. May cause distrust of business owners.

[0003]   The scene was not cut out, but rather TQM, ISO, TPM while busy It has been implemented without complaining. And in the field, there are many troubled equipment, inadequate jigs and tools, The quality is affected by things that are not your responsibility, such as inconsistent standards and staffing. It is supporting that it is desperately leaked.

[0004]   We have many activities with zero defects as our annual policy, but we are unable to achieve our goals. However, it is ideal to have zero defects, and as long as there are process variations, there will be a few defects. I have come to think that there is nothing. However, when a serious complaint occurs, a huge amount of Verification is continued until loss is guaranteed and zero defects are guaranteed. . Therefore, zero defects are not ideal, and we have no choice but to aim as a real problem. Came.

[0005]   In this way, the social demand for quality is increasing more and more in recent years. The stringent quality requirements for the car industry are significant. Even if the defect rate is a few ppm However, even if it costs a lot of money for a defect that impairs its function, it is necessary to take measures. It is in. To address this, car manufacturing companies have set extremely high quality goals: zero defects. We are working to improve it. On the contrary, the current worries of the manufacturing industry are process rationalization. It is difficult to manage and makes quality unstable, such as frequent changes toward It is toward an easy environment.

[0006]   Existing quality that continues from the 1955's, including analysis, management, and improvement starting from the control chart method Although the management method has contributed to many quality improvements, Then, it takes a lot of time and man-hours to cope with the situation. Also the following There were also issues to be improved in the “QFD Initiative”.

[0007]   Here, the basic concept of quality assurance in QFD is to connect each stage and The clarification is that it must be carried over to the final stage. won. And in the manufacturing industry, the required value of the product to be shaped and the manufacturing process The means of putting in (things that the builder should do) are clearly contrasted and can be verified. Had to be. QFD is sequentially developed based on the binary table However, the “method of dropping into the manufacturing area” has not been fully established in the past, and Was not determined.

[0008]   Therefore, from around 1986, "QFD quality assurance efforts for important safety parts "Definition of guarantee level, QA table, QA certification line, important point management board," By developing such methods and forms, we obtained a great quality improvement result. Then about It has been successfully deployed to more than 100 companies for 10 years, but the method is incomplete. From this, it was also confirmed that there were variations in the improvement results and weakness in the retention.

[0009]

[Problems to be solved by the device]

  So, again, to realize the "realization of zero defects" which is the quality required by customers, The on-site warranty status was re-verified. From this verification result, work standard, QC process chart, There are many inconsistencies and omissions in work conditions, etc. I was found to have been leaked.

[0010]   In order to clarify the whole picture, we have to renew in the “quality plan” which is the purpose of ISO. Tried to verify. As a “quality plan” defined by ISO9000 in the past, QC There were some cases where the schedules were diverted easily. As a result, management resources and management means Many defects and omissions were found. Making this improvement is a clue to the improvement of defects. I found out. Clarify and maintain the relationship between product assurance and process assurance. It has become clear that the process will be stabilized if the

[0011]   This invention was made in view of the above problems, and based on the above experience. , TQM which is a management tool for traditional management method and QFD approach, Quality management aiming at zero defects by modularizing core technologies of ISO and TPM The purpose is to provide a digital system.

[0012]

[Means for Solving the Problems]

  In order to solve the above problems and achieve the object, the invention according to claim 1 is devised. The quality control work table can be arranged in either the row direction or the column direction for one or more processes. Enter the required items, management resources and management means in the above process It is characterized in that each entry field is provided.

[0013]   The quality control work table according to the invention of claim 2 is a guarantee method of the product itself. And the content related to the guarantee method of the process of the product are entered in parallel. It is characterized by having an entry field.

[0014]   Further, the quality control work table according to the invention of claim 3 is arranged in the row direction or the column direction. On the other hand, for one or more cause items, the criteria and grounds for the cause items , Field for entering at least one of actual measurement, consistency and improvement Characterized by

[0015]   In addition, the quality control work table according to the invention described in claim 4 is Entry fields for entering the related contents and each item according to the invention described in claims 1 to 3. An entry field for entering confirmation items including the contents related to the quality control work table, and Fill in the fields for inferring the state and the details for inferring the cause. And an entry field for entering details regarding the determination of the cause and countermeasures. ~ At least one of each quality control work table and standard document according to the invention of claim 3 It is characterized by the provision of an entry field for entering the contents regarding one revision.

