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MSA interview questions and answers

16/11/202428/02/2024 by TECHIEQUALITY

MSA interview questions and answers:

Hello Readers! Today we will discuss on some popular Interview questions of MSA (Measurement System Analysis). MSA is one of the popular techniques/Methods/Tools among the five core AIAG tools. Basically, the company follows the MSA to know the condition of the gauge /instrument and to know the effectiveness of the appraiser. MSA (Measurement system analysis) is classified into two types i.e. [1] Gauge R & R and [2] Attribute type MSA. If you would like to learn more about Repeatability vs. reproducibility and also you could download the Free Template from the below links. MSA interview questions and answers are given below.

DOWNLOAD the QC / QA / 7QC Tools Excel Template. Learn more about the below topic as;

Repeatability vs Reproducibility | Discussion of Key difference.

Verification vs Validation | What is difference between verification and validation?

Corrective Action vs Preventive Action

Rework vs Repair |IATF Requirement for Control of Reworked/ Repaired Product

MSA interview questions and answers:

Q1: MSA are supposed to be conducted before,

FMEA
APQP
SPC
Control Chart

Ans.: C

Q2: Acceptance criteria for attribute gauge study for Misalarm

Ans.: A

Q3: Reproducibility is high due to

Equipment variation
Wrong instrument used
Variation due to appraiser
None of the above

Ans.: C

Q4: Gauge R&R study acceptance criteria

R&R<10%
ndc < 5
Both option A&B
R&R>30

Ans.: A

Q5: Elements of a measurement system

Instrument
Inspector, instrument, part, characteristics etc.
Inspector, instrument, checking method, environment etc.
None of the above

Ans.: C

Q6: Appropriate statistical study to capture precision

Bias
GR&R
Linearity
None of the above

Ans.: A

Q7: Repeatability represents variation due to

Instrument
Equipment
Appraiser
None of the above

Ans.: A and B.

The above questions are commonly asked in interviews (may be in written or PI). To know more about MSA, read the MSA AIAG Latest manual. You can also read our other useful posts from the below link

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why why analysis methodology | 5-why analysis step by step guide

28/02/2024 by TECHIEQUALITY

why why analysis methodology | 5-why analysis step by step guide:

Hello readers! Today we will discuss “why why analysis methodology”. How effectively you can do the 5-why analysis. This analysis is the common tool used in the industry to find out the root cause of the problem but most of the people make mistakes during why-why analysis. So we will talk about the step-by-step methodology of why-why analysis. The why-why analysis is one of the inputs for executing the 8D report, CAPA (Corrective action and preventive action), and RCA (Root Cause analysis). Click on the below-given link to download the 8D and CAPA format.

Download 8D Format , CAPA Format & 5W1H Format.

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why why analysis methodology:

Step-1: Identify the Problem.

Step-2: Understand the Problem.

Step-3: CFT team formation.

Step-4: Identify the Potential cause

Step-5: Why-why analysis.

Understanding the why-why analysis methodology by example:

Let Part number 123 find ingate shrinkage after the shot-blasting operation. So this case process-QA engineer started the why-why analysis by using the above methodology.

Identify the Problem:

At the shot-blasting operation, a process-QA engineer identified that two number casting got rejected due to ingate shrinkage.

Understand the Problem:

Understanding the problem means technically knowing what exactly is it? How is it occurring? (potential cause). In the above example, we are supposed to have knowledge on “what is shrinkage?

CFT team formation:

If you think that the problem may be due to issues with the melting parameter, moulding parameter, or design. Then you have to create a CFT team considering with the above departments.

Identify the Potential cause:

Now initially individual members will identify the potential cause. And then combine all members of the CFT team will identify the potential cause. Let’s see, in case of a shrinkage problem what would be the final list of potential cause.

Why-why analysis:

In this section, we are supposed to identify the significant cause of the potential cause. We have already identified the potential cause with the help of the CFT team and represented it through cause and effect diagram.

