1. Brief introduction of quality-related content
1, basic concept
QC: (quality control) Quality control
QM: (Quality Manager) Quality Management
IQC: (incoming quality control) incoming inspection
IPQC: process inspection (in process quality control)
FQC: (final quality control) final inspection
OQC: (Delivery Quality Control) Delivery Inspection
QA: (Quality Audit) Quality Assurance
Quality record
QE: (Quality Engineering) Quality Engineering
QP: (quality plan) quality plan
2. Basic terminology
2. 1 quality control: operating techniques and activities adopted to meet quality requirements.
2.2 Quality: reflects the sum of the characteristics and characteristics of the entity to meet the explicit or implicit needs of users.
2.2. 1 Entity is something that can be described and studied independently.
Entity can be: activity a, process b, product c, organization system or any combination of the above.
* Description: The product is the result of an activity or process.
Product: A. It can include services, hardware, software or process materials, or any combination of them;
B it can be tangible (such as components or process materials), intangible (such as knowledge and concepts), or a combination of the two;
C products can be expected (e.g. provided to customers) or unexpected (unwanted results).
2.2.2 Explicit or implied requirements
A explicit demand is the requirement of laws and regulations or the conditions listed in the contract, while implicit demand is relatively explicit demand;
B Requirements include: performance (availability), availability, reliability, maintainability, durability, safety, environmental protection, economy and aesthetics.
Performance: according to the functional requirements of the purpose of product use, including normal performance, special performance, efficiency, etc.
Applicability: Applicability of products to different specific consumer groups.
Reliability: the ability of the product to complete the specified function within the specified time and under the specified conditions.
Maintainability: the convenience and feasibility of product fault maintenance.
Durability (life): the period during which the product can be used normally, including service life and storage life.
Safety: To ensure the safety of products in circulation and use.
Environmental protection: the degree of harm to the environment caused by the production, circulation and use of products.
Economy: the total cost in the product life cycle, including production cost and use cost.
Aesthetics: product appearance, aesthetics, modeling, decoration, style, color, packaging, etc.
2.3 Quality: to create products or services that meet the needs of the public at the lowest cost.
2.3. 1 mass representation
1. Market quality: the quality required by consumers;
2. Design quality: the target quality that the company hopes to achieve is subject to the blueprint or design specification;
3. Manufacturing quality: the quality of products actually manufactured with the design quality as the goal;
4. Grade concept: the classification or ranking of stents with the same function but different quality requirements (for example, our customers in Europe and Japan have strict requirements, while those in the United States have relatively low requirements);
2.3.2 The expression of quality is to judge the required items separately and standardize them to form inspection standards;
2.4 Quality management: systematic utilization of all quality-related resources (including manpower, technology, equipment, raw materials and funds, etc.). ) so that products can achieve quality objectives economically and effectively.
2.5 Inspection: the activity of measuring, inspecting, testing or measuring one or more characteristics of an entity and comparing the results with the specified requirements to determine the qualification of each characteristic.
2.6 Quality cost: define the related cost of quality control, plus the cost of evaluating and feeding back whether products and services meet the quality requirements, and the cost incurred by factories or customers due to non-conformity.
2.6. 1 quality cost classification:
1. Prevention cost: the cost of preventing defects and nonconformities. (such as quality planning, new product review, quality control activities, manufacturer consultation, internal staff education and training, etc. )
2. Evaluation cost: the cost of evaluating product quality to maintain the established quality level. (such as incoming inspection, process inspection, quality audit, test fees, etc.). )
3. Internal failure cost: the cost caused by the defects that the materials and products do not meet the requirements of the company. (such as scrapping, heavy work, etc. )
4. External failure cost: the cost incurred after the defective and unqualified products are delivered to customers. (such as complaint handling, return handling, compensation, after-sales service, etc.). )
2.6.2 Distribution ratio of quality cost
Prevention: Identification: Failure = 20%: 30%: 50% Under normal circumstances, it is normal and acceptable that the proportion of quality cost to sales volume is less than 10%; If it exceeds 15%, the profit will drop sharply; If it exceeds 20%, it will be unprofitable or lose money.
2.7 Description of defect classification: defect ≠ unqualified.
Defects are generally divided into three categories:
Critical is abbreviated as CRI.
Major is abbreviated as: major.
Minor is abbreviated as MIN.
1. Serious defects: defects that bring danger and insecurity to product users and have a fundamental impact on product performance;
A. this will bring danger
B.the product is not available at all.
2. Main defects: defects that lead to failure or greatly reduce the expected performance of unit products, but do not cause unsafe conditions;
A. the main function cannot be played out.
And the use value of the product is reduced.