[0016]

[Embodiment of device]

  The preferred implementation of the quality control work table according to the present invention will be described below with reference to the accompanying drawings. The form will be described in detail. FIG. 1 shows the quality control work according to the embodiment of the present invention. It is explanatory drawing which shows the outline | summary of the (Y) method which uses a table.

[0017] (Contents of (Y) method)   First, regarding the contents of the (Y) method relating to the quality control work table according to the present invention explain. (Y) Method is carried out within the planned period and process range. This is a method of a series of quality improvement work that There are the following items as intellectual and mental structures cultivated.

[0018] (1) A sense of trust in the people at the site. (2) A scientific attitude to accept the facts of the field as they are. (3) Simultaneous exertion of eyes, attention and concentration from various perspectives. (4) A rich sensitivity that organizes, systematizes, and simplifies things that are complicatedly related. (5) Understanding to follow scientific procedures and methods verified by the most advanced practices. (6) A habit of always having goals, motivating and continuing. (7) On-site training to see, read, listen, calculate, write, speak, and acquire Customs. (8) Ability to detect small changes in advance.

[0019] (How to decide the goal of the (Y) method)   There are various quality conditions on site as mentioned at the beginning. The content is also from% to pp m, and even closer to zero defects. Therefore, here is the goal: It

[0020] (1) In the% area process, first move to the ppm area. (2) The process in the ppm region is to the defect-free region. (3) The current zero defect area process will be expanded by expanding the period and quantity range. Close to zero.

[0021]   The "zero defect area" here limits the period, quantity, and process, and the Achieving a good zero. Generally speaking, zero defects are considered in the infinite state. At first, I imagine the difficulty, and I feel that it is impossible. There If you set a goal that limits time, quantity, and process, the method and possibility will be considered, and as a goal There is no resistance and a sense of accomplishment is obtained. Conventional 1/2, 1/5, 1/10 There are ways to decide, but the grounds are not clear in practice. Customer demand is zero defects, There is no end to this, and it is an approaching approach. That is, "Reduce the defects and be awarded From the “era when it was awarded” to the era when “awards for maintaining the status of not producing defects” It is intended to change.

[0022]   In other words, zero means that the cause of defects is zero, and we aim for zero defects. The first condition is the required quality of the process, quality status, quality system, management means, management resources. Is to reveal the whole picture of in detail. Suddenly, don't get into the problem . Even if the problem is solved, there is no guarantee that defects will be zero.

[0023] ((Y) Method condition)   (Y) The following are conceivable conditions for the method. (1) Decide the period and operate quickly. (2) Achieve results reliably and achieve zero defect area. (3) Everybody can do (group leader, section chief). In addition, each department is specialized To cooperate. (4) Utilize TQM, ISO, TPM, etc. (5) Daily production activities and improvement activities should be integrated. (6) Do not require difficult techniques or long-term training. (7) The operation of quality assurance should be clarified and maintained. (8) Applicable regardless of company size, process type, new period or current.

[0024] ((Y) Method operation conditions)   (Y) The following are possible conditions for operating the method. (1) Enter the site and thoroughly observe and become familiar with management resources and management means. (2) Overall picture of quality data, complaints, deliveries, process defects, scrap, and rework up to now To clarify. (3) Clarify all management methods, standards, forms, data, etc. (4) Clarify statements of facts and speculations during operation.

[0025] (Philosophy of achieving zero defects)   In order to achieve zero defects, consider the following. (1) There is no chance of being defective. There is always a cause. (2) Disclose all information related to defects. Do not hide to protect yourself. (3) Do not make simple management cut-offs because of the increase in management costs (small It is difficult for the manager, section manager, and group leader to take care of the management of such causes. Goodness will not disappear). To be a strict person with no ambiguity Is. (4) The entire process from material input to shipment, the required quality of the process, management resources, and management Immediate visibility of the entire quality system and individual content, such as steps To do. (5) Know all the relationship between the content of failure and its cause. And the tube of the cause Know that the work is being carried out. (6) When a new defect occurs, analysis is performed until the cause is clarified. true If the cause of the problem is not clear, continue to observe the “probable cause” as a management target. thing.

[0026] ((Y) Method theory and concept)   (Y) In practicing the method theory, first, contingency is denied. That is, I think that there is always a cause for defects. Then, activities (management, improvement) are input from the cause system. It In addition, the management of the cause system is based on the core technology of TQM, ISO, TPM. Make use of Joule. Modularization makes the functions simple and clear. module For example, from TQM as a control means As a quality management system from analysis method and ISO, quality plan, standardization, Documentation and management resources from TPM include facility maintenance and PM analysis.