To identify the significant cause from the above C&E Diagram, we need to use the methodology like brainstorming method, validation method, and hypothesis testing method. With the help of the brainstorming and validation method, we found that the “wrong gating system” is the significant cause. So now we will do the Why-why analysis by CFT team members.

Problem: Wrong gating system.

Why wrong gating system?

Ans.: gating system was modified

Why gating system was modified?

Ans.: Gating system was modified w.r.t customer complaint but gating system was not validated before mass production.

Why gating system was not validated?

Ans.: There was no time to validate the part because production planning was scheduled without prior consideration of tool validation

RC: Improper Production planning and Schedule.

Once you completed the analysis you can document these in a 5-whys analysis template.

Funnel Approach of Why-Why Analysis:

Once you identify the potential cause then we could also use the funnel approach to identify the Root cause by 5-why analysis.

In the above funnel diagram, we have mentioned three basic stages and applied some tools/ methods/ testing like validation, brainstorming, hypothesis testing, etc. to identify the significant cause in stage-2. and then applied the 5-why analysis to detect the Root cause in stage-3. In this way, we can use this approach to identify the RC.

Why-Why Analysis Methodology to Identify the Multiple Root Cause:

In the above section, we learned the two different methodologies for why-why analysis. and in both case, we found a single root cause. we know that theoretically there will be a single root cause of a problem but technically there will be a minimum one root cause of a problem. So here we have mentioned in the below figure for the methodology to identify the multiple root causes.

Why-Why Analysis for Multiple Root Cause

Step-1: Identification and Understanding of the Problem

Step-2: CFT Team Formation and list up the Potential Causes by using tools like Brainstorming, CTP Matrix, Fishbone Diagram, etc.

Step-3: Significant Cause identification with the help of Brainstorming, Hypothesis Testing, Validation, etc.

Step-4: Identification of Root Cause by why-why/ 5W1H analysis of each individual Significant Cause.

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7QC Tools Excel Template |DOWNLOAD Format

28/02/2024 by TECHIEQUALITY

7QC Tools Excel Template |DOWNLOAD Format:

7QC tools are the most important tools that are used to analyze the Non-conforming products or services. As you know that the manufacturing process is a dynamic operation where common or special causes are always available at any extent. For analysis, the common and special cause’s 7QC tools are usually used. 7QC tools consist of [1] Pareto chart [2] Cause and Effect Diagram [3] Histogram [4] Scatter Diagram [5] Control Chart [6] Check sheet [7] Graph /Process flow. We have prepared a simple Excel template/ format and offering it here to our valuable readers to download these formats /templates. Links are given below to download the 7QC Tools Excel Template.

DOWNLOAD-Pareto Chart Excel Template/ Format.

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DOWNLOAD Control Chart Excel Template/ Format.

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Usages Matrix of 7-QC Tools:

7QC Tools	Problem Identification	Process Analysis	Solution Development	Result Evaluation
Pareto Chart	Yes	Yes		Yes
Fishbone Diagram	Yes	Yes
Histogram	Yes			Yes
Scatter Diagram		Yes	Yes	Yes
Control Chart	Yes	Yes		Yes
Check Sheet	Yes	Yes		Yes
Flow Char	Yes		Yes

Benefits of 7QC Tools:

Identifies Problem.
Priorities task.
Give importance to planning.
Process analysis.
Result evaluation.

The Techiequality.Com has been helping its readers with all extensions to enhance their skills with best industrial practices w.r.t QA, QC, Six Sigma concept, Lean design, lean manufacturing, business excellence, 5’S, etc. So mentioned some posts below that you would love to read…

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I hope the above information is useful to you for your skill enhancement and deployment of 7QC tools in your organization …

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How to calculate process performance (Pp & Ppk)?

28/02/2024 by TECHIEQUALITY

How to calculate process performance (Pp & Ppk)?

