First Time Quality

PPM

TIME
 First Time Quality
Training Module
Training Objectives:

To Understand

ü What First Time Quality Is

ü Why It Is Important
ü Why We Need to Measure It
ü How to Calculate It
ü What the FTQ Deployment Process is
ü What the Basic Quality Tools Are
ü How to Apply the Quality Tools
ü What the Deliverables are that each Plant Will be Responsible for
Monitoring and Reporting

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 First Time Quality
Training Module
What is First Time Quality?

ü FirstTime Quality is a measure of the number of pieces

rejected in a manufacturing process versus the total
number of pieces attempted

REJECTS

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 First Time Quality
Training Module
Why is FTQ important?

ü Because if we don’t make good parts the first time, we have to

inspect in quality

◦ We know inspection is at best 85% effective

◦ Therefore, anytime FTQ is greater than 0, we are dependent on inspection to

protect the customer

ü To reduce manufacturing costs

ü Toeliminate waste through the value stream and meet customer

requirements (takt time)

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 The Role of Inspection

Catch Defects D
D

Inspection is like a filter Filter

Inspection misses some defects

Defects not caught D

Problem
Voice of the Customer

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 The Role of First Time Quality Process

Catch & Count defects 1

2

React to ALARM LIMITS

Reaction Plan

Follow Reaction Plan

ZERO Defects Forward

Voice of the Customer

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 The Role of First Time Quality Process
Analyze Data Problems

Understand Defects and

4

3 3
Decide the Order of Priority: 2 2 2
2
1 1 1 1 1

A B C D

Assign problems to Responsible

Cross-Functional Group: 2 Team Works
2 1 Problems
1

Select and
Plan the Improvement: 1 Right Information 2 Right Cause 3 Right Timing
DEFECT
Hour
1. ----------------------
Glass
2. ----------------------
3. ----------------------

Fix the Biggest Problems First:

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 First Time Quality
Training Module
Why does FTQ need to be measured?

ü Main Reasons:

◦ It is the first signal that a process is out of

control

◦ It allows us to respond to problems internally before they reach our

customers

◦ It measures improvement from corrective actions implemented

If we don’t fix our quality problems internally, we will never

be able to fix our external customer issues

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 First Time Quality
Training Module
How is First Time Quality calculated?

üFTQ is reported in parts per million (PPM) defective

üIt can be measured at any step in the manufacturing process

where parts are rejected

üIt is calculated by counting the number of pieces rejected versus

the total number of pieces attempted

üThe total number of pieces attempted includes all good pieces

produced plus all pieces rejected

üPieces rejected are all parts scrapped or reworked prior to usage

X 1,000,000 = FTQ PPM
by subsequent processes. The actual calculation looks like this:

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Number of Pcs. Rejected
 First Time Quality
Training Module 1 2
Tally Sheet

3 4 5 6 7 8
Operations HR. HRS. HRS. HRS. HRS. HRS. HRS. HRS.

How is First Time Quality calculated? 1

ü An example at the cell level:
2

3 28
Cell “A” has six operations
1 2 3 4 5 6 4

28 16 5

6 16

Reject data is collected at operations 3 and 6

Cell “A” produced 1040 good pieces during the first hour of production.

= X 1,000,000 = 40590 PPM FTQ

At OP.3, 28 pcs. were rejected.
10 At OP.6, 16 pcs. were rejected.
 First Time Quality
Training Module
What is the First Time Quality Improvement Process?

ü FTQ process defines a common process to be used by all Delphi E & C

manufacturing plants to meet the business plan requirements and drive
defect-free manufacturing

ü The FTQ process defines:

◦ Process Steps
◦ Stakeholders
◦ Deployment Chart (functional flow chart) for identifying lead functions
◦ Control Plan for Tracking Implementation

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 FTQ Improvement
Process

IMPLEMENT
ALARM
REACTION
PLAN
YES NO

DEFINE NO INSTITUTION-
REACTION
IDENTIFY & SELECT & NEW LEVEL YES
COUNT ALARM RECORD ANALYZE IMPLEMENT ALIZE
PLAN & PLAN EVALUATE OF
DISCREPANT EXCEEDED DATA DATA IMPROVEMENT LESSONS
ALARM IMPROVEMENT QUALITY? LEARNED
PARTS ?
LIMITS

TOOLS FOR TOOLS: TOOLS: EXAMPLES: TOOL: TOOL: TOOLS:

IDENTIFICATION: - CONTROL - PARETO - CROSS-FUNCTIONAL - ACTION PLAN - RUN CHART - PFMEA
- PROCESS CONTROL CHART - CAUSE & EFFECT TEAMS - PROCESS CONTROL PLAN
PLAN (FISHBONE) - CHANGE BOARDS - LOOK-ACROSS-CHART
- BOUNDARY SAMPLES - CONCENTRATION - RPN REDUCTION - 5 WHY'S
DIAGRAM - STATISTICAL ENGINEERING
TOOLS FOR COUNTING: - FLOW CHART PROJECTS
- PARTS COUNTERS - HISTOGRAM - GATE CHART
- TALLY SHEETS - SCATTER ACTION PLAN:
- SIZED CONTAINERS DIAGRAM - WHAT, WHEN, WHO
- CHECK SHEET
- 5 WHY'S

IDENTIFY ANALYZE PLAN IMPLEMENT EVALUATE

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 FTQ Improvement Process
Stakeholder Footprint
Plant A
CELL

