QUALITY ASSURANCE CHAIN

Purpose Of QAC

Looks for control item or control new point in every process that in the existing has not been taken care of. By taking care of control item or control the new point is expected problem happened will not reoccurrence.

Control item is important Item from a 4M factor in every motion (impulse) observation

Example : Position of inspector ocular

Control point is detail from important item from a 4M factor in every motion (impulse) observation

Example : Inspector Ocular distance from work substance

Inspector Canthus to work substance

Controlled Factors

Control point which will be searched every process to cover 4M factors (Material, Machine, Man, Method), for environmental factor / Environment is added to Machine factor.

a. Material = All thing becoming product or part of the product.
Example : Press Part, Nut Weld, Bolt, Wire, paint , etc
b. Machine = Engine / device applied forms the product. Besides, environmental factor ( example: temperature, weather , lighting , humidity ) also include in part of this Machine.
c. Man = Man who is doing processs produce / Inspection / keeping / scheme so that the product is formed.
d. Method = All thing related to control 3M ( Material, Machine, Man ) to run carefully.

Step by step of QAC

A. Election of Theme Problem

Till Now QAC is done based on problem happened to the product.
Theme Criterion Problem that need to be done activity QAC :

a. Safety Problem
Problem which can menace safety of its(the consumer.
b. Pareto Problem After Market
Problem which very often emerges in end user
c. Pareto Problem Inspection
Problem which very often is found in Inspection Line

Although that way not closed possibility that this QAC also applicable to increase performance from a process without based on from problem happened.

B. Makes Level 1 QAC

What intended Level 1 is Mapping accross the board to process forming the product.
First step is do surveying overall of process related to formation of the product, either process in internal or process in external ( supplier ).

Second step is do detail Job Content from each process that is intended Job Content is principal activity done in every process.

Third step is writes down theme title studied ( sees red line ),
Writes down " probably cause" which happened or possibility that there will be in column category

Gives signal for position where the " probably cause" happened on course " before" ( before QAC )
Gives signal for position where the " probably cause" can be detected on course " before" ( before QAC )
For area job content having potency happened problem is given by special marking ( green colour ).

Fourth Pace is writes down control point which now is taken care of in every process as according to factor Material, Machine, Man & Method. Control point written down can based on SOP, WI, or document of standard applied by that moment. Sees the area is breaks redlining.

 C. Makes QAC LEVEL 2 :

It is activity of 4M analysis to inspection areas, Purpose of this 4M analysis is look for control point-control new point in every process. First pace when doing analysis is with making detail motion/ impulse Inspector / Machine based on reconnaissance of direct is field ( genchi-genbutsu ).

a. Writes Down Motion / Kinetic

Writes down in detail impulse Inspector / operator & engine is hardly important More detail ( break down ) the impulse increasingly either due there by we can 4M Analyze with interest detail so that control point found more amount.
b. The best way to detailing motion can / kinetic is by doing reconnaissance of direct is field ( genchi-genbutsu ).
c. Does reconnaissance every motion in 4M
In doing inspection, we must think " zero mind " mean mind we don't tied to control point/standard which is the existing have been taken care of. Writes down all control point found when doing reconnaissance, good of that is control point have been in standardization as well as control point which has not been standardization.
Writes Down Standard to control point which we know at standard column and writes down Y ( Yes ) if the standard have been in standardization in document of work, and writes down N ( No ) if that standard had not in standardization in working document. Writes of actual condition of the control point which we know at column Actual and writes down Y ( Yes ) if condition of the actual equal to standard which we write down in standard column and writes down N ( No ) if condition of the actual unlike standard.

d. Confirm Item evaluation
Status Control point which is in the standard N still ( No), or its the actual N still ( No ) is we conceive of Confirm Item.
Confirm the item we evaluated again to ensure that the Confirm Item of course has influence to problem we are overcoming.
e. Does Improvement to Confirm Item
After we ensure that some confirm item has influence to problem which we overcome, the next pace is by doing Improvement to apply Confirm Item in order to become Control point permanent. Improvement done covers : Standardization to working document and transformation at work. Ascertains to do socialization & training to Inspector / related operator to application of control point.

D. Makes QAC LEVEL 3

It is activity of 4M analysis to Production areas.
Purpose of this 4M analysis is look for control point-control new point in every process. First pace when doing analysis is with making detail motion/ impulse Operator / Machine based on reconnaissance of direct is field ( genchi-genbutsu ).

Paces done is the next equal to making Level 2.

E. Improvement activity

Analysis having taken steps 4M either in level 2 or 3, we will find control point which its(the status N still ( no ) in standard or actual. Ideally we must do refinement to all control point, but because limitation of time, we can choose to do refinement ( priority ) to control point which very influential to theme we are studying based on agreement between team QAC.
Improvement done covers : refinement in field , refinement of document or training to operator or inspector.
Create kaizen list to control point which we would do refinement so that easy to do control.

F. Evaluation activity

Does evaluation to refinement which has been applied, ensures that operator / inspector and work leader knows refinement done. Periodical control to application of the refinement of vital importance that effects of correction is really felt.

(source Toyota TMMIN)