Hi Readers! Today we will discuss on How to calculate process performance? The Pp (Process Performance) provides a measure of how well the process will satisfy the variability requirements. The Index of process performance is termed as Ppk. It takes the process location as well as the performance into account. Before discussing on calculation part, I would request my all readers kindly go through the formula of Pp and Ppk. And if you are interested in downloading our free Excel template then click on the below download link.

DOWNLOAD Excel Template/Format of Pp & Ppk calculation with Example.

How to use Pp & Ppk Template / Format in your process to calculate the index value? Step-1: Download the Template/ Format from the above links. Step-2: Read the note mentioned in the excel template. Step-3: Only the yellow color box (mentioned in format) is changeable and other values will calculate automatically.

The formula of Pp (Process Performance):

Pp = ((USL-LSL)/ (6 X S))

[Where USL=Upper specification limit, LSL=Lower specification limit, and S= Standard Deviation]

Formula of Ppk (Process Performance Index):

Ppk = Minimum of PPU or PPL

PPU= ((USL-Average of average)/ (3 X S))

PPL= ((Average of average-LSL)/ (3 X S))

Note: Pp ≥ Ppk.

Example:

A Company ZYX Ltd has collected 100 numbers readings of Pouring temperature having the specification range from 1420°C to 1400°C and calculates the process performance and its index to know the performance of a process, which means how well it satisfies the variability requirement. So we have the 100 numbers of reading and we will calculate the Pp & Ppk value;

Sl. No.	1	2	3	4	5	6	7	8
SG1	1409	1410	1412	1410	1408	1414	1413	1411
SG2	1408	1410	1412	1410	1408	1414	1413	1411
SG3	1408	1409	1411	1410	1405	1413	1411	1410
SG4	1406	1409	1410	1409	1405	1413	1411	1410
SG5	1406	1408	1410	1409	1404	1412	1411	1410

Table-1

Note: SG=Subgroup

9	10	11	12	13	14	15	16
1413	1408	1413	1412	1410	1409	1412	1408
1413	1408	1413	1412	1410	1408	1412	1408
1411	1405	1411	1410	1410	1408	1411	1405
1411	1405	1411	1410	1409	1406	1410	1405
1410	1404	1411	1410	1409	1406	1410	1404

Table-1

17	18	19	20
1412	1408	1410	1408
1412	1408	1410	1408
1411	1405	1410	1405
1410	1405	1409	1405
1410	1404	1409	1404

Table-1

Calculation:

Pp=20/ (6 X 2.69) =1.24

PPU= (1420-1409.04)/ (3 X 2.69) =1.36

PPL= (1409.04-1400)/ (3 X 2.69) =1.12

Ppk=1.12 (Minimum of PPU or PPL).

Sample Format:

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Process Performance Example (Pp) & Ppk |Download Format

24/02/2024 by TECHIEQUALITY

Process Performance Example (Pp) & Ppk |Download Format

Hello Readers! Today we will discuss and measure the process performance (Pp) and its index (Ppk) with industrial examples. If you are interested in gaining basic knowledge about Process Performance, then go through the below link and also on this platform you can download the Excel templates or formats. details have been illustrated with a Process Performance Example.

DOWNLOAD EXCEL TEMPLATE (Pp & Ppk and many more.)

Example-1:

We are having 100 numbers of readings of Total clay of green sand used in the metal manufacturing industry. Details of the reading are given below;

Sl.No.	1	2	3	4	5	6	7	8	9	10
Subgroup1	12.50	12.70	12.80	12.90	12.80	12.90	12.80	13.00	12.90	12.70
Subgroup2	12.50	12.90	12.90	12.90	12.80	12.90	12.70	13.10	12.90	12.90
Subgroup3	12.50	12.80	12.50	12.90	12.90	12.80	12.90	12.90	12.90	12.80
Subgroup4	12.80	12.80	12.80	13.10	12.90	12.80	12.80	12.80	13.10	12.80
Subgroup5	12.60	12.80	12.70	13.00	12.70	12.70	12.80	12.80	13.00	12.80

