tcb_roadmap_to__qualitiy_vol1

These are known as the quality features establish

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Unformatted text preview: ality UNIDO unit 5.qxd 3/10/05 1:04 PM Page 13 c. Mark the box or location in red letters, or paint it red. d. Separate or dispose of defective goods as soon as they are identified. Establish procedures for dealing with abnormalities 6. As well as dealing with defective goods, you also need to have a system for dealing with abnormalities. An abnormality is any item or event in the production process that is different from what it should be. Not all abnormalities are defects, but mostly they are, and they must always be seen as indicating that something may be wrong. It is essential to establish procedures to identify and deal with any abnormalities that may occur. You will find a full description of dealing with abnormalities in Unit 9. For the moment, here are some brief guidelines. 7. Set up the following procedures, so that any abnormalities can be dealt with when they emerge: a. A procedure for identifying an abnormal product. b. A procedure for checking the quality of an abnormal product: the quality features that should be examined, such as shape, size, accuracy, and appearance. c. A procedure for reporting abnormalities: the steps to be taken by the employee who sees and reports the abnormality, and the steps to be taken by the superior who receives the abnormality report. d. Procedures for: i. Checking the machine or production process where the abnormality occurred, and verifying product quality. ii. Checking, when necessary, the production processes immediately before and after the process in which the abnormality occurred. iii. Checking initial production after the manufacturing process has started again. e. A procedure for restarting operations again, and returning to the normal production process: i. The instruction that is to be given to return to normal production. ii. The method of informing the production processes before and after: hanging plate, call buzzer, patrol light, or verbal communication. iii. The method of verifying that operating status and quality are now OK. Discussion The following questions ask you to think about how the ideas in the text could be applied in your company. Some of the ideas may not be relevant to you. Concentrate on those that are relevant. Keep notes of your conclusions – you will need them to prepare your action plan afterwards. Where appropriate ask yourself the RADAR questions. Note: Always include in your discussion any figures referred to in the text, if you feel these are relevant to your company. a. Parag. 1.Do you often have defective finished goods in your workplace? Give some examples. How do you distinguish them from non-defective goods? Do they cause any problems with keeping accurate stock levels? Do you ever ship defective products? A Roadmap to Quality 13 Unit 5 - Disposal and Storage UNIDO unit 5.qxd 3/10/05 1:04 PM Page 14 b. Parag. 2: The text suggests some types of quality features that could be examined for defects and marked. Which of these would apply in your workplace? Give some examples. Are there any other quality features that you would add to the list? c. Parag. 3: Several kinds of display material are suggested. Which of these would be useful in your workplace? For which objects? Which other types of display might you add to the list? d. Look at the sample form in Figure 5.2a for reporting the occurrence of a defect. Would this be useful in your company. How would you fill it in for a typical defective item? Would you follow a similar reporting route? e. Parag. 4. Apply the RADAR questions to this system for removing defective items from the workplace. f. Parags. 5 and 6: Five procedures are suggested for dealing with abnormalities. Apply the RADAR questions to these. (This may be a long discussion!) Action plan Draw up a detailed and concrete action plan for removing defective items from your work place. (If you feel it useful, also include suggestions for dealing with abnormalities). Alternatively you may choose to prepare one action plan when you have discussed several texts. You might like to follow the 6-Point Structure. Unit 5 - Disposal and Storage 14 A Roadmap to Quality 3/10/05 1:04 PM Page 15 Figure 5.2a Immediate notice of occurence of abnormality Responsible Department Immediate Notice of Occurrence of Abnormality (II) Abnormality Level (X,Y,Z, etc.) No. Defect Category Number Mark Quantity of Defective items Department when directory was made Discovery Date Number Inspected Month/Date/Time Individual who discovered Lot Size (Assumed) Defect Rate % In what state was the defect? How was the defect discovered? 1. What kind of defect occurred in what quantity? 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