Quality Control Progress 2014
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Transcript of Quality Control Progress 2014
UPP- Operation Dept. – Quality Control Unit
1
UPP
Quality Control Unit
Quality Control Management
Checked
Agenda
2
UPP
Quality Control Unit
ISO QMS documents 1
Concepts and Introduction 2
Manpower & Shifts 3
Quality Section Workflow 4
Quality Control Analysis 5
Monitoring Percentage
Rate Of Failure
Kinds of defects
Summary
Customer Complaint & Additional Cost 6
KPI’S 7
Quality Plan 2014 & 2015 8
General Topics 9
Quality Control Back ground
3
UPP
Quality Control Unit
Unit Till Apr 2013 Starting from June 2013 Till Date
Press Check Data only for
1st sheet Approval
Check Data and color for 1st sheet approval Monitoring No. of processes based On Achieved Production Processes Identify Printing issues with documentation for the samples (Printing / Finishing ) Monitoring products based on Standard Measurements Dampening water measurements Identify TVI Carve Variance for each machine
Binding&Final stage
Daily inspection report
Daily inspection report (last status - % of checked – office copies - flagged copies) Monitoring No. of processes based On Achieved Production Processes Final stage report (Recording for kind of error noticed) No. of process checked related to No. of Error (Error %) Quality in process Binding (New activity added in Hifelx software on July)
Quality Section analysis
Not Available Reduce Customer Complaint Reduce reprint due to quality issues Errors analysis related to Units and kind of errors Root cause analysis to identify pain area and sharing information with all
departments Achieve Monthly Rate of failure Target improve Quality Control activities
Quality Section Workflow
4
UPP
Quality Control Unit
Finishing
Folding
Binding
Manual Binding
Post pressPress
Ok sheet / Online checking
Measurement devices
Press / Ok sheet / Online checking
5
UPP
Quality Control Unit
Read Job Docket
Verify job
specifications
Make ready Decision
Start Printing
Check density
Online checking
WaitingNext Process
OK sheet
Not Ok
ok
ok
Not Ok
Press / Finishing
6
UPP
Quality Control Unit
Read Job Docket
Verify job
specifications
Make ready
Decision Start processing
Check for
defects
Online checking
OK sheet
Lamination FoilingUVEmbossing Die Cutting
Next Process
ok
Not Ok
Not Okok
Post press/ Folding
7
UPP
Quality Control Unit
Read Job Docket
Verify job
specifications
Make ready Decision
Start FoldingOnline checkingNext Process
OK sheetNot Ok
ok
Not Ok
ok
Post press / Manual Binding
8
UPP
Quality Control Unit
Read Job Docket
Verify job
specifications
Make ready
Decision
No
Start processing
YesCheck for
defects
Online checking
1st Copy approve
Saddle stitchManual bindingPerfect binding
Next Process
Hard case
Not Ok
ok
Final Stage
9
UPP
Quality Control Unit
Read Job Docket
Decision
Packing
checking
Rejected by QC
Not Ok
ok
Delivery point
Decision
Accepted copies
SortingRandom
One by One
Corrective actions
Not Ok
ok
Agenda
10
UPP
Quality Control Unit
Manpower & Shifts
Quality Section Workflow
Quality Control Analysis
Monitoring Percentage
Rate Of Failure
Kinds of defects
Summary
Customer Complaint
Additional Cost
KPI’S
Quality Plan 2014
11
UPP
Quality Control Unit
Quality Control Monitoring % (Printing Nov 2014)
Quality Control Monitoring % Printing ( Jan - Oct 2014 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300
50
100
150
200No of processes done in printing No of processes approved by QC
No
of P
roce
sses
Jan Feb Mar April May June July August September October November0%
20%
40%
60%
80%
100%
120%
57%
33% 35% 36% 37% 39%
72%
97%
80%
96% 96%
Printing
Monitoring Percentage per M/C
12
UPP
Quality Control Unit
Checked by QC Not checkedChecked By PressSIGN
14198%
32%
Rotoman Monitoring 98%
3895%
25%
KBA215 Monitoring 98%
32%
9377%
2521%
KBA105 Monitoring 98% 2
3%
3255%
2441%
KBA74 Monitoring 96%
Monitoring Percentage per M/C
13
UPP
Quality Control Unit
Checked by QC Not checkedChecked By PressSIGN
21%
7449%
7650%
KOM 8COL1 Monitoring 98.3%
84%
2211%
16485%
KOM 8COL2 Monitoring 96%
44%
1716%
8480%
KOM 4COL Monitoring 96 % 1
2%
2657%
1941%
ROLAND 500 Monitoring 98%
Monitoring Percentage per M/C – Overall Score – Quality Evaluation per M/C
14
UPP
Quality Control Unit
54%
2925%
8070%
SM52 Monitoring 96%
KOM8COL2
KOM8COL1
KOM4COL
KBA105
KBA74
ROLAND500
SM52
0%
20%
40%
60%
