![ Verification Part Claim
phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test
mechanism Object scope countermeasure Prevent a reocurrence Application to similar
Diisi informasi terkait aktual part NG.
Contoh:
Summary dari verifikasi part claim
s
Drawing Actual
Contoh: Dimension Length Collar Band B
Insulator Standard 7 ± 0.50 mm (berdasarkan
drawing)
Length collar abnormaly, actual dimension
length 9 mm [ standard : 7 ± 0.5 mm]
Band B
Collar
Band A
Informasi standard dari
Drawing / limit sample/
standard lainnya maupun
informasi part claim (apabila
part NG dikirimkan balik ke
AHM).
Informasi kondisi
aktual dari part klaim
(part NG).](https://image.slidesharecdn.com/panduanar10langkah-250123063051-8086e4d9/85/Panduan-AR-10-langkah-problem-solving-dalam-manufactur-4-320.jpg)
Panduan AR 10 langkah problem solving dalam manufactur
- 1. 10 AR Problem Solving Agus Ali Mahfudz Indonesian Tooling Technology 2024
- 2. Title Part No. TR No Model Model Year Factory Line Maker Production Date Packing Date Occur Date LOCATION TR Date LOT No. Qty Claim Total Rank Mohon diisi dengan informasi detail dari trouble report (T/R) Ilustrasi gambar yang didapatkan dari T/R phenomenon progressed Actual article analysis FTA or process analysis Reconstruc tion test mechanis m Object scope counterme asure Prevent a recurrence Applicatio n to similar
- 3. Contoh : Informasi masalah diterima oleh supplier Nov 14th 2017 phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Nov 14th 2017 Nov 17th 2017 Des 15th 2017 Des 14th 2017 Des 05th 2017 Des 18th 2017 Jan 12nd 2018 Informasi aktivitas penting yang dilakukan Diisi dengan Waktu Informasi aktivitas penting yang dilakukan Diisi dengan Waktu Diisi dengan Waktu Diisi dengan Waktu Diisi dengan Waktu Diisi dengan Waktu Diisi dengan Waktu Diisi dengan Waktu Diisi dengan progress aktivitas yang dilakukan di supplier
- 4. Verification Part Claim phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Diisi informasi terkait aktual part NG. Contoh: Summary dari verifikasi part claim s Drawing Actual Contoh: Dimension Length Collar Band B Insulator Standard 7 ± 0.50 mm (berdasarkan drawing) Length collar abnormaly, actual dimension length 9 mm [ standard : 7 ± 0.5 mm] Band B Collar Band A Informasi standard dari Drawing / limit sample/ standard lainnya maupun informasi part claim (apabila part NG dikirimkan balik ke AHM). Informasi kondisi aktual dari part klaim (part NG).
- 5. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Segmen Main press Visual Inspection 100 % Center assy Center move to driven assy Stamp & visual inspct Slide JIG 100 % Slide JIG 100 % Raw Material Delivery To AHM NKI Move to Assy ( STOCK ) Part claim detected NG by slide JIG Part masspro OK by slide JIG Dimension of Slide Jig : 3.23 mm = Thicknes max F/D : 3.08 mm Toleransi flatness : 0.15 Max Slide JIG assy not detect NG part , because only check for completeness Parts. GUARANTEE PROSES FCC Diisi dengan FTA/ proses analisis (Informasi terkait analisis dari setiap flow proses supplier,beserta potensi terjadinya masalah). Format bebas Contoh:
- 6. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Process Main Press Move To Assy ( Stock Disk Clutch Friction ) Centre Clutch Assy Stamp and Visual Inspection Potential Problem Fltaness NG ( Part Bending ) Part Bending during storage in the box Causing bending Disk Clutch Friction Can’t detect NG Part Actual Analysis 100% guaranteed by slide jig Proces Assy OK, but slide Jig after process assy can’t detect NG Part Bending. Because Slide Jig After assy designed for checkking completeness part. Condition disk clutch friction bending can not be seen because in this process part already mounted spring So the GAP condition is not visible. Judge O X O Slide Jig Can Detect NG Part Found Not Good Condition of Box ( the surface is essentially wavy ). This Condition causing Disk Clutch Friction Bending during storage in the box Diisi dengan FTA (faul tree analysis)/ process analysis lainnya. Format bebas Contoh:
