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1

MDi BU Quality Review

March 2019
Content
1.BU Quality update 2

2.CQA update

3.Factory Quality Update : CMP

4.Factory Quality Update :APD

5.WHS Quality Update :

6. IQA Quality Update :

7.Offshore Quality Update :


3

BU Quality Update-MDi
1. Highlights/Lowlights
2. QRM – MDi Status
3. BIQ updates
4. Other Initiatives
1. Highlights/Lowlights : MDi
Month Highlights
4

 .

Positive Opportunities Negative Threats


2. QRM – MDi Status
QRM - MDi Achievements    
Plant Score % Target % Status Comments
  CMP 47.0 47.0   PFMEA project - Require Expedite

  APD 47.0 47.0   All Project are Meet Target

  WHS 47.0 47.0   QMS - Not meet target

QRM - Key Accomplishment    


    CMP
  1 Prepared Tranining sysllebus for shopfloor employee QRM Achievement
  2 Develop Structured meeting Framework
3   CMP
    APD 50
  1  
  2  
3  
    WHS 0
1  
2  
3   WHS APD
3. BIQ Updates
BIQ Updates            

  Score Update            
  plant Score            

1 CMP
2 APD

  Major Challenges            

  plant Key Challenges          


1 CMP

2 APD
4. Other Actions Initiatives
No Action Initiated Relevant Project Stage
       
       
       
       
       
       
       
       
       
       
       
       
       
       
8

CQA Update-QMS review


1. Monthly Highlights
2. Internal Quality Audit summary
3. Major Quality Issues of Outsource Process
4. Changes that could affect the QMS
1. Monthly Highlights

Monthly Highlights –January 2019


9
2. Internal Quality Audit Summary

Factory CMP APD WHS IQA Total

No of audits conducted 10

Total NCs

No. of NCs closed within 90 days

No. of NCs exceeded 90 days

% of NCs closed within 90 days

Target – %
3. Major Quality Issues of Outsourced Process

11
4. Changes that could affect the QMS
12
Status
Plant # of changes
Approved Pending Rejected
CMP

APD
WHS

IQA

Important Changes

© 2011 Camoplast Solideal Inc. All rights reserved.


12
13

Factory Quality Update- CMP

1. Highlights/Lowlights
2. Inflow/Outflow
3. Key Quality Problems
4. Customer Complaints & Status
1. Highlights/Lowlights : CMP
Month Highlights YTD Highlights

14

Positive Opportunities Negative Threats


15

Factory Quality Update- APD

1. Highlights/Lowlights
2. Inflow/Outflow
3. Key Quality Problems
4. Customer Complaints & Status
Quality Inflow MB
& 2nd stage Out Flow Rejection.
In Process rejected (PPM)
50000

40000 43004
39174
30000 Actual 16
PPM

28027 27229
20000 24190 Target
20797 19868 20237 21098 16333
17453 15542
10000 15230

0
18 Ap r-18 ay-18 un-1 8 8 8 8 8 8 8 9 9
Mar- M J Jul-1 Aug-1 Se p-1 Oct-1 Nov-1 Dec-1 Jan-1 Feb-1

Month

Compound Wise Rejected Rejection of February-2019


50000
40000 10%
1%
30000 Low SG
High HD
Kg

High Viscosity
20000 38% High SG
High SG-UCD
10000 25% High SG-UCD
High SG High Viscosity
0
High HD Low SG
E

E
8

01

6
3

25

01

1
32

91

45

78

27
R

-R

-R
-6

52

1-
2-

5
F-
-

P-

55
32
IL

TR

52
B-
B-

-
96

R
H
-6

-8
-5

ET
-1

TR

R
IL
R

JT
AT

Compound 26%
Camso 2019
Quality Inflow FM
& 2nd stage Out Flow Rejection.
Inprocess Rejected (PPM)
60000
50000 55707
40000 17
30000 38551 40872
20000
32338 31364 30455 27592 27118
25909
24088 25499
PPM 10000 17241 17009 In process
0 (PPM)