[0027]   And as a method to effectively function and support this modularization, four work tables To set. These work tables clarify the actual state of the causal system in a wide, deep and precise manner. To do.   1) Quality plan table (Y table A (see Fig. 3))   2) Simultaneous product process guarantee table (Y table B (see FIG. 4))   3) Cause verification table (Y table C (see FIG. 5))   4) Cause analysis table (Y table D (see FIG. 6))

[0028]   In addition, verify the cause system in advance and correct the problem. Also, the site is intelligent Carry out specific activities.

[0029]   This theory is “caused by traditional inductive QC with inductive results”, but is it the cause? The biggest feature is that it is a deductive method to enter. Here, induction is a reasoning And is one of the thinking procedures. General propositions or laws from individual concrete facts Is to derive. Whereas deduction is to derive universality from speciality, deduction is , Is a type of reasoning. If we accept the premise, we must accept the conclusion. The proof in mathematics is typical.

[0030] ((Y) Points to keep in mind when creating a method)   Note the following points when creating a specific program. That is, (1) Denying the "random chance of failure", the cause search was the first step. To achieve this, It was important to understand the whole picture of defects. Therefore, a person who is familiar with the site can Wide, deep and in-depth grasping work was incorporated.

[0031] (2) The field has been said to keep the standard. But in reality There were many cases where what was not specified was implemented as "tacit knowledge." Not It is important to change "tacit knowledge" to "formal knowledge" to achieve good zero. Manufacturing The people in the field know that, and the work standard book created by the staff It is easy to occur. Therefore, it is a method that can be created and used by people in the field.

[0032] (3) In addition, there are various on-site management systems depending on the company. Has been done. Quality requirements have increased and the on-site management system has become complicated. The above education and training and improvement activities are required to be improved. The association of these management systems I took note.

[0033] (Procedure of (Y) method)   As a basic program procedure, first create a quality plan, Clarify the criteria before starting improvement. Compared with the improved QC problem solving method, From the beginning, clarify the actual situation of the management resources and management measures that affect quality. Aims to suppress defects from the beginning. The quality plan (table) is an index that captures the whole picture. It can be used for associating products and parts with the role of a box.

[0034]   The procedure of the (Y) method is composed of the following 15 steps.   Procedure (1): Select products and processes and set goals.   Step (2): Determine process layout, route and unit process.   Procedure (3): Collect required quality items, market, delivery, and process defect data.   Step (4): Examine all management resources and management means for each process.   Step (5): Create a quality planning table (Y table A) and clarify the criteria.   Step (6): Create a product process simultaneous guarantee table (Y table B).   Step (7): Create a cause verification table (Y table C) and pre-verify the product and process.   Step (8): Improve equipment, standards, and inconsistencies by verification.   Procedure (9): Y Tables A and B are revised and work is performed.   Step (10): Create a cause analysis table (Y table D) for chronic and sudden failure.   Step (11): Remedy found equipment, deficiencies in standards, and inconsistencies.   Step (12): Y tables A, B and C are continued until the defect is zero.   Step (13): Measure and evaluate customer dissatisfaction.   Step (14): Reflect in management review.   Step (15): Enter achievements, impressions, and future challenges.

[0035]   For the zero realization procedure by continuous improvement, refer to the PDCA classification in Fig. 2. It is as shown in the application table. That is, the above procedure (1) to procedure (15) are shown in FIG. As shown in, each item is classified into PDCA and improvement procedure items.

[0036] (Contents of each procedure)   Next, each content of the above procedure (1) to procedure (15) will be described. First, the hand In order (1), products and processes are selected and goals are set. Specifically, product name, process Name, production volume, process manager, number of people, immediate goals, etc., and describe.

[0037]   Next, in step (2), a process layout drawing, a route, and a unit process are determined. In particular , Stand and observe. Then, with imitation paper, memos, digital cameras, etc. To shoot. Also, draw the movement range of the worker. In addition, equipment, molds, jigs, measuring instruments Fill in, etc. See also standards, forms, record keeping bulletins. Also, the material Enter the range of the unit process by looking from the charge input to the product discharge. Also non-conforming See how to handle goods. At that time, try to see the actual situation as it is.

[0038]   Next, in step (3), data on required quality items, market, delivery, and process defects are collected. Meru. Specifically, the requirements and process quality items for each process, such as inspection standards and internal customary items. Collect eyes. In addition, quality data, that is, repair, scrap, post-process, defective delivery, etc. And data such as market complaints. The period is about 6 months, or 1-2 years To do. At that time, the management method of quality information is also examined. In this way, quality items, quality Collect data.