80%
100%82% 80% 83% 88%
73%82% 77%
Overall M/C Quality Score
KOM8COL2 KOM8COL1 KOM4COL KBA105 KBA74 ROLAND500 SM520%
20%40%60%80%
100%
82%
84%
66%
90%
69% 76
%
77%91
%
93%
70%
94%
72% 81
%
77%
Primaries % (Start) Average Primaries % (End) Average
Quality Control Monitoring % Binding, (Nov 2014 )
15
UPP
Quality Control Unit
Quality Control Monitoring % Binding, (Jan – Nov 2014 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
No of pro-cesses done in Binding
53 72 92 106
152
80 58 52 62 75 63 52 42 40 62 112
85 51 66 91 49 76 73 73 81 71 32 22 52 53
No of pro-cesses ap-proved by QC
32 58 78 83 139
63 43 0 53 63 30 24 13 16 48 100
71 34 59 76 21 51 52 54 63 59 23 10 52 53
1030507090
110130150
No of processes done in Binding VS No of processes Approved by QC
No
of
Pro
cess
es
Feb Mar April May June July August September October November0%
20%
40%
60%
80%
100%
120%
75%87% 88%
96%
76% 72%87% 83%
56%
74%
Quality Control In Binding (Monitoring)
16
UPP
Quality Control Unit
Checked by QC Not checked by QC
ProcessNo Of proces
sCheck
edNot
checked % Remarks
Folding 804 565 239 70% Etihaad menus
Saddle
72 60 12 83%
Etihaad menus,Few jobs binding done more than one time
P.Binding91 78 13 86%
Few jobs binding done more than one time
56570%
23930%
Checked by QcNot checked by Qc
Folding Monitoring 70 %
6083%
1217%
Checked by QcNot checked by Qc
Saddle Stitching Monitoring 83%
7886%
1314%
Checked by QcNot checked by Qc
Perfect Binding Monitoring 86 %
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Error % 6% 0% 5% 5% 8% 6% 10%
4% 5% 3% 6% 0% 4% 0% 11%
7% 4% 4% 0% 3% 5% 5% 0% 5% 3% 8% 5% 0% 5% 5%
1%
3%
5%
7%
9%
11%
6%
0%
5%5%
8%
6%
10%
4%5%
3%
6%
0%
4%
0%
11%
7%
4% 4%
0%
3%
5% 5%
0%
5%
3%
8%
5%
0%
5% 5%
% of error VS No of processes checked - Nov, 2014Er
ror
%
Rate of failure Nov , 2014
Rate of Failure, Nov 2014
17
UPP
Quality Control Unit
Rate of Failure, Jan - Oct 2014
Jan Feb Mar April May June July August September October0%
5%
10%
15%
20%
25%
7%5% 4%
6%4% 4% 3% 3% 2%
5%
Rate of failure %Rate of failure 2013 was 23%
Rate of failure 2014 target is 10%
18
UPP
Quality Control Unit
Kind of defects and No. of repetition Jan - Oct 2014
Kind of Defects 2013
Color varia
tionse
t-off UV
scum
Cutting is
sues
Foilin
g
hickies
rolle
r marks
regist
ration m
ark
Lamination
Folding is
sues
line m
arks
powder
Uneven Jo
ints
Scra
tches
Uneven sp
ine0
10203040506070 61 63
617 18
3 8 5 6 29
194 5 9 3
Total No. of repetion related to kind of defects SEP - DEC 2013
0
50
100
150
200
250
300
125105
250
49
122
5117 8 10 28 20
4917 32
3 8 14 2 3 4 1 1 5 1 2
Summary, Jan – Oct 2014
19
UPP
Quality Control Unit
Summary Jan - Oct, 2014
Total No. of process checked by QC printing 10600
Total No. of process checked by QC binding 6256
Total No. of process checked by QC final check 5389
Total No. of defects noticed in final check 792
Total No of complaints 17
Total No of rejected jobs 12
Total No of risk delivery jobs 66
Risk Delivery reports, Jan – Nov 2014
Jan Feb Mar April May June July August September October November0
2
4
6
8
10
12
14
16
6
10
6 6
0
2 2
14
12
5
3
Customer complaints 2012 / 2013 / 2014
Customer Feedback Analysisand Complaints and Product Conformity (Till 24 Aug 14)
Complaints 2012 : 63Complaints 2013 : 86Complaints 2014 : 30
2012 2013 2014 % of Diff against 2012 % of Diff against 2013Materials 4 7 Prepress 3 3 1 33% 33%Printing 21 33 14 67% 42%Binding 20 10 6 30% 60%Manual Binding 2 Packing 3 1 2 67% 200%Delay in Delivery 4 2 7 175% 350%Quality 7 0%Stores 1 General 6 22 63 86 30
KPI’s 2012 - 2013 - 2014criteria Target Score Achieved Score
Sr 2012 2013 2014
1 Ensure printing start’s with Standard Measurements i.e. ˃ 85% primaries (Color Density) 15% 0% 4% 14%
2Monitoring No. of processes Achieved by Production related to No. of quality Checked processes i.e. ˃ 95% Monthly result
15% 0% 8% 12%
3 Identify and adjust TVI Carve for each machine 15% 0% 0% 10%4 Devices Calibrations Plan 5% 2% 3% 5%5 Quality Control Team Possibilities 5% 1% 3% 5%6 Reduce Customer Complaint 10% 5% 5% 10%7 Reduce reprint due to quality issues 10% 5% 5% 10%8 Achieve Monthly Rate of failure Target 10% 0% 2% 9%9 improve Quality Control activities 10% 0% 5% 8%
10 improve Team communication and Technical skills 5% 2% 4% 5%Total 100% 15% 39% 88%
Y2012 Y2013 Y2014
Achieved Score 0.15 0.39 0.88
5%15%25%35%45%55%65%75%85%95%
KPI's
