Step 1.Definition of A, B and C Type defectsRole of the operator is most important in Quality Management.hile !or"ing on the machine operator has to #e $ery alert hene$er the defect is generated operator has to analy%e the phenomenon and !rite !hether it is A, B or C type of defect. &e has to understand !ith !hat action the defect is eliminated. '(ample for A Type Defect.OK OKNot OKUSLLSL1.)ut put is )* initially.+.Becomes ,)T )*.-.Action ista"en #y the operator...Becomes )*.Action ta"en #y the operator.A type defects are caused #y Sporadic Causes.These defects occur suddenly and !ill continue till ta"ing correcti$e action.Can #e sol$ed through !hy !hy analysis.By ta"ing correcti$e action the defect can #e corrected.Phenomenon Cause Countermeasure.Size variation. Tool bluntProvide counter to facilitate tool changingMethodology of sol$ing A Type phenomenon.*ai%en for Reducing A type defect / )D o$ersi%e on AS .0.1D'A2 Tool life monitoring Before After,o counter for tool life monitoring'lectronic counter !ith Auto machine shut off.1.)ut put is )* initially.+.Becomes ,)T )*.-.,) action ista"en #y the operator...Becomes )* on its o!n.'(ample for B Type Defect.OK OKNot OK,o Action ta"en #y the operator.USLLSL'(ample for B Type Defect.OK OKNot OKB Type defects are generated due to chronic causes.These defects generate gradually and disappear itself !ithout ta"ing correcti$e action.By ta"ing countermeasures for all the a#normalities this type of defect can #e corrected.Methodology for sol$ing B Type defects is 3Manalysis.,o Action ta"en #y the operator.USLLSL'(ample of B type defect 4 )n AS .0 machine !hile chec"ing the )D of the component continuously one component found o$ersi%e !hen ne(t component is chec"ed it is found )*.So !ithout action of the operator the machine is producing o" component on its o!n.e can ta"e practical e(ample of defect )D o$ersi%e on AS .0 machine.hile continuously chec"ing)D of the components on AS .0 machine first component is )*. During machining of the second component chip is trapped #et!een component and tool so the component is not o" during the third component no chip is trapped so the component is o".e ha$e to do 3M analysis of the phenomenon.1.)ut put is ,)T )* initially.+. Action ista"en #y the operator...Becomes )*. 5Setting scrap6Not OK'(ample for C Type Defect.Action ta"en #y the operator.USLLSLC type defects occurs during set up.These defects occur in the first product !hen the set up is done.By ta"ing correcti$e action the defect can #e corrected.By pro$iding tool setting master and set up aid this type of defect can #e eliminated.Phenomenon Cause Countermeasure.Size variation. Wrong setting. Provide Tool setting master.Damage. Measurement error during setting.Change analog to Digital.Methodology of sol$ing C Type phenomenon. Before After,o gauge for )D form tool setting on AS .0 machine Tool setting gauge pro$ided for )D form tool setting.*ai%en for 1n4house Re7ection C Type Defect 2 )D o$ersi%e 1D'A 2Tool setting gaugeBefore After,o gauge for Recess tool setting on AS .0 machineTool setting gauge pro$ided for recess tool setting. *ai%en for 1n4house Re7ection C type 2 8ip, undersi%e1D'A 2 Tool setting 9augeStep +.Collecting the data in A B and C Type from all the Machines.QM Shop:!oc"er #rm $earingCELL DEFECT PHENOMENON%& %' %( %) %* +, +% ++ +- +. +& +' +( +) +* -, -% -+ -- -. -& -'%& %& %& %& %& %- %- %+ %+ %+ %+ %+ %+ %+ %+ %+ %+ %+ %+ %+ %+ %++ %, , , , % + - - - - - - - - - - - - - - - -Sr No # $ C /1 76 3 8 57 10 15 0 3 8 6 6 18 10 96 8 41 35 46 65 194 0 02 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 03 0 2 0 8 6 3 3 0 1 2 5 0 2 0 2 0 6 7 3 0 0 04 B 0 0 7 0 5 2 0 0 0 0 0 0 0 18 0 0 0 0 0 0 0 05 1 0 22 32 9 18 19 14 4 50 79 54 11 17 162 3 21 11 3 9 0 06 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 3 0 2 0 07 0 0 2 1 0 0 4 0 0 0 2 2 13 5 0 0 9 5 0 4 0 08 A 10 14 8 3 14 9 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 09 B 118 17 3 9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 010 B 2 4 10 8 12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 011 11 5 19 39 48 5 17 40 15 8 3 107 10 41 112 24 84 36 82 22 0 012 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 013 0 0 5 2 2 0 2 2 0 0 0 0 0 0 0 0 61 40 99 0 0 014 1 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 015 0 40 0 42 93 11 0 1 1 0 0 0 0 26 0 0 14 4 13 0 0 0TOTAL QTY 0 0 0 0 219 85 84 201 199 63 52 60 29 67 95 181 46 203 284 68 230 152 265 231 0 0#ug,& #pr,& Ma0,& 1un,& 1ul,&WeeDe! e"# P$e%o&e%o%Mo%#$W'(#$ )%(er*'+e ,F-"e .r'%('%./P-r-00e0'*& NOT O1,F-"e .r'%('%./De!e"# P$e%o&e%o% '00e(1-'+e%2"3&30-#'4eDefectphenomenonW'(#$ O4er*'+e,F-"e .r'%('%./D-&-.e &-r ,5D .r'%('%./5D C$-##er ,5D .r'%('%./OD )%(er*'+e, OD 6r'%('%./OD O4er*'+e , OD 6r'%('%./F0-# &-r, OD 6r'%('%./B3r%'%., OD 6r'%('%./OD O7AL5TY, OD 6r'%('%./5D )%(er*'+e ,5D .r'%('%./B3r%'%.,F-"e .r'%('%./B3r%'%. ,5D .r'%('%./5D O4er*'+e ,5D .r'%('%./T-8er 3%e93-0 ,5D .r'%('%./15 1515151513 1312 12 12 12 12 121212 12121212 121212842032301522652310 06828446181956729605263199201852190510152015 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 360100200300400500600De!e"# P$e%o&e%o% TOTAL QTYMachine Defect Phenomenon4562102468F-"e .r'%('%. OD .r'%('%. 5D .r'%('%.Machines2o.of Defect phenomenonDe!e"# P$e%o&e%o%De!e"# 8$e%o&'%o% '00e(Step -.:orming Team and Doing "ai%en for "illing the defect.Kaizen for killing defect Phenomenon for Rocker Arm*ai%en 1dea SheetResult areaa ;