[0039]   Next, in step (4), all the management resources and management means are checked for each process. Specifically, first, an imitation paper or the like is prepared. And based on the above process layout drawing, Management resources (equipment, jigs, tools, measuring instruments, molds, parts, materials, consumption (Items, limit samples, Pokayoke, identification cards, labels, etc.) further, Quality regulations, standards, work standards, equipment inspection sheets, quality recording sheets, priority points Components, QC process chart, setup procedure, product process simultaneous guarantee chart, quality record, nonconforming product processing base Gather all management measures such as standards, education and training standards, environmental standards, safety management standards, and Write out on papermaking.

[0040]   Next, in step (5), a quality planning table (Y table A) is created to clarify the criteria. . Specifically, first, A4 paper or imitation paper is prepared. Next, in step 3 above Enter the required quality and quality data examined on each step of the imitation paper. And in step 4 Enter the collected management resources and management means for each process. Where management resources and management The classification of the items of scientific means should be decided after considering each unit after considering each process. You can either classify it in advance and fill it out. Also, fill in management means Is the standard name and management number. When there is no management number, only the name is used. Sutra The same goes for resources. The format may be vertical writing or horizontal writing. However, any format may be used. What is a quality plan table? It is a pull. A detailed description of the quality plan table will be given later.

[0041]   Next, in step (6), a product process simultaneous guarantee table (Y table B) is created. concrete First, prepare the format of the product process simultaneous guarantee table. About the product process simultaneous guarantee table The detailed description will be given later. Next, for each process in the quality plan, The current guarantee method for the corresponding items from the management resources and management means to the applicable product process simultaneous guarantee table Fill in. Similarly, in order to guarantee the product, the guarantee method in the process, management resources, management Fill in the corresponding column of the process from the management means.

[0042]   Next, in step (7), the products and processes are identified in the Y tables A and B, and the cause verification table (Y table C). Create and verify in advance. In addition, in step (8), the equipment and standard Prepare and improve inconsistencies. Specifically, first, a cause verification table is prepared. Next, Verify each unit process. The applicable quality, management resources, and management means are Fill in from the chart. In addition, enter the reference value for each item. In addition, the standard value on site Verify the actual situation, and fill in any deficiencies or inconsistencies. Here, deficiencies are equipment and jigs. , The instrument is damaged or defective, and the inconsistency is the difference between the standard document and the actual one. For the verified inadequacies and inconsistencies, make improvement plans and implement countermeasures. And of the measures Confirm implementation on site. The above is carried out for all the unit steps.

[0043]   Next, in procedure (9), the Y tables A and B are revised and the work is carried out. In particular First of all, the quality plan table and the product process simultaneous guarantee table have been revised through the implementation of process verification improvement. Check for the presence. In case of revision, it will be issued as the latest version. Also improved Educate and train workers about the equipment and standards. After that, carry out daily work It In addition, create a check sheet to indicate whether there are any abnormalities in the process, Figure out from. Then, the roles of the workers, team leaders, and section chiefs are decided, and the process is managed. To do. In addition, section managers and factory managers take monthly control and take corrective actions for defective deliveries. It In addition, a quality plan table is created for new products and new processes, and management resources and management measures are Take preventive measures.

[0044]   Next, in step (10), a cause analysis table (Y table D) for chronic and sudden failure is created. . Specifically, first, the target of failure is determined. For example, if the delivery is Whether it is a recurrence or a recurrence, and if it is a process defect, it is chronic or sudden. Next, when making a cause analysis table, first, the state of defect detection ((1) when, (2) where , (3) Who, (4) How, (5) Content of defect). And bad Estimate and verify the raw cause. For that purpose, first of all, quality plan and product process Prepare a warranty card. Then, the generation process is estimated based on the content of the defect. Also delivery Estimate the date of occurrence from the lot. Also, check for similar defects in the process, and further In addition, the change points (workers, materials, equipment failures, etc.) on the day of the occurrence process are also analyzed. It Then, we carefully inspect the business resources and management means from the quality plan table to estimate and verify the cause. . Then, take measures against the probable cause.

[0045]   Here, FIG. 6 is used as the format of the analysis plan table. Detailed explanation of analysis plan Will be described later. Enter descriptive information according to the analysis plan procedure. In the traditional style, Formally guessing the cause and causing the negative effect of confirming the site without verification Take note and clarify facts and speculations.

