UPDATE FROM TS SHOP FLOOR

“THE ROAD TO ZERO DEFECTS”

It has been always said that PMI is way far from ‘Zero-Defects’  manufacturing, and TS Division is absolutely on a fairly distant position as well, considering the quality performance in the first three quarters of FY 2008. Operations has faced a thundering number of customer complaints. Compared with last fiscal year, the figure is undeniably a headache. To worsen the scenario, add some few lot-outs and low yield and now the headache becomes practically unbearable. But of course, this does not go unnoticed under our watch. We are trying the best we could to cook just the right medicine for it. We never lose hope and did not cease trying, there's this phrase that we envision... "Impossible is just the untried!" Come to think of it, at some point we may say that something is impossible to get thru but who can say such if he has not even tried. ‘Zero Defects’ is not a DREAM, the more appropriate term is GOAL.

Year 2008 maybe considered the worst in terms of quality problems but it is also the year when various projects and programs were born. In an optimist‘s mind, it is the year of more learning for the division. To counteract the challenges, TS has introduced and implemented actions that will enhance the performance of operations, to trap the problem before it reaches the hand of the customers. It was tough but we believe it will be worth the while. To list down a few, (1) SPC tools such as FMEA, MSA, & Trend Charts became word of mouth in the division. FMEA was introduced to all shop floor workers and implemented to general assembly flow processes and new products. Attribute MSA was conducted to visual operators, inspectors and staff to calibrate their capability in identifying the defective from the good one and vice versa. Trend Charts were used to monitor machines and product performances to solve problems before they arrive. These were just the start and are still going on for full implementation. (2) Amidst the tight schedule of production, trainings, refreshers, orientations, were conducted every once in a while to enhance the know-how and develop the skills which are essential for effective execution of every job. Regular meetings were organized to address all issues related to quality problems. (3) Formulated a more stringent criterion on qualifying and maintaining machines, tools, jigs and other aspects related to operations. The prime intention is to promote awareness and eventually develop self-inspection and self-auditing. (4) Some previously defunct activities were temporarily restored to make immediate resolution and have assurance that the defects will be less and trapped when not eliminated. Such activities include additional checkpoints on critical stations, increased samples during monitoring, and 200% inspection by re-activating Production Buy-off Inspection. All these may mean additional man-hours and a waste, but is actually a small price to pay if it can ensure quality deliveries to customers. (5) Living with Poka-Yoke principle, the concept was infused in all programs, projects and actions. From fabricated tools and jigs, to Systems and Instructions being generated, the aim is always to eradicate possibility of error.

All these actions may not be foolproof and may not guarantee excellent quality, and still, the road to ‘Zero Defects’ may be long, rough and full of obstacles, but making the first steps and knowing where we are going, is enough to know that there will come a day that we will be there. For there are no easy means in achieving a goal, you just have to get started and stick with it. We just have to always be directed to the vision, be on the road and keep moving…