- 7. Phenomenon Progressed Actual article analysis FTA or process analysis Reconstruction test Mechanism Object scope Countermeasure Prevent a recurrence Application to similar Blind Test to Operator Assy Insulator 1st Blind Test IHP operator Diisi dengan summary dari reconstruction test yang dilakukan. Add 3 pcs collar length 9 mm to normal collar WIP box Normal assembly process 3 pcs wrong collar assembled to band B assy Diisi dengan reconstruction test di supplier untuk menemukan penyebab dan/ atau membuktikan terjadinya part NG. Lengkapi dengan ilustrasi gambar/ pembuktiannya. Contoh:
- 8. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Diisi dengan FTA (fault tree analysis)yang telah terbukti kebenarannnya berdasarkan reconstruction test yang telah dilakukan. Dibagi menjadi penyebab dari why made dan why sent; dan buatkan dalam bentuk diagram FTA (sertakan bukti, bila ada) Contoh: Phenomenon Insulator tightening cannot be carried out Incoming Inspection BAND B Installation Only check completeness & appearance of Band B, no attention to collar dimension. No Instruction to check appropriate-type of sub parts include collar length Weakness of OS Incoming Inspection ARAI No Check Point Collar Length at Inspection standard incoming Band B Collar mix in WIP box No Control of WIP box Weakness of OS Assy Band B IHP Only check completeness of sub assy & plating appearance, no check point collar dimension Weakness of OS BAND B Instalation ARAI Final Inspection Weakness of OS Final Inspection IHP
- 9. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Mohon diisi dengan lot traceability dari part NG di supplier.
- 10. Process Problem Countermeasure Progressed Due Date Move To Assy ( Stock Disk Clutch Friction ) Storage Stock Disk clutch Friction with Polybox potential causing Bending Change methode storage Disk Clutch Friction with Hanger Done 11st Dec 2017 phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar After oiling Disk Clutch Friction covered for prevent kontami. Diisi informasi terkait semua counter measure dari Supplier. Mohon disampaikan Due date dari setiap counter measure. Contoh:
- 11. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar problem why why why why Real cause C/M direction Solve problem Occur No control of WIP box when type change happen (Band A to Band B) No instruction to check & cleaning WIP box before type change begin Weakness of Operation Standard Lack of experience when create OS Poor Q- Guarantee knowledge Lack of know how to create good Q- gurantee process Improve know how to create good Q- guarantee process Add instruction to check & cleaning WIP box into knowledge management Outflow Only check completeness of sub assy & plating appearance, no check point collar dimension No instruction to check collar type Weakness of Operation standard Didn’t challenge to create reliable Q- Guarantee (pokayoke 100%) . Lack of know how to create good Q- gurantee process Improve know how to create good Q- guarantee process Create reliable pokayoke jig to ensure 100% Q-Guarantee Problem C/M direction Solve Problem C/M rule change , system change Finish date Occur Improve know how to create good Q- guarantee process Add instruction to check & cleaning WIP box into knowledge management Add instruction to check & cleaning WIP box into knowledge management Feb 2018 Outflow Improve know how to create good Q- guarantee process Create reliable pokayoke jig to ensure 100% Q-Guarantee Create reliable pokayoke jig to ensure 100% Q-Guarantee Feb 2018 Diisi informasi terkait Why- why analysis, beserta dengan Real cause dan counter measure nya. Contoh: Diisi informasi terkait perbaikan pada rule/ sistem di supplier. Diisi dengan due date
- 12. phenomenon progressed Actual article analysis FTA or process analysis Reconstruction test mechanism Object scope countermeasure Prevent a reocurrence Application to similar Diisi informasi terkait aplikasi counter measure untuk part- part lainnya yang similar. Contoh: Problem C/M Rule Change , System Change Application to similar PIC Feb 2018 Keterangan (bila ada) M1 M2 M3 M4 Occur Revise OS assy Band insulator All line IHP, type K15, K45 & K56 IHP Plan Act Outflow Revise collar check method using hand jig 100% All line IHP, type K15, K45 & K56 IHP Plan Act