[0046]   Next, in step (11), the found equipment, deficiencies in standards, and the improvement of inconsistencies should be corrected. Konu. Specifically, regarding the probable cause, "cause", "standard", "standard", "work" Controlled resources by further observing processes by classifying them into “work”, “improvement”, “implementation” and “confirmation” , Improve management resources. Here, the “standard” is equipment, jigs, technical standards, work targets. Associates are included. Also, “improvement” includes new equipment, new methods, and the like.

[0047]   Next, in step (12), the quality plan table (Y table A) and the product process simultaneous guarantee table (Y table) B), the cause verification table (Y table C) is continued until the defect is zero. Specifically, the steps above If you continue to, delivery defects will decrease and become stable only at some time. Next, start process defects To do. There is a record of scrap of process defects, but there is a record of simple rework. Make a clear definition of defects and record for all. And all the defects Target at the same time. Create a cause verification table (Y table D) for each defective item and improve it. Proceed. In this way, the quality plan table (Y table A), product process simultaneous guarantee table (Y table B), Continue to improve with the cause verification table (Y table C) aiming for zero defects.

[0048]   Next, in step (13), the degree of customer dissatisfaction is measured and evaluated. Specifically, We will clarify the whole picture of defective delivery and complaints to customers for one year. And 6 months in the first half And 6 months in the latter half of the period, "increasing", "no change", "decreasing" Ru ". Also, the in-house post-process is evaluated in the same manner. And the goods Quality loss cost (disposal cost, rework cost, inspection cost, overtime due to reduced productivity) Cost, external compensation cost, inventory cost due to unstable quality, etc.).

[0049]   Next, in step (14), it is reflected in the management review. In particular, The results of quality improvement programs aimed at zero defects are used internally as a part of ISO activities. Objective evaluation by quality audit management review.

[0050]   Finally, in step (15), enter the results, impressions, and future challenges, and finish the series of steps. Finish.

[0051] (Contents of the quality plan table (Y table A))   Next, the contents of the quality planning table (Y table A) will be described. Figure 3 is a quality plan table It is a chart showing (Y table A). In FIG. 3, the quality planning table 300 shows the process , One or more steps (step 1, step 2, ...). here, The process means processing, work unit, moving unit, machine unit, person unit, and the like. And In the “process” column 301, the process name, function, content, etc. are entered.

[0052]   In addition, as a quality management system, "required quality", "management resources", " Each item of "management means". In the "Required quality" column 302, quality standards and defect items Enter defective items, required takt time, required cause unit, etc. "Management Resources" column 303 Enter equipment, molds, jigs, tools, tests, measuring instruments, materials, auxiliary materials, people, etc. . In the "management means" column 304, there are technical, work, inspection, setup, inspection, record, nonconformity. Enter items, education, standards, etc.

[0053]   Further, there are two methods of arranging the constituent elements, that is, a horizontal format and a vertical format. Choice is process and structure The one with the best combination of components will be used. In this way, the quality planning table 300 In one or more steps, either in the row or column direction, Entry fields 302 to 30 for entering required quality, management resources, and management means 4 are provided respectively.

[0054]   Next, a procedure for creating the quality planning table (Y table A) will be described. Quality plan table 30 0 is created by the following procedure.

[0055] (1) Observe the site.   Here, stand on the side of the target process. Then, watch the movements of the equipment and workers. Also Look at the flow of materials, parts, and products, and start observing according to the flow order. here So, the point of observation is not to look for the process, but to see the actual situation as it is. It is to guess. For example, incoming parts, material storage locations, locations, and Observe how to handle, such as storage, delivery, transportation equipment, transportation method, and how to handle slips .

[0056]   Also, observe the method of inputting parts and materials into the process. Specifically, parts , Equipment and people who produce materials while processing, moving, processing, and moving within the process Observe the movement of. Also, observe the handling of final product inspection, packaging, storage, and shipping. It See also storage of standards, forms, records, check sheets. Also, jigs, Look at the tool. Also, observe how to handle nonconforming products. Records of observations are notes, It can be a photograph, digital camera, VTR, etc. This observation is for quality planning, Not for use in improvement. Therefore, if a defect is discovered, do not point out.

[0057] (2) Create a layout diagram of the process. (3) Create processing routes (flows) for products and processed products. (4) A unit process is determined based on the process contents according to the processing route. (5) Investigate required quality and quality status data. (6) Create an observation record of management resources. (7) Collect management tools, standards and forms. (8) The quality planning table 300 is created by classifying each unit process.