Table-1

11	12	13	14	15	16	17	18	19	20
12.80	13.00	12.70	12.90	12.80	12.70	12.90	12.80	13.00	12.70
12.80	13.10	12.90	12.90	12.80	12.90	12.90	12.80	13.10	12.90
12.90	12.90	12.80	12.90	12.90	12.80	12.90	12.90	12.90	12.80
12.90	12.80	12.80	13.10	12.90	12.80	13.10	12.90	12.80	12.80
12.70	12.80	12.80	13.00	12.70	12.80	13.00	12.70	12.80	12.80

Table-1

Process parameters;

Characteristics	Total clay of green sand
Process:	Sand Preparation Process

USL	14
LSL	12

Calculation:

The formula of Pp (Process Performance):

Pp = ((USL-LSL)/ (6 X S))

= (14-12)/ (6 X 0.13) = 2.64.

The Formula of Ppk (Process Performance Index):

Ppk = Minimum of PPU or PPL

PPU= ((USL-Average of average)/ (3 X S))

PPL= ((Average of average-LSL)/ (3 X S))

Ppk= Minimum of PPU or PPL = Min. (3.06, 2.22) = 2.22

Summary of calculation:

Note: Click here to know more about manual calculation and download the free excel template from the above link.

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How to measure process performance (Pp & Ppk)?

24/02/2024 by TECHIEQUALITY

How to measure process performance (Pp & Ppk)?

Hello Readers, Today we will learn “how to measure process performance?” Process Performance and its index can be measured by calculating the value manually or by using an Excel sheet or by using the software. In this post, we will calculate the Pp and Ppk value, but you can download the free Excel template or format for your ready reference, this offer is available for a limited time period! Don’t waste your time; just download the Format or Template from the below link.

DOWNLOAD the Excel Template/Format of Pp & Ppk.

How to use Pp & Ppk Template / Format in your process to calculate the index value?
Step-1: Download the Template/ Format from the above links. Step-2: Read the note mentioned in excel template. Step-3: Only the yellow color box (mentioned in Template) is changeable and other values will calculate automatically.

How to measure process performance (Pp & Ppk)?

As you know we have already told you that process performance and its index can be easily measured through an Excel sheet or by using the software. For manual calculation, we have to give more attention in basic knowledge and formula part. So, Pp and Ppk formula is given below, kindly go through it.

Formula of Pp (Process Performance):

Pp = ((USL-LSL)/ (6 X S))

[Where USL=Upper specification limit, LSL=Lower specification limit and S= Standard Deviation]

The formula of Ppk (Process Performance Index):

Ppk = Minimum of PPU or PPL

PPU= ((USL-Average of average)/ (3 X S))

PPL= ((Average of average-LSL)/ (3 X S))

Note: Pp ≥ Ppk.

Example:

A process engineer has collected 100 numbers of readings of molten grey cast iron carbon percentage.

Details of readings are given below:

Sl.No.	1	2	3	4	5	6	7	8	9	10
Subgroup1	3.22	3.28	3.21	3.23	3.27	3.24	3.24	3.22	3.24	3.28
Subgroup2	3.21	3.29	3.26	3.23	3.28	3.21	3.26	3.21	3.26	3.29
Subgroup3	3.25	3.23	3.24	3.21	3.29	3.25	3.24	3.23	3.25	3.27
Subgroup4	3.20	3.20	3.25	3.25	3.25	3.26	3.26	3.22	3.26	3.27
Subgroup5	3.21	3.25	3.26	3.28	3.24	3.21	3.28	3.21	3.25	3.28