8
8

9
r-1

p- 1
Target

r-1

y -1

n- 1

l- 1

g- 1

t- 1

v -1

c -1

n- 1

b- 1
Ju

Oc
Ma

Ap
(ppm)

Ma

Se

Ja
Ju

Au

No

De

Fe
Month

Compound Wise Rejected (Kg)


Rejected of February 2019
9%
High HD
25000
Scorch particles 6%
20000 28% High SG
Low Viscosity
15000
Low Ts2 Low HD
10000
Kg Low SG Low HD (Without
5000
24% Chemical)
0 Low HD (Without
5 0 2 5 3 4 1 2 2
04 -70 - 60 -38 225 -92 112 - 63 611 - 85 -78
5 1 Chemical) Low SG
-1 -
SM - NS - TR -TR TR R DT 2- H- - TR TR- JTR -HP
2- 2 2 2 2- 2- 2 A 2- 2 Low HD
2-
Low Ts2
Compound High HD
1%
3% 29% Scorch particles

Camso 2019
Quality Inflow Calendering
CMP & KTD Rejected due to Calendering Issue
Monthly Rejects Due to Calender - Rejects Due to Calender-Pareto Anal-
2.78
CMP(Kg/Ton) ysis of February
3.80 2.62 2.50
98 100 120 18
89 94
3.10 2.92 2.71 2.53 2.06 2.22
2.50 4.00 5050 100
2.50
69 76 84
3.00 4050 59 80
2.00
2.5 3050 43 60
Kg/Ton

2050 21 1037805 40
1.00 1048 466 384 360 268 246 168
1050 20

Kg
108
0.00 Achiev 50 0
ment D T T T) D IP LE S E S
EA ES PL ES
Ju 8
Ju 8
Ma 1 8

Au 8
Se 18
Oc 8
No 8

F e 19
19
Ap 8

D e 18
Ja 8
N IN N
EF U ST
R
TI
C
1
l- 1
U
1

t- 1
r-1

1
PO PL JO O KN SAM KN
n-
r-
y-

n-
b-
g-
p-

v-
c-
( W P G R
R P E A IC IC
Ma

M E A M IN P .C
Target C
O
N
D R AG C
O D H TH Q TH
S LE SC AM ER BI
N
R
C
ER SS
S A D O V E
Month LE C V O L
O SC

MTD Rejected Due to Calendering Issue


Rejects Due to Calender-Pareto Analysis
Monthly Rejects Due to Calender -
of Febrouary-MTD93 98 100
CMP(Kg/Ton)-MTD
1.66

87
1.80

1.65

4000 100
72 80
1.67

1.62
1.58
1.96
1.52

1.83
1.45

1.80
1.65

3.00 3000 18 61 80
49 60
2.00 2000 37

664
40
Kg/Ton

1.11

658

446
1.00 1000

428

397

198
20

307

174
255

79
0.00

Kg
Achiev
0 0 %
Au 8
Ap 8
M 18
J u 18
Ju 8

Se 18
O c 18

D e 18
J a 18
F e 19
19
N o 18
l- 1
1
r-1

ment
n-

v-
c-
n-
b-
r-
-

g-
p-
t-
ay
Ma

Target
Month

Camso 2019
RRW-MB,FM & Calendering

19
Rubber Related Waste -MB+FM
Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19
Month

Cleaning rubber-Kg 4470 4219 5660 9154 13533 15788 10679 19778

Scrap compounds-Kg 14153 25560 30596 20614 16476 26540 32254 22856

QC sample-Kg 2474 2330 3160 2280 1800 2317 2407 1720


RRW-FM+MB
PRODUCTION-ton
14845 15660 16160 14813 13960 14706 16005 13543

TOTAL RRW-Kg 21097 32109 39416 32048 31809 44645 45340 44354

Target Kg/ton 3.260 3.238 3.215 3.193 3.170 3.148 3.148 3.100

Achieved RRW-Kg/ton 1.421 2.050 2.439 2.163 2.279 3.036 2.833 3.28

Camso 2018
Quality Out Flow-MB & FM
Out Flow–(Properties + Processability ) MB & FM
3000
2400 Processability(p 20
pm)
1800
1637
PPM 1200
1459
600 261
420 515
144 257 148 163
0 52 69 58
65 99 31
66 27
87 105 58 0 180
0
r-1
8 18 18 18 18 18 t- 1
8 8
1 1 8 19 -1
9
y- n- ul- g- p- c v- c- n- b
Ap M
a Ju J Au Se O No De Ja Fe

