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©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDNationalCostofQualityNationalCostofQualityProgrammeProgrammeZephyrSilkscreenCo(ZephyrSilkscreenCo(PtePte)Ltd)Ltd©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDPresentationOutlinePresentationOutlineAnintroductiontoZephyrSilkscreenAnintroductiontoZephyrSilkscreenWhatisCOQWhatisCOQHowwecarriedoutCOQHowwecarriedoutCOQTheanalysisTheanalysisTheimprovementactionTheimprovementactionThebenefitsThebenefits©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDAnIntroductiontoZephyrSilkscreenAnIntroductiontoZephyrSilkscreenspecializingintheprintingofhighqualitynameplates,panelfronts,labels,overlays,scale-windows,tapeseals,self-adhesivesetc.,,includesthefabricationofinsulatedpartsandresilientmaterials.©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDAnIntroductiontoZephyrSilkscreenAnIntroductiontoZephyrSilkscreenS$14MinsalesrevenueandafullyownedfactoryinChangiSouth.Machineryincluding27semi-automatedscreen-printingmachineryandfully-automatedscreen-printingmachinerywithUVink-printingandcuringcapabilities.$14,000,00027UV©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDWhatisCOQWhatisCOQTheobviousansweristolookinwardsatcostreduction.ThebiggerquestionisHOW...?Theobviousansweristolookinwardsatcostreduction.ThebiggerquestionisHOW...?RevenueCostProfit,,?Isitpossibletoincreaseprofitsinaneconomicdownturn,whenrevenuesareeitherflatoronthedecline?,,?Isitpossibletoincreaseprofitsinaneconomicdownturn,whenrevenuesareeitherflatoronthedecline?RevenueLossesCost©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDFailureCostFailureCost(External)=(External)=40%40%FailureCostFailureCost(Internal)=(Internal)=30%30%PreventionCost=PreventionCost=10%10%((EgEgQualityTraining)QualityTraining)AppraisalCost=AppraisalCost=20%20%((EgEgInspection)Inspection)PPAAF(I)F(I)F(E)F(E)CostofCostofConformanceConformanceCostofNonCostofNonConformanceConformanceWhatisCOQWhatisCOQ--ThePAFModelThePAFModelFocusonNonConformanceCost(:)(:)–PAF©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDHowWeCarriedOutCOQ1.IdentifyCost2.CollectData3.IdentifyOpportunities4.MakesThingsBetter5.ShareGains1.2.3.4.5.©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheAnalysisTheAnalysisIn-comingInspectionIn-processInspection(SPC)Out-goingQCInspectionHighrateofOQCrejectsandlowdetectionrateatin-process––©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheImprovementActionTheImprovementActionVerifyOQCrejectsProblemsolving(QC7Tools)andSPCtrainingLookatcontributorsforOQCrejects,SPC©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheAnalysisTheAnalysis--LongProcessCycleTimeLongProcessCycleTimeSemiAutoPrintingProcess–55%51%14%ProductiveTimeSet-upTimeBreakTime©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheImprovementActionTheImprovementAction––LongProcessCycleLongProcessCycleInkTestisthemaincontributortosetInkTestisthemaincontributortoset--uptime.uptime.AhighproportionofinktesttimeistakenupbythelongAhighproportionofinktesttimeistakenupbythelongsearchfortherightink.Storageofinkwasnotsearchfortherightink.Storageofinkwasnotorganisedorganisedwell.well.ActionitemsincludeActionitemsincludereorganisingreorganisinginkstorageandinkstorageandappointingadedicatedpersonforinkissueandtrackingappointingadedicatedpersonforinkissueandtracking–.©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheBenefitsTheBenefitsQualityRejects0.00%2.00%4.00%6.00%8.00%10.00%12.00%JunJulAugSepOctNovDecJanFebMonth%RejectOQCIn-processCleanRm,CleanArea,Shiki©SINGAPOREPRODUCTIVITYANDSTANDARDSBOARDTheBenefitsTheBenefitsCOQSavings(20,000)020,00040,00060,00080,000100,000120,000JunJulAugSepOctNovDecJanFebMonthSavings($)CostSavings-CumCostSavings-MonthlyOQCS$300KSavingsinYr1!!