C. Serious appearance problems
D. affecting the sales of products
3. Secondary defect: the defect that the product performance or other technical indicators do not meet the requirements of the product technical indicators, but does not affect the effective use of the product:
A. The secondary functions can't be brought into full play, but it will not affect the normal use of the product;
B. small appearance problem;
C it can be easily corrected or repaired, such as slight stains;
D. it will not affect the sales of products.
2.8 Corrective measures: measures taken to prevent the recurrence of existing unqualified defects or other undesirable conditions and eliminate their causes.
2.9 Preventive measures: measures taken to prevent potential unqualified defects or other undesirable conditions and eliminate their causes.
3. Comparison of old and new quality concepts
Consider the content
Outdated ideas
new concept
A. Definition
Beautiful and dazzling
comply with the requirements
B. System
Identify (check)
prevent
C, implementation standards
Acceptable quality level (AQL)
No defect (zero defect)
D, measurement method
Quality index or defect rate
Quality cost
Meet requirements: meet customer requirements;
Prevention: good quality focuses on prevention, preventing the occurrence of defects and reducing the cost of failure;
Defect-free: the operation standard is defect-free, and it is required to be done for the first time every time, otherwise the pass rate after multiple processes is extremely low.
4. Eight principles of quality management (conditions for success)
4. 1 Focus on customers: organizations (companies) depend on customers. Therefore, organizations (companies) should understand the current and future needs of customers, meet their requirements, and strive to exceed their expectations.
4.2 Leadership: Leaders have established the unified purpose and direction of the organization (company), and they should create and maintain an internal environment that enables employees to fully participate in achieving the goals of the organization (company).
4.3 Full-time participation: People at all levels are the foundation of an organization (company). Only when their full-time participation, can their talents bring benefits to the organization (company).
4.4 Process method: The activities and related resources can be managed as a process, and the expected results can be obtained more efficiently.
4.5 System management method: Identifying, understanding and managing interrelated processes as a system will help organizations (companies) to improve the effectiveness and efficiency of achieving their goals.
4.6 Continuous improvement: Continuous improvement of overall performance should be the eternal goal of the organization (company).
4.7 Fact-based decision-making method: Effective decision-making is based on data and information analysis.
4.8 Mutually beneficial relationship with suppliers: An organization (company) and suppliers are interdependent, and mutually beneficial relationship can increase the ability of both parties to create value.
5. Six elements of quality control: objectivity, fairness, flexibility, rationality, perseverance and communication.
6. Five tasks of daily management:
Quality, cost, delivery, safety and morale
7. Four major costs and nine quality dimensions
A. Four major costs: prevention cost, appraisal cost, internal failure cost and external failure cost.
B nine levels: performance, usability, maintainability, reliability, durability, safety, economy, aesthetics and environmental protection.
8. Ten principles of successful on-site quality control
(1) Let's work together in Qi Xin, and all members will participate.
2 planning.
③ A strong desire for quality awareness.
④ Independent management
⑤ Strengthen daily management.
⑥ Independent supervision
All landowners considerable patience and perseverance.
(8) Independent inspection.
⑨ Creativity ⑩ Education and training
9. Six reasons for website quality failure
① There is no written quality system.
(2) unauthorized changes.
(3) Expired or invalid documents have not been removed from the site.
④ Use uncalibrated instruments and equipment.
(5) not according to the written quality system.
⑥ ineffective or useless preventive and corrective measures
10. Six tasks of quality management
① Maintain and improve product quality.
② Control and improve the existing problems and eliminate their systematic causes.
③ Prevent potential problems and realize feedforward control.
④ Record the process and results of quality control.
⑤ Maintain the environment.
⑥ Reduce quality cost.
1 1. Techniques for finding problems
(1).
A. System reason: controllable and uncontrollable
B. accidental causes: uncontrollable and accidental.
(2) the method to explore the problem
First, the association method
A- 1。 Similar association rules: the problem of similar association.
A-2。 Law of opposites and associations: the problem of opposites of associations.
A-3。 Similar Association Rules: Association Similarity Problem
B, specification (condition) setting method
Pre-set specifications and conditions, and then use this as a standard to achieve.
The defect list method lists all defects and tries to avoid them.
D, wish list method
E, brainstorming method uses collective thinking to make ideas agitate each other, produce a chain reaction and generate creativity.
12. Four stages and six steps to solve the problem
12.1:The four stages of PDCA cycle, also known as pdsa, were put forward by Deming, an American quality management scientist.
Plan-plan to do-perform inspection-inspection action-process.
Six steps of 12.2:
A. Identify the problem: identify the problem point.
B. Grasp the current situation: investigate the current situation of problems, the degree and proportion of bad conditions, and the production and application.