[0058]   Next, the verification procedure of the quality planning table (Y table A) 300 will be described. First, the product Verify the regulatory requirements of the quality system and the quality planning table 300. Next, the actual process The state, management resources, and management means are verified. And clarify inconsistencies in each process To For example, if the work does not match the standards, or the work is However, there is no standard. Next, the cause is estimated and management resources and standards are set. Plan and implement improvement plans and countermeasures. In addition, add or change the quality planning table 300. To do.

[0059]   As described above, the quality planning table (Y table A) 300 is You can understand the status of management resources and management methods, and find out the inadequacies. In addition, the standard Become a dex. It should also be used for ISO and QS inspections and quality audits of delivery destinations. You can It is also necessary for creating and verifying the product process simultaneous guarantee table 400 described later. . Furthermore, it can be used for education and training.

[0060] (Contents of product process simultaneous guarantee table (Y table B))   Next, the contents of the product process simultaneous guarantee table will be described. Figure 4 shows the product process simultaneously It is a chart showing a guarantee table (Y table B). In FIG. 4, a product process simultaneous guarantee table 400 In the process unit, the result, that is, the guarantee method of the product itself and the It is a table in which the guarantee method of the factor of the result is described in parallel.

[0061]   In the product process simultaneous guarantee table (Y table B) 400, the following actions are to be guaranteed. Acclimatization and implementation. (1) Determine warranty items. (2) Determine the guarantee standard. (3) Determine the measurement method. (4) Determine frequency and timing. (5) Document the above procedure and data recording method as a standard document.

[0062]   The product process simultaneous guarantee table (Y table B) 400 is composed of vertical units of process. Please fill in the right side of the product ("Warranty content column 401 of" Product ") In the guarantee content column 402) of “Process”, set the procedure of each guarantee action of the process for each item. Set. In this way, the content of the guarantee method of the product itself and the process of the product An entry field will be provided to enter in parallel with the content regarding the guarantee method of.

[0063]   In addition, when selecting products and processes, a quality plan table (Y table A) 300 is created. Existing products and processes. In addition, the required quality standard documents (drawings, inspection Standards and forms registered as management resources and management means It And an auxiliary table (required quality, management resources, management method related table) is created for each process. To do. Here, each item is specified according to the definition of assurance from the inspection standard document. In addition, process guarantees corresponding to product guarantees will be provided.

[0064]   The point of the product process simultaneous guarantee table (Y table B) 400 is to define the warranty items and their contents. It is for the sake of clarification that no one can train the simultaneous production process guarantee table 400 for anybody. It is easy to do. Ensure assurance items, standard values, measurement methods, frequency, documentation, etc. If you try to fill it out, you have to clarify the ambiguous things. Will come.

[0065]   There are many kinds of standard documents and data in the process, but these control items, inspection items, points The inspection items and quality characteristic values were ambiguous, inconsistent, and missing. Also product warranty Many items, that is, inspection items and the number of extracted items, are written, but actually omitted There are some processes that have been implemented, and some processes that take a lot of man-hours. . Neither had any problems. Also, the process guarantee items are the product guarantee items. It is easy to create a correspondence with eyes by verifying work standards and control process charts. Natural As a matter of fact, the details of the process guarantee items become more detailed. Also unknown It cannot be filled in and is left blank.

[0066]   A comparison of existing standards and product process guarantee tables in the case of press assembly B. This process includes a quality matrix table, control process chart, inspection standard document, and other products. It is managed by many standards such as business standards. The important quality of this process is It is a missing piece of contact peeling part, a dimensional deviation of assembly, about it matrix It is repeatedly written on the management process chart and inspection standard. But how about this in the process So much is not written in detail about how to guarantee it.

[0067]   Therefore, it is possible to check the on-site work, work standard documents, technical standard documents, etc. to simultaneously maintain the product process. I made a certificate 400. This includes voltage, current, welding Process guarantee items such as area electrode replacement are written. Also, the dimensional deviation is due to the assembly jig It is stated that the locating pin position and the wear control guarantee it. sand In the product process guarantee table 400, you can see the guarantee relationship between the product and the process at the same time. It is also simple and easy for workers to understand.

[0068]   As described above, the product process simultaneous guarantee table (Y table B) 400 shows the product and process The guarantee relationship becomes clear. The rationale for the number of samplings and the timing will become clear. Duplication of standards, The shortage becomes clear. The lack of records and data becomes clear. Factor control of process assurance Becomes clear. Definition of terms is required. Management is simplified. Man-hour required for creation You can do it at work without doing it. Easy for anyone to understand. Common products can be used. Work Also useful for audits. When a defect occurs, it is useful for investigating the cause. Also useful for new products It can be created without standing and without QFD development. Useful for organizing ISO documentation Have the effect. In addition to the manufacturing site, quality assurance of drawings, molds, equipment, etc. It can also be used for office management.