Achi
eved
Sco
re
Manpower & Shifts
Quality Section Workflow
Quality Control Analysis
Quality Plan 2014 & 2015
Agenda
Quality Plan 2014 - Color Management Improvement
23
UPP
Quality Control Unit
pressSIGN Software & TECKON measurement devices
عن تقل ال بنسبة الجودة مستوى العالمية % 30رفع القياسية المواصفات من . االستدامة حيث من ، المال رأس وأصحاب والعاملين العمالء رضا مستوى رفع الـ على للحصول الماكينة وضبط إعداد وقت % 50بواقع OK Sheetتوفير للـ الالزمة الطبع أفرخ عدد عن Make-readyتوفير تقل ال % 30بنسبة الـ وارتفاع Operatorتدريب االنتماء زيادة على يساعد مما عالمية تكنولوجيا أحدث استخدام على
بالنفس الثقة. للعمالء قيمة وإضافة ، والمرتقبين الحاليين العمالء لدى الثقة زيادة . للمطبعة للتسويق كأداة استخدامها يمكن كما
o Raising of quality level by not less than 30% of the international standard specifications o Raising of satisfaction level for Customers, workers and stockholders , in terms of sustainability. o Saving the time of adjusting the machine to get the OK Sheet by 50% o Saving number of sheets of Make-ready by at least 30% o Operator training on the use of the latest global technology, which helps to increase the sense
of belonging and high self-esteem o Increase the confidence of existing and prospective customers, and add value for customers. o It also can be used as a marketing tool for the Press.
Quality Plan 2014 - Color Management Improvement
24
UPP
Quality Control Unit
pressSIGN takes you quickly and easily to your own or international printing standards. pressSIGN’s five easy steps reduce make-ready times and improve your color.
بمكان الخاصة المقاييس أو العالمية المقاييس على الجودة اعتماد إمكانيةالعمل.
الالزم الوقت تقليل النظام هذا باستخدام يمكن محددة خطوات خمس فىالـ على والحصول الماكينة OK Sheetلضبط
pressSIGN Software
40% 73%
• implement FOGRA - ISO 12647- 2 for certificate : Process Standard Offset (PSO) Audit
Quality Plan 2015
Benefits are as follows:1. Material specification is clearThe optical parameters of both ink and paper are specifically described in their respective standard. Incoming materials can easily be verified when materials are inspected.2. Cost of Quality is lowerSince quality is built inside each process the chances of problems from reaching the print buyer is very minimal, if not, totally avoided since these are detected early on and are prevented from being passed on to the next work center. 3. Uniformity & ConsistencyRegardless of shift, the same aim points remain. Whether we have a new employee in either prepress or press, the same output will be met every time. The same quality level will be delivered to the customer tomorrow and several months from now. 4. For print buyersA clear set of requirement is communicated to them (ie. bleed allowance, resolution, ICC profiles, etc.) ensuring the files are prepared according to our press requirements. But even if the customer's files are not conforming to our color requirements we can feed this into a color server that will remap the colors to the colors of our press without any problems. Some form of automation is involved in this process. 5. For print providerCustomer demands will be met especially international buyersA more efficient operation in the printing complex's supply chainA reduction of make ready waste, time and costSpecial cause variation is avoided6. PSO CertificateTo successfully get a PSO certificate is a validation that the entire process in the organization is world class. It is an indication that we are doing the right things right. It tells us that in each process that we do is adding value for the customer. 7. Higher revenue This depends on the company's marketing and sales strategy and also on the day to day operation in production where post calculation is regularly monitored as one of the KPIs. But this is another story.
By the way, once certification is achieved, customer's expectation will be higher, the shareholder's expectation in terms of investment return will be greater. These are just some of the realities and the challenges that I have faced once a company is certified. How to make it sustainable...that is the greater challenge.
Total result
7 Months 17 New reports Done in 2013
Quality Control Unit
27
UPP
Quality Control Unit
Thanks For your readingThanks for MY Team
for their HARD effort
ArunodayEssam HemadhVinod Kumar
BickashHarriSumanThirtaIchchhaGopalRoyJino
&
Ahmed Gado