Data Table-1

11	12	13	14	15	16	17	18	19	20
3.26	3.31	3.28	3.24	3.27	3.21	3.28	3.24	3.27	3.21
3.25	3.20	3.29	3.21	3.28	3.26	3.29	3.21	3.28	3.26
3.24	3.26	3.27	3.25	3.29	3.24	3.23	3.25	3.29	3.24
3.26	3.22	3.27	3.26	3.25	3.25	3.20	3.26	3.25	3.25
3.24	3.22	3.28	3.21	3.24	3.26	3.25	3.21	3.24	3.26

Data Table-1

Calculation:

Characteristics	%C
Process:	Melting Process
USL	3.3
LSL	3.2
Std. Dev.	0.03
PPU	0.65
PPL	0.61
Pp	0.63
Ppk	0.61

How to calculate process performance (Pp & Ppk)?

Process Performance (Pp) & Ppk Excel Template |DOWNLOAD

Process Capability Template

How to measure process capability (Cp & Cpk)? Download Excel Template

24/02/2024 by TECHIEQUALITY

How to measure process capability (Cp & Cpk)? Download Excel Template

Hello readers! Today we will discuss how to measure process capability (Cp & Cpk). As you know that process capability and its index can be measured by using an Excel template or by using software like Minitab etc. We are offering to our readers for a limited time period to download the approved excel format, so download the template from the below link.

DOWNLOAD Excel Template of Cp & Cpk.

Process Capability (Cp):

Process Capability (Cp) is a statistical measurement of a process’s ability to produce parts within specified limits on a consistent basis
It gives us an idea of the width of the Bell curve.
The Process Capability for a stable process is typically defined as ((USL-LSL)/ (6 x Standard Deviation)).

Process Capability Index (Cpk):

It shows how closely a process is able to produce the output to its overall specifications
More Value of Cpk means more process capable.
Cpk value <1 means the bell curve will be out of USL/LSL
Common Cpk vale=1,1.33,1.67 & 2
The Cpk value of a start-up manufacturing organization is supposed to be 1.33.
The Process Capability Index for a stable process is typically defined as the minimum of CPU or CPL

How to measure process capability (Cp & Cpk)? (Industrial Example):

Characteristics	Green Sand Permeability
Process:	Green sand moulding process
USL	200
LSL	180

Table-A

Sl.No.	1	2	3	4	5	6	7	8	9	10
Subgroup1	190.00	189.00	189.00	191.00	190.00	192.00	188.00	191.00	189.00	189.00
SG2	191.00	188.00	188.00	191.00	191.00	193.00	187.00	191.00	188.00	188.00
Subgroup3	192.00	190.00	188.00	192.00	192.00	189.00	189.00	192.00	190.00	188.00
SG4	192.00	188.00	189.00	189.00	192.00	190.00	189.00	189.00	188.00	189.00
Subgroup5	193.00	189.00	190.00	190.00	193.00	188.00	190.00	190.00	189.00	190.00
Mean	191.60	188.80	188.80	190.60	191.60	190.40	188.60	190.60	188.80	188.80
Max	193.00	190.00	190.00	192.00	193.00	193.00	190.00	192.00	190.00	190.00
Min	190.00	188.00	188.00	189.00	190.00	188.00	187.00	189.00	188.00	188.00
Range	3.00	2.00	2.00	3.00	3.00	5.00	3.00	3.00	2.00	2.00

Table-B

Sl.No.	11	12	13	14	15	16	17	18	19	20
Subgroup1	189.00	191.00	190.00	189.00	189.00	191.00	190.00	191.00	190.00	191.00
SG2	188.00	191.00	191.00	188.00	188.00	191.00	191.00	191.00	191.00	191.00
Subgroup3	190.00	192.00	192.00	188.00	190.00	192.00	192.00	192.00	192.00	192.00
SG4	188.00	189.00	192.00	189.00	188.00	189.00	192.00	189.00	192.00	189.00
Subgroup5	189.00	190.00	193.00	190.00	189.00	190.00	193.00	190.00	193.00	190.00
Mean	188.80	190.60	191.60	188.80	188.80	190.60	191.60	190.60	191.60	190.60
Max	190.00	192.00	193.00	190.00	190.00	192.00	193.00	192.00	193.00	192.00
Min	188.00	189.00	190.00	188.00	188.00	189.00	190.00	189.00	190.00	189.00
Range	2.00	3.00	3.00	2.00	2.00	3.00	3.00	3.00	3.00	3.00

Average of Range	2.75
Averge of Mean	190.11
Std.Dev.	1.182287188
USL	200
LSL	180
Cp	2.82
Cpk	2.8

To know more about the manual calculation then click-here.