C. Explore the reasons: from the perspectives of people, machines, materials, environment, measurement and law.
D, formulate countermeasures: formulate corresponding temporary countermeasures and permanent countermeasures according to the reasons.
E. Implementation countermeasures: apply countermeasures to review and confirm the implementation improvement, and check the effectiveness of the implementation of countermeasures.
Second, MQM (modern quality management) related knowledge
Composition of modern quality management system: (1, quality assurance system; 2. Process assurance system; 3, check the system)
The utility of modern quality management: (1, defining quality control responsibilities and quality requirements; Establish the whole process quality control system; Establish a quality prediction system; Establish a mechanism for all employees to participate in quality improvement activities; 2, improve the quality awareness and improvement ability of employees)
Three points of pursuing quality: (1, quality meets customer requirements and expectations; 2, the product quality level is determined according to the existing production technology level and customer consumption requirements; On the basis of continuous improvement of technology, we will continuously improve the quality level and meet the needs of customers at economical and competitive prices. )
Maslow's five levels of needs are: (1, physiological needs: hope to be met; 2. Security needs: I hope to have a stable life, a good material environment and avoid danger; 3. I hope to get love, gain social status, be famous and be trusted; 4. Respect for needs: I hope to be affirmed by the society, and I want to finish my work with confidence and in a tone; 5. Potential realization needs: I hope to be creative, and I can give full play to my own ability to realize my potential ability)
The customer's requirements and expectations correspond to Maslow's five levels of needs: (1, physiological needs-performance applicability: availability; 2. Security requirements-credibility: availability, reliability and security; 3. Emotional needs-emotion: aesthetics; 4. Respect demand-people-oriented design and sales service; 5, potential realization-potential realization: improve people's ability. )
What is quality management (1), which refers to the use of systematic concepts and methods to focus on the same goal of improving product quality;
2. Strictly organize the production and business activities of all departments and links of the enterprise, and stipulate their responsibilities, tasks and authorities in quality management; 3. Establish an organization to organize and coordinate these activities; 4. Provide products and services that satisfy customers at the most economical level. )
Resources on which quality management is based: (1 First, product design specifications, which are the specifications followed by quality management. What level the product can reach depends on the specifications of the product at the time of design. In order to ensure that the mass production can meet the design specifications stably, there must be an implementation review process in the design process.
2. Generally, a product can only be completed with the assistance of raw materials provided by suppliers. The supplier's quality management system and level is an important part of the company's quality management and an important input resource for quality management. For this kind of resources, the company should have corresponding organizations to test and constantly urge suppliers to improve their level. 3. The most important resource of quality management is the technicians who master quality management. The process control of quality management is to establish a set of quality management system that can operate effectively. 4. Equipment and instruments that must be used in quality management are indispensable material resources for quality management. The process control of quality management is to establish a set of quality management system that can operate effectively. )
The quality assurance system in modern quality management includes: (1, quality policy and objectives; 2. Responsibility and authority; 3. Quality system; 4. Quality document management; 6. Quality record management; 7. Manage the project; 8. Quality improvement; 9.4M change management; 10, management in case of exception; 1 1, corrective and preventive measures; 12, supplier management; 13, mass production evaluation. )
The process assurance system in modern quality management includes the following contents: (1, preparation of work instructions; 2. The homework instruction class must be attended; 3. Operation realization 4. Management of recycled materials; 5, equipment and fixture management; 6. Batch management and identification; 7. Process control. )
The inspection system in modern quality management includes the following contents: (1, inspection point setting; 2. Check the preparation of specifications; 3. Check the certainty of the specification; 4, check the rigor of adjustment; 5, check the implementation; 6. Batch management and identification; 7, check the equipment management; 8. Management of safety specification parts. )
High-quality finished products refer to: (expenses incurred to ensure and guarantee satisfactory quality and losses caused by failure to achieve satisfactory quality)
Composition of quality cost: (1, prevention cost; 2. Appraisal fee; 3. Loss cost; 4. Quality cost of external activities; )
The preventive cost in quality cost includes: (1, external certification of quality system, ISO9000 certification, etc. ; Fees for certification of safety standards in various regions and countries; 2, guide and assist suppliers to implement the cost of the supply guarantee system; 3. incoming packaging; 4, incoming inspection, manufacturing process, finished product inspection in advance. 5, employee education and training costs)
Appraisal expenses in quality cost include: (1, IQC incoming inspection personnel expenses, and destructive inspection expenses of incoming inspection; 2. Personnel expenses such as process inspection IPQC, online inspection FQC and finished product inspection OQC, as well as the cost of consumables invested; 3. Entrust the appraisal and test fees to the outside; External calibration cost of measuring instruments; )
The loss cost in the quality cost includes: (1, internal loss cost: the loss caused by the failure to meet the quality requirements before the delivery of the product. It is common to provide services again; Processing, rework, maintenance, retesting, scrapping and production stoppage due to quality problems. 2. External losses: expenses incurred after delivery because the products do not meet the quality requirements; Such as product maintenance, warranty return, direct costs, discounted sales due to product defects, product return costs, liability compensation costs, etc. ; )
The external activity cost in quality cost includes: (composed of external quality assurance cost, which refers to the cost paid to provide the required objective evidence according to the customer's requirements under the contract situation. For example, many customers will ask suppliers to provide material certificates and entrust external inspection agencies to issue inspection reports. )
Third, quality assurance related knowledge
IQC function: (Inspect spare parts provided by suppliers according to engineering drawings or contracts, samples, supplier delivery inspection reports, etc. ; And allow qualified products to be put into storage; Rejection, classified inspection and special procurement of unqualified products; And is responsible for tracking defects and supervising suppliers to take improvement measures to prevent the recurrence of defects. )
In manufacturing industry, there are usually four main items (design, material supply, manufacturing technology, storage and transportation) that have a direct impact on product quality. In all walks of life, the proportion of its main quality is as follows:
No industrial project design, manufacturing, storage and transportation.
