CASE STUDY ON QUALITY DEFECT
Sheet No. 1
QM PILLAR
Dept: XYZ
QM Coordinators:
Presenter: ABC
Data collection on defects
Collect data of defects occurred during last
6 Months.
•
•
•
•
•
Scratch :
Fin:
Size:
Lap:
Crack :
Nos. / %
Nos. / %
Nos. / %
Nos. / %
Nos. / %
Sheet No. 2
Data collection on defects
1st Priority
due to high
in Nos.
Nos.
Defectwise status
16
14
12
10
8
6
4
2
0
Sheet No. 3
14
11
8
6
Scratch
5
Fin
Size
Lap
Crack
History of Crack Defect
Nos.
Crack Defect Data
16
14
12
10
8
6
4
2
0
Sheet No. 4
1st Priority due to
high in Nos.&
increasing &
repetitive
14
11
8
6
5
Apr-08 May-08 Jun-08
Jul-08
Aug-08
Defect selected for case study
Sheet No. 5
CRACK DEFECT SELECTED FOR
CASE STUDY
Define & Classify the various
Crack defects
Sheet No. 6
• List out Various types of Crack defects one by
one & define each type of crack defect.
• Surface crack
• Internal crack
• Off corner crack
• Star crack
• Transverse crack
Visual photograph of each type of
Crack defect
Sheet No. 7
• Show visual photograph / sketch / drawing of
each type of crack. (May be one slide for each
type of crack defect)
Crack Defect Vs Identifying 4M
Conditions
Sheet No. 8
Crack Defect Defect Mode Material Machine Method
Surface crack
Internal crack
Off corner Crack
Star crack
Transverse
Applicable
Not applicable
Man
Caused by Raw Material Condition ?Sheet No. 9
Crack
Material condition Actual
Defect
Required
condition
Surface
Crack
Internal
crack
Off
corner
Star
Crack
Transvers
e
Gap
Analysis
Caused by Machine Condition ?
Crack
Machine condition Actual M/c
Defect
Required
condition
Surface
Crack
Internal
crack
Off
corner
Star
Crack
Transvers
e
Sheet No. 10
Gap
Analysis
Caused by Method Condition ?
Sheet No. 11
Crack
Method condition Actual Method Gap
Defect
Required
followed
Analysis
Surface
Crack
Internal
crack
Off
corner
Star
Crack
Transvers
e
Caused by Man skill Condition ?
Crack
Defect
Surface
Crack
Internal
crack
Off
corner
Star
Crack
Transvers
e
Man condition
Required (Skill)
Actual Man
condition
Sheet No. 12
Gap analysis
Root cause analysis
Sheet No. 13
Find actual root causes through Why-Why analysis
for each Gap identified.
Countermeasure
Root Causes
Material
Machine
Method
Sheet No. 14
Countermeasure Plan Resp.& Tgt Status
Date
1)
2)
3)
4)
1)
2)
3)
4)
1)
2)
3)
4)
Countermeasures
Root causes
Countermeasure Plan
Man
1)
2)
3)
4)
Sheet No. 15
Resp.& Tgt Status
Date
Confirmation of Quality CharacteristicsSheet No. 16
Confirm whether all Quality characteristics are
within Standard norms / specifications.
Furnish the data here or in different slides.
 Chemical
Metallurgical
Mechanical
Physical
Process characteristics
EFFECTIVENESS OF COUNTERMEASURESSheet No. 17
Cracks Defect trend
after counter measures taken
6
5
5
Nos.
4
3
2
2
1
1
0
'Jun-08
'Jul-08
'Aug-08
0
0
'Sep-08
'Oct-08
Standardization
Sheet No. 18
Standardize the activities w.r.t Materials, Machine,
Methods and Man
Update all concerned W Is , SF Standards,
Inspection plans, Inspection standards, Check
lists, Process controls …etc.
Update Training records
Sheet No. 19
ALL FACTORS
RESPONSIBLE FOR
CRACK DEFECT
ELIMINATED