[0069] (Contents of the cause verification table (Y table C))   Next, the contents of the cause verification table will be described. FIG. 5 is a cause verification table (Y table C). FIG. In FIG. 5, the cause verification table 500 shows a result for each process. The guarantee method of the result, that is, the product itself and the guarantee method of the process, that is, the factor of the result, are It is a table described in columns. That is, one or more in either the row or column direction. For each number of cause items, the criteria, basis, actual measurement, consistency and improvement in the cause items Provide an entry field to enter at least one of the related contents. This allows the quality meter Demonstrate the criteria of the cause inferred from the chart 300 and the product process simultaneous guarantee table 400 Is.

[0070]   Here, the selection of the cause to be entered in the “cause item” column 501 is performed by the quality plan table (Y table A ) 300, product process simultaneous guarantee table (Y table B) 400 , By guessing. In addition, the criteria for the cause of entry in the “criteria” column 502 is the Y table. It shall be completed in the current standards for A and B. Also, the “ground” column 503 The rationale for the standards to be filled in is to clarify the determination of the standard values entered in the current standard document. It If quoted from the technical standard, enter the technical standard NO. Technical standard If there is no written description and it is an implicit value at the site, it is the experience value.

[0071]   For the actual measurement entered in the “Measurement” column 504, confirm the cause selected at the site. Measure and enter the measured value. The consistency entered in the "Consistency" column 505 is Compare the reference value with the actual measurement value, and if there is a match, enter "Yes". And, " In the “improvement” column 506, if there are no defects, it is determined as a reference value and the fact is entered. In addition, if there is a risk of defects, consider and improve the technical standard document and enter that fact. It On the other hand, if they do not match, enter “None” in the “Consistency” column 505 to indicate a failure. If it is zero, the “improvement” column 506 is entered based on the actual measurement value. Well If there is a problem with the measured value, improve the standard value and re-determine it, and enter that fact. It

[0072]   The basis of a quality management system is the estimation of the cause and its confirmation. Is. The inductive method that has been used in the past does not It is verified by a statistical hypothesis test. On the other hand, method (Y) uses one principle We speculate on a number of causes and there are few data. How to verify the cause in this case As a method, using the cause verification table (Y table C) 500, the basis for determining the standard value of the cause is compromised. Verification method based on the consistency between correctness (estimation by the background law) and actual measurement, and whether or not there is a defect Is used.

[0073] (Contents of the cause analysis table (Y table D))   Next, the contents of the cause analysis table will be described. FIG. 6 is a cause analysis table (Y table D). FIG. In FIG. 6, the cause analysis table 600 applies the (Y) method. Of product delivery defects, process defects, and other defects in the current process, and causes Estimate, confirm, improve, and revise Y table A, Y table B, and Y table C. for that reason, An entry field for entering details about the process of defect discovery ("Progress of defect discovery" column 60 1) and an entry field for entering confirmation items including the contents related to Y table A, Y table B, and Y table C ("(Y) Method Confirmation" column 602) and estimation of the state at the time of failure occurrence Fill in the fields ("Guess the state at the time of failure" column 603) and the cause Entry field ("reason for cause" field 604) for entering the content of the theory, and confirmation of the cause An entry column (“Determine cause and countermeasure” column 605) to fill in the details regarding the countermeasure, and a Y table A, Y table B, Y table C and the entry fields for entering the contents related to the revision of the standard document ("Y table "A, B, C, revision of standard document" column 606).

[0074]   Then, enter A to G in the “Progress of defect detection” column 601, and enter “(Y) method Confirmation ”column 602 is filled in. And "guess about the state when a problem occurs" In a column 603, the process, occurrence time, charge, work state, and other facts at that time are entered. At this time, in the case of guessing, enter (guess). Next, in the “cause inference” column 604, Fill in A to D and infer the cause. Then, take measures against the confirmed cause, and The reason is entered in the “determination of cause and countermeasure” column 605. Finally, Y table A, B, C, standard Revision of the document, and to that effect in the "Y table A, B, C, revision of standard document" column 606 To enter. At this time, if the paper is insufficient, any paper may be added. This is on the cover Try to use the style.