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Process Performance Example (Pp) & Ppk |Download Format

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Process Performance (Pp) & Ppk Excel Template |DOWNLOAD

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Pull Production System | Concept

23/02/2024 by TECHIEQUALITY

Pull Production System | Concept

Pull Production System: Hello Reader! Today we will discuss the most popular tools or principles of TPS (Toyota Production System) is namely called PPS (Pull Production System). Mr. Taiichi Ohno had implemented this concept in the TPS system in Toyota Company. PPS is nothing but it is a manufacturing system in which production is based on the actual demand of customers (OEM, Tred, T-1, or end-user, etc.). The main purpose of a pull-production system is JIT and Low Inventory Production.

Know More: Toyota Production System History, Tools & Principles.

Pull Production System (PPS):

Pull production is not so easy to implement, Toyota Company took 20 years to effectively implement the PPS. In Traditional manufacturing products are processed in batches of materials from one workstation (WS) to another and in each work station executes much work with several types of material flow, because there are many jobs that need to be executed at each workstation or machine, so it is difficult to synchronize the flow of materials.

Later it would result in large amounts of in-process inventory at various workstations. But in the pull production system, the manufacturing unit develops a system that will indicate the demand of material flow in each stage so that there will eliminate the need for large amounts of inventory and also need to be implemented the KANBAN system to coordinate the flow of materials between the work station in such a way that the inventory will minimum or low in each stage i.e. in any stage of the process, or finish product stage. It’s just following the JIT (just-In-Time) Production.

Note;

Companies or manufacturing units that are not following the PPS may hold a high inventory, which is a big challenge and business risk in the manufacturing industry. In 2019, the Automobile industry is suffering and facing the problem may be due to the market inventory of finished products in various stages. Always it is better to follow the PPS system. Manufacture the Products as per market demand or Customer demand.

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Jidoka Autonomation, Bakayoke & Yo-I-don |Concept in TPS

23/02/2024 by TECHIEQUALITY

Jidoka Autonomation, Bakayoke & Yo-I-don |Concept in TPS

Hello Reader! Here we will describe three important elements of TPS (Toyota Production System) are Autonomation (Jidoka), Bakayoke & Yo-i-don. These three elements are very useful and frequently used in manufacturing units to reduce the number of defectives products and improve the quality of the process.

Read more…TPS, TPS History, Pull Production System.

(Jidoka) Autonomation:

Autonomation is a word coined by Toyota that means Autonomous defect control. Jidoka allows the operation to have a built-in quality at each work step so that the workforce (operators) does not have to watch the operation or machine to control the process defect.

Illustration:

Autonomation (Jidoka) doesn’t pass the defect to nest operation, doesn’t make defects, and doesn’t accept defects. The Must-probably production system is controlled by the just-in-time system but if there is an existing of process defect the autonomation system will help you to control the process defect control for an automatic process, if it’s a manual process then we have to implement the Bakayoke system which is the older name of Poka-yoke (Error proofing).

Sometimes in a fully manual process where Bakayoke is not possible to implement, normally a red colour stop button is used for any defects detected during operation. The line problem is then fixed up before work is resumed. Andon light system is generally used in the Jidoka system.

Andon light system:

Details: Generally andon light system having three different colors. Which indicates some meaning to take action i.e.