1 electronic assembly industry 30% 3 to 40% 3% 0.5 to 1%
2 Electronic components 1 in 3 in 4 out 50 in 0. 1 to 1 in.
3 Plastic industry 0. 1 to 0.5% 4 to 50% 4 to 0. 1 to 0.5%
IQC sampling scheme can be divided into: (counting value sampling: testing short board and bad number; Metered value sampling: testing various important and measurable characteristics of materials; Special inspection analysis sampling: mainly reliability analysis or component analysis)
Counting sampling refers to: (refers to the inspection of the samples of this batch of products for defects or unqualified products, such as burrs, stains, short feet, inconsistent sizes, breakage, etc.
Experience of total quality management training
I have benefited a lot from this total quality management system training. I deeply feel the gap between learning and understanding quality management standards, so it is necessary to attend such training. As a workshop equipment manager, I should not only apply what I have learned in the quality system documents to my work, but more importantly, lead my workshop staff to implement it.
Quality is the partner of success, and the implementation of standards is the guarantee of quality. Nowadays, the implementation of standards has been paid attention to by our company and has become a passport for the company to prove the quality of products and work. The implementation of the standard provides scientific guidance for improving workshop management and improving the quality of products and services. After this training, I have a comprehensive understanding of total quality management. The following is my own study and understanding, and I also talk about my own views in combination with my work.
The focus of this training is statistical technology, and statistical knowledge is one of the effective tools for quality management and quality control. Through understanding the current situation, project establishment, measurement, analysis, correction, reasonable improvement, optimization of the scheme, organization and implementation or prevention, the expected results are achieved. In the process of this training and study, although I don't know much about statistical technology, I feel the importance of statistical technology in enterprise management after the explanation of Director Hu of Workshop 7. It is not only a statistical technique, but also a means of workshop equipment management. Through the understanding and digestion in my spare time, I applied the Pareto Diagram method in statistical technology to the maintenance of centrifugal pumps in my workshop. Due to the large number and models of centrifugal pumps in our workshop, many manufacturers are involved. It is necessary to analyze the fault of centrifugal pump in our workshop. We know that although there are many factors affecting quality problems, only a few factors play a decisive role, and most of them can be ignored, so centrifugal pumps are frequently maintained.
This analysis method can analyze the reasons. By collecting the maintenance records of centrifugal pumps in the past, we found that the reasons leading to equipment maintenance are as follows:
1, frequent leakage of mechanical seal of centrifugal pump;
2, machine seals and other parts have quality problems;
3. The maintenance quality of mechanics needs to be improved;
4. Equipment damage caused by improper operation;
5. Corrosive process media will corrode equipment;
6. There is something wrong with the quality of equipment spare parts;
7. The working environment of centrifugal pump is poor, and the daily maintenance is not in place.
Through the analysis of pareto chart, it is found that the causes of frequent damage of centrifugal pumps are mainly concentrated in two aspects: the daily maintenance of centrifugal pumps is not in place and the maintenance quality of maintenance workers is problematic, accounting for about 75% of the weight. In the future, according to the problems analyzed above, I will put forward targeted solutions that lead to frequent damage of centrifugal pumps.
Through this study, I have a deeper understanding of the application of statistical theory in enterprises and the importance of statistical theory in production practice. But for those who have just set foot in this field, I not only lack theoretical knowledge, but also can't apply it freely in practice, and there is still a long way to go. But as a equipment manager, I believe I will accumulate experience in practice, make continuous progress, and work hand in hand with workshop leaders and other employees to make my workshop well.