CELL Plt B OPERATOR OPERATOR OPERATOR OPERATOR OPERATOR

2 3
1
Plt C

4 5 6
TEAM
LEADER
7 8 N

MEMBERS:
- TEAM LEADER
- OPERATIONS/MANUFACTURING
- QUALITY ENGINEER
- PROCESS ENGINEER
- INDUSTRIAL ENGINEER
CROSS-
- MAINTENANCE
FUNCTIONAL
- PRODUCT ENGINEER
TEAM
- SUPPLIER QUALITY

PROCESS PRODUCT
ENGINEERING OPERATIONS QUALITY MAINTENANCE PC&L
ENGINEERING
MANAGER MANAGER MANAGER MANAGER MANAGER MANAGER

PLANT MANAGER

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 First Time Quality Improvement Process
Deployment Flow Chart
CFT QUALITY PROCESS PRODUCT INDUSTRIAL
ENGINEER OPERATIONS ENGINEER ENGINEER MAINTENANCE ENGINEER
PROCESS
DEFINE REACTION
PLAN & ALARM LIMITS

IDENTIFY & COUNT

DISCREPANT PARTS

IMPLEMENT ALARM
REACTION PLAN (IF
EXCEEDED)

RECORD DATA

ANALYZE DATA

SELECT & PLAN

IMPROVEMENT

IMPLEMENT
IMPROVEMENT

EVALUATE

INSTITUTIONALIZE
LESSONS LEARNED

LEAD SUPPORT

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 First Time Quality
Training Module
DEFINE
REACTION PLANS
&
Process Step 1 ALARM LIMITS
IMPLEMENT
ALARM
REACTION
PLAN

YES NO
YES
DEFINE NO
IDENTIFY & INSTITUTION-
REACTION ALARM SELECT & NEW LEVEL
COUNT EXCEEDED RECORD ANALYZE IMPLEMENT ALIZE
PLAN & PLAN EVALUATE OF
DISCREPANT ? DATA DATA IMPROVEMENT LESSONS
ALARM IMPROVEMENT QUALITY?
PARTS LEARNED
LIMITS

TOOLS FOR TOOLS: TOOLS: EXAMPLES: TOOL: TOOL: TOOLS:

IDENTIFICATION: - CONTROL - PARETO - CROSS-FUNCTIONAL - ACTION PLAN - RUN CHART - PFMEA
- CAUSE & EFFECT TEAM S - PROCESS CONTROL PLAN

Define reaction plan and alarm limits

- PROCESS CONTROL CHART
PLAN (FISHBONE) - CHANGE BOARDS - LOOK-ACROSS-CHART
- CONCENTRATION - RPN REDUCTION - 5 WHY'S
- BOUNDARY SAMPLES
DIAGRAM - STATISTICAL ENGINEERING
TOOLS FOR COUNTING: - FLOW CHART PROJECTS
- PARTS COUNTERS - HISTOGRAM - GATE CHART
- TALLY SHEETS - SCATTER ACTION PLAN:
- SIZED CONTAINERS DIAGRAM - WHAT, WHEN, WHO
- CHECK SHEET
- 5 WHY'S

IDENTIFY ANALYZE PLAN IMPLEMENT EVALUATE

You have to start someplace…

üAlarm limits must be based on current process reject data or available

data from MQ2, Run at Rate, historical data, etc.

üAlarm limits must be statistically calculated

üAlarm limits must be communicated to operators so they can react

üIf alarm limits are exceeded, there must be a reaction plan to

implement
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 First Time Quality
Training Module IDENTIFY &
COUNT
DISCREPANT YES
IMPLEMENT
ALARM
REACTION
PLAN

NO

PARTS
YES
DEFINE NO
IDENTIFY & INSTITUTION-
ALARM NEW LEVEL

Process Step 2
REACTION RECORD ANALYZE SELECT & ALIZE
COUNT EXCEEDED IMPLEMENT EVALUATE OF
PLAN & DATA PLAN LESSONS
DISCREPANT ? DATA IMPROVEMENT
ALARM IMPROVEMENT QUALITY?
PARTS LEARNED
LIMITS

TOOLS FOR TOOLS: TOOLS: EXAMPLES: TOOL: TOOL: TOOLS:

- ACTION PLAN - RUN CHART - PFMEA
IDENTIFICATION: - CONTROL - PARETO - CROSS-FUNCTIONAL
CHART - CAUSE & EFFECT TEAM S - PROCESS CONTROL PLAN
- PROCESS CONTROL
PLAN (FISHBONE) - CHANGE BOARDS - LOOK-ACROSS-CHART
- CONCENTRATION - RPN REDUCTION - 5 WHY'S
- BOUNDARY SAMPLES
DIAGRAM - STATISTICAL ENGINEERING
TOOLS FOR COUNTING: - FLOW CHART PROJECTS
- PARTS COUNTERS - HISTOGRAM - GATE CHART
- TALLY SHEETS - SCATTER ACTION PLAN:
- SIZED CONTAINERS DIAGRAM - W HAT, WHEN, WHO
- CHECK SHEET
- 5 WHY'S

IDENTIFY ANALYZE PLAN IMPLEMENT EVALUATE

Identify and count discrepant parts

ü Operators must have sufficient tools and skills in order to

identify product discrepancies

ü Tools to enhance the operator’s ability to identify product

discrepancies include:
◦ Boundary Samples
◦ Illustrations
◦ Photographs
◦ Gages

ü Tools for counting discrepant parts include:

◦ Parts Counters
◦ Tally Sheets
◦ Sized Containers
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