[0075]   (Y) Even if the method is expanded, the remaining cause or recurrence of the known cause may occur. Due to this, defects or defects may occur. Cause analysis table (Y table D) 600 is those To prevent the recurrence of the cause of. This Y-table D continues until zero is achieved.

[0076]   Thus, according to the present embodiment, (1) The theory, concept, and procedure of the program have been clarified, and the convenience of application has been improved. (2) The management man-hours have been reduced by making it possible to handle ISO examinations and external examinations in a unified manner. (3) Document management No. is clearly specified and managed collectively. It is possible to prevent know-how from leaking. (4) It is possible to use it in parallel with the current methods such as TQM, ISO, and TPM. (5) Clarified relations and positioning of various materials (enhanced index function ). (6) The effect was improved quickly so as not to fall into rut. (7) The procedure is clear, and the section chiefs and team leaders can do it. (8) Can be continued in daily work. It can be incorporated into the quality system. (9) Anyone can easily perform step management using a personal computer. (10) Verification and creation can be done at the initiative of the site, and equipment and technical departments can be actively engaged. It is used as a tool (making it easy to request equipment that is reliable in the field and providing standards). Can be mentioned.

[0077]   Also, as an addition to the needs of the people on site and consideration for activities, (1) Being clear and easy for anyone to understand. (2) Things that can be done mainly by the field leader by closely contacting the site. (3) What you can do with a gentle hand, and how to achieve results in a short period of time. (4) Applicable to any process or work. (5) What you can do either by handwriting or by using a computer. (6) The manual should be easy to teach. (7) Be easily translated into English. (8) Applicable to new products and new processes from the beginning of mass production. (9) Procedures should be logically constructed. (10) The theory of zero defects is clear, and there is confidence in zero defects. Can be mentioned.

[0078]

[Effect of device]

  As described above, according to the present invention, the traditional management method and the QFD type approach are used. Modulates core technologies of management tools such as TQM, ISO and TPM And the effect of being able to obtain a quality management system aiming at zero defects Play.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing an outline of a (Y) method using a quality control work table according to an embodiment of the present invention.

FIG. 2 is an explanatory diagram showing an application table by PDCA classification of a zero realization procedure by continuous improvement of (Y) method.

FIG. 3 is an explanatory diagram showing contents of a quality control work table (quality plan table (Y table A)) according to the embodiment of the present invention.

FIG. 4 is an explanatory diagram showing the contents of a quality control work table (product process simultaneous guarantee table (Y table B)) according to the embodiment of the present invention.

FIG. 5 is an explanatory diagram showing contents of a quality control work table (cause verification table (Y table C)) according to the embodiment of the present invention.

FIG. 6 is an explanatory diagram showing contents of a quality control work table (cause analysis table (Y table D)) according to the embodiment of the present invention.

[Explanation of symbols]

300 Quality plan table (Y table A) 301 "Process" column 302 "Required quality" column 303 "Management Resources" column 304 "Management means" column 400 product process simultaneous guarantee table (Y table B) 401 "Product" warranty details column 402 “Process” guarantee content column 500 Cause verification table (Y table C) 501 "Cause item" column 502 "Standard" column 503 "Basis" column 504 "Measurement" column 505 "Consistency" column 506 "Improvement" column 600 Cause analysis table (Y table D) 601 "Progress of defect discovery" column 602 “(Y) Confirm method” column 603 "Guess the state at the time of failure" column 604 "Cause inference" column 605 "Determining the cause and countermeasures" column 606 “Y table A, B, C, revision of standard” column

Claims (4)

[Scope of utility model registration request] 1. An entry column is provided in one of a row direction and a column direction, for each one or a plurality of processes, in which a requirement item, a management resource and a management means in the process are entered. Quality control work table. 2. A quality control work table, which is provided with an entry column for writing in parallel the content regarding the guarantee method of the product itself and the content regarding the guarantee method of the process of the product. 3. A criterion in the cause item for each one or more cause items in one of a row direction and a column direction,
A quality control work table, which is provided with an entry column for entering at least one of the grounds, actual measurement, consistency, and improvement content. 4. An entry column for entering details regarding the progress of defect discovery, an entry column for entering confirmation items including details regarding each quality control work table according to the invention described in claims 1 to 3, and a defect. Entry fields for entering the details about the estimation of the state at the time of occurrence, entry fields for entering the details about the reasoning of the cause, entry fields for entering the details about the determination of the cause and countermeasures, and the claims 1 to 3 A quality control work table characterized in that each quality control work table according to the invention described above and an entry field for entering at least one revision of the standard document are provided.