Built-In Quality
(= Build Quality Into Process)
Membangun Kualitas
ke dalam Proses
“I always like
to challenge organizations
to have “lack of time”
be the first problem statement
that they have to solve in their
continuous improvement work.
Do we really not have time?”
~ Mark Graban
“The medicine I am prescribing for you is a miracle drug
and very powerful, but there is one problem with it.
It won’t work unless you take it.
There are a lot of people in the world
who worry the medicine and side effects are bitter,
and avoid it .”
~ Shigeo Shingo
22
BUILT-IN QUALITY Concept
Final Inspection Vs The Four Pillars of BIQ
OCCURRENCE
PREVENTION
by Doing Perfect Job
1 2 3 4
P1 P2 P3 P4 Inspection Delivery
No Final Inspection!!!
No No No No
Defect Defect Defect Defect
OUTFLOW PREVENTION
@ Each Gate (=Gate Checker)
33
BUILT-IN QUALITY Tools Right on Time,
First Time
Planning Design Test Production Delivery Customer
2
6
4
5
44
BIQ Tool #6: Feedback System
Practical Problem Solving FAST RESPONSE:
Stop & Respond
@ Every Abnormality
Go & See @ Gemba
Clarify & Define Problem
REAL ROOT-CAUSE:
Most Likely Root Cause
Multiple 5-Why’s Analysis
Countermeasures
HAND-OVER POINTS
Between Functionals:
SUSTAINING: JidokaTracker
One Point Lesson Briefing Area
Kaizen Fish Market Briefing Area
Standardization Daily Action Log Briefing Area
Yokoten
55
Stop & Respond @ Every Abnormality
“Go & See.
Ask 5 Whys.
Show Respect.”
Supervisors &
Engineers
work together
for instant resolution
“Touched.
Felt.
Understood.”
66
“A relentless barrage of ‘whys’ is the best way
Multiple 5 Why’s Analysis to prepare your mind to pierce the clouded veil of
thinking caused by the status quo. Use it often.”
~ Shigeo Shingo
Missing Components
Why? Why? Why? Why? Why?
Nozzle stuck Nozzle bent Solder
paste dry Component Component
Why? Why? Why? height drops
Nozzle over press Spring Feeder problem wrong off in the
Why? ends not Why? Printing too reflow
Flat prevent Feeder not many boards Why? oven during
Board warping Feeder
(applicable for the nozzle Locked / not calibration Incoming top
both sides) from turning setup properly out issue reflow
Output
Why? Why? driven /
-Support foam Operator not following
Reflow
problem (too high) handling / not Handling takt time Variation
between temperature
-Depends on bottom trained on this problem too high
vendors
side comp. height SOLUTION
Backlog/
SOLUTION 1. Technicians to train operators
machine Profiling
on the proper handling method
1. Adjust the height downtime wrong
2. Nozzle check to be performed too high SOLUTION
of the foam
at the end of the shift and change 1. Adjust the part
2. Design new spring the bent nozzle
with both ends flat data (height)
SOLUTION
Solution the 1. Fix the SOLUTION
Root-Causes! machines [Link] new profile
77
Energizing Before-After Template
“Quick and crude is better
than slow and elegant.”
99
FAST RESPONSE
Feedback System REAL ROOT-CAUSE
HAND-OVER POINTS
SUSTAINING
10
10