Colour Code	Condition	Action
Green	Normal Operation	Move on to the next operation
Yellow	Problem Appeared	Fix up the problem
Red	Production or M/C stopped	The Problem needs to be identified and to be fixed up

This is one of the best tools which is frequently used in the manufacturing industry. But in a fully automation factory, machines or operations can be controlled through a wireless, or wifi connection to control the process or machine defect smartly and you can resolve the problem very promptly.

Yo-I-Don system:

It means Ready, set, go. This system involves teamwork between adjacent operations to ensure that work at the station is balanced. After completion of operation at each work station, all operators need to press the special button if any station sees a red light, which means it indicates delays and the entire line stops until all red lights are off. When this happens, workers nearby help each other to complete the work.

After completion of operation at each work station, all operators need to press the special button if any station has seen the red light, which means it indicates delays and the entire line stops until all red lights are off. When this happens, workers nearby help each other to complete the work.

After completion of operation at each work station all operators need to press the special button if any station has seen the red light, which means it indicates delays and the entire line stops until all red lights are off. When this happens, workers nearby help each other to complete the work.

Benefits of Autonomation:

Reduces the number of defective product
To increase the productivity
Improve the process quality
Empowers peoples
Enable separation of interested parties’ work and machine.
Prevent defective (Before delivering to the next workstation.
Man-power saving

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Quality at the source | Steps to Implement It

23/02/2024 by TECHIEQUALITY

Quality at the source | Steps to Implement It:

Hi Reader! Today we are going to discuss Quality at the source. In a traditional manufacturing process involves the inspection at every phase of production. Inspection only can detect defects and not prevent defects and also manually it is difficult to 100% check or inspect the product at every stage of production. If it could not be detected at the time and stage of each phase then at a later phase/ stage, defective products were either reworked, repaired, or scrapped. Otherwise, these were passed on to PDI and later on to end-users or customers.

Download the Free 7QC Tools Excel tools template or format with an industrial example.

In the smart production (Lean production system or TPS system) system manufacturing units are implemented so many tools (like Jidoka, Andon, Poka-yoke, etc.) to control the defects at the source and stop them there. And one more effective concept is QM (TPM) to implement at the shop floor to control the defect at every stage. As we know that operators are in a better position than inspectors than inspectors to discover the defects and fix them if they are unable to fix them, then they can stop the line and they will intimate the technical expert to fix them at the source. In such a way a smart production industry could able to control the quality at the source.

Steps to implement Quality at the source:

Standardize the Work.
Self-check.
Successive check
Visual standard
Autonomation

Illustration of Steps:

Step-1: Standardise the work process, materials, tools, machine set-up, tools changeover, tools life, trained the workers or operators, etc.

Step-2: Involve the workers or operators in checking or measuring the key parameters of quality themselves. And let them make the necessary corrections to fix-up the problem.

Step-3: Regular checking for quality downstream.

Step-4: Master sample, Visual signboard, physical acceptance criteria sample display at work station, Pareto chart, cause and effect diagram, run chart or line chart, etc.

Step-5: Implementation of Autonomation line Andon light, Poka-yoke, etc.

Principles:

The above steps are based on three key principles as Philosophical, operating technique, and physical device. Empowering the employee to stop producing the defective product (Philosophical principle) at the production line and enforce instruction, sequence, and execution through visual standards. And finally, the physical device principle follows the Autonomation concept means installing the physical device such as Poka-yoke, Andon light, or signal to control the quality at the source (enhance the quality product and eliminate the defects at the source.

Single line definition:

Quality at source is an effort of an organization to improve the quality of products by having a worker or operator act as their own operation, and never allow passing defective products to the next process.

Benefits of Quality at the Source:

To improve Productivity.
Awareness of the importance of quality.
Empowerment of workers or operators to achieve the desired quality.
To reduce the wastages.

Useful Articles:

Jidoka Autonomation, Bakayoke & Yo-I-don |Concept in TPS

Pull Production System | Concept

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