Month
Properties Processability

Properties Issue 4850


Processability
4227
Issue
4050
3250
Low Viscosity
Kg
0 2450 Colour out
Kg 1650 Bagging
850 400
120
50
54 - 38
5
- 54
1
Plant R -3 R TR
2 -G B 2- T
Plant
Customer Complain – Outflow details

21

Highlights
Operational issues continuously dropped
due to regular QC checkups and new
Com plaint quality gate
No complaints reported at APD Camso 2019
Customer Complaint
Plant Wise Client Complaints(With NCR+Non NCR) of Feb-
ruary-2019
11 22

9 1
7 With NCR
11 Non NCR
No 5
8
3 1 3
3 1
1 2 2
D - 01 KT
D
D-0
1
D - 02 D 02
ET MT ET MT

Plant.

Processability Issue
4500 4227
4000
3500
3000
2500 Low Viscosity
2000 Colour out
Kg 1500 Bagging
1000 400
500 120
0
D - 02 KT
D
D - 01
ET MT
Plant Camso 2019
23

Quality - APD
1. Highlights/Lowlights : APD
Month Highlights YTD Highlights

24

Positive Opportunities Negative Threats


Quality Inflow
Quality In Flow
12000

9903

8689
10000

7852
7601
8000

6005
5952
25
6000
PPM
4000

2000

0
Sep Oct Nov Dec Jan Feb
Achievement Target

Contribution for Internal Defects (February 2019)


500
Defects Categorization (February 2019)
447
450
400
350
300 Short mold (Hole)
250
25% Short mold (Edge)
Pcs

200 41% Flow mark


150
100 71 14%
50 2 1 20%
0
Flap Spacer Bladder Air bag
Camso 2019
Quality Outflow
80 Quality Out Flow 71
70
60
50 44 47
40 36 36 36
PPM 32 26
30
20
10
0
September October November December January February

Customer complaint product wise(Last Six Customer complaint Reason wise (Last six
month) month)
12 11
10
Pleat
8
No of complaint

22% Qty Variation


6 36% Air Leak
Other
4
21%
2
2
22%
0
Air Bag Flap
Camso 2019
Rubber Related Waste ( Last Six month)

Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19

Ancillary Product 553 1032 479 173 581 486 27

Recycle Product 0 192 82 492 239 0

Flash 1959 4383 3875 3317 4280 3338

Other 254 407 326 112 218 243

Total (Kg) 2766 6015 4762 4094 5318 4067

Target (Kg/Ton) 4.26 4.26 4.26 4.26 4.26 4.26

Achievement (Kg/Ton) 3.20 5.47 4.26 3.30 4.40 3.25

Camso 2019
28

Factory Quality Update- WHS

1. Highlights/Lowlights
2. Actions Initiated & Status
1. Highlights/Lowlights : WHS
Month Highlights YTD Highlights

29

Positive Opportunities Negative Threats


2. Quality Initiatives
No Action Initiated Relevant Project Stage
       
       
30
       
       
       
       
       
       
       
       
       
       
       
       
31

Factory Quality Update- IQA

1. Highlights/Lowlights
2. Actions Initiated & Status
3. Key Quality Issues
1. Highlights/Lowlights : IQA
Month Highlights YTD Highlights

32

Positive Opportunities Negative Threats


2. Actions & Key Issues

No of Incoming Lots Completed  

   
33
No of Lots Hold  

   

No of SCAR Generated  

   

Major Quality Issues  

   

Quality Issues  

Supplier  

Remedial Action  
34

Thank You

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