03.08.

29
冷製３部
Development of displaying ｢20 basic quality rules｣ at the work area
and recital （Declaration to abide） -’03 ＰＱ activity-

１．｢20 basic quality rules｣ display ２．Basic rule recital activity

（Bulletin Example）

・Recite 1 item/1 day in order

during Touch & Call when beginning
work.

３．Create ｢Declaration to follow rules｣ status chart

Color in (Blue, Red) results on
the [Status chart] whether the
０３年度　冷製３部ＰＱ活動　

｢ルール遵守宣言！｣ 遵守状況 　
　
｢全員参加のルール遵守活動｣

－　今日も１日、ルールを｢守ります｣｢守りました｣　　　自己管理　－

29
30 31 12月
1
2
生産　　課　　係 item declared (recited) that day
氏名　　　　　　　　　　　　

was followed or not .

28 11月 3
27 10月 4
26 9月 5
25 6 ：守れた
：守れなかった
24 7

23 8

22 9

・Place conspicuously around 21

20
19 12
11
10
← Regarding the status chart, it
is sent to each section leader
18 13

assembly line side or area

17 16 15 14
守り切れなかったルール
課長
ﾙｰﾙ№ 月日 なぜ、守り切れなかったのか？ 今後、守り切るための私の誓い 確認

where meetings are held

５ 9/5 作業に追われ、つい照合を怠ってしまった 確実な照合作業を行うため追われた時は必ずラインを停止する Ｋ

with the QACM reports.

Size (A5 or A6) is voluntary

depending on display location.

Please contact the Inspection Lab with any questions （TEL：6218,6612）

 ０３年度 冷製３部ＰＱ活動
｢全員参加のルール遵守活動｣

Basic Quality rules

【Declaration to follow today’s rule！】
①When switching part numbers 〔changeover〕 remove all
remaining parts of ran model before supplying new part number.

If remaining parts are not checked・・・ No remaining

parts！

Even if mistake was made by the associate

that handled the changeover, responsibility Parts box
also lies on you if you work without
checking yourself. Parts box or

Impact to customer
・If checking for remaining
Assembly defects （wrong parts）, etc flow out
parts is difficult, clarify reason
Will lead to direct loss and lines stopping
and notify management
【Declaration to follow today’s rule！】
②Display detail of defective parts
and isolate after sorting What was the defect?
Good part or bad part？
Oh well…
If you do not sort and isolate・・・

Part will get mixed up and the effort

you put into finding the defect will
become wasted

Impact to customer
Will become secondary calamity due
to screening leak・mixed defect and ・Prepare tags for clarity
lead to direct loss and lines stopping
and install isolation boxes
【Declaration to follow today’s rule！】
③In screening defective parts, separately display Sorted Parts・
Parts To Be Inspected and do not place them next to one another

・If you do not display separately and isolate・・・

Even if sorting is conducted, if defective

parts are mixed, sorting work will have to
be redone and all efforts will be wasted Defects Good

Impact to customer
Will become secondary disaster due to
screening leak・mixed defect and lead ・If the environment for
to direct loss and lines stopping screening is not complete,
report to management
【Declaration to follow today’s rule！】
④Do not omit P checks on the simple notion that
“other processes are checking too…”
If W checks are omitted・・・
Since the process in front is also doing
There is a danger that others No wrong fit checks, maybe I can skip it…
think “They will do it for me” Fit good！ parts！
and part may run without any
inspections
Impact to customer
Assembly defect （Tightening defect) and
process skip (missing parts) may flow out
and lead to direct loss and lines stopping ・Question
management why W
checks must be done
【Declaration to follow today’s rule！】
⑤Conduct collation checks to confirm loading・
shipping・transferring products are correct
If collation checks are
not properly done・・・ Diagrams good！
Kanban good！

Flow out of 100% defect.

442100-1234
Collation checks confirm that
products are correct. It is not
to check for defects.
Product good！

Impact to customer
Assembly defects (wrong parts) etc Let’s check that
flows out and leads to direct loss products match up
and lines stopping
【Declaration to follow today’s rule！】
⑥Do not handle multiple part numbers at the same time

All ready！
If handling at the same time・・・ There’s still
some space
I might as well do
this one now too!
Will unconsciously forget
what part number you are
running and may not catch
your mistakes

Impact to customer ・Stick to 1 part number/1

Wrong parts may be delivered and pallet and do not prioritize
lead to direct loss and lines stopping work efficiency only.
・Discuss with manager
about streamlining work
【Declaration to follow today’s rule！】
⑦If being pressed by line speed (line tact) due to an
accident, do not strain to recover but stop the line.

Even if you strain to recover・・・ I won’t make it

No one will compliment that

“You’re working really hard.” If
troubles occur, you will be
scolded for not stopping.
Impact to customer
Quality drops due to hurried work ・Stop line once and
allowing non-quality-compliant then recover for delay
parts to flow out, leading to direct
loss and lines stopping
【Declaration to follow today’s rule！】
⑧Report to manager if cost is prioritized
over quality
If you don’t report・・・ Lets not inspect all pieces
to prioritize productivity…

Quality evaluations (random) are decided

based on process capability, but if cost is
prioritized, greater loss and defects may
flow out from the massively expanded Quality
defect screening lot Productivity

Impact to customer
Quality drops due to unstable work and ・Report to manager
leads to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑨Only conduct items within your authority (and ability) during
machine fault recovery, notify some one off line and wait for
anything beyond that

If you go beyond your authority・・・ Don’t worry.

Leave it to me!

Naturally it must be correct,

even if you are not confident
in the judgment.
Will be scolded if wrong.

Impact to customer
Parts not meeting required quality standard flow ・Stop the machine and ask
out leading to direct loss and lines stopping manager for judgment
【Declaration to follow today’s rule！】

⑩Use designated tools (Jigs/measuring tools) properly!

If not properly used・・・

Work will be more
efficient if I didn’t
There is no way good results are obtained by have to use it…
changing those items (jigs, tools) that were
designed for the process in order to obtain
process capability.
・Investigate and find
Impact to customer out why it must be used
Parts not meeting required quality standard flow
out leading to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑪Stop line first when abnormalities arise
and call and wait for management
There is something wrong
If trouble is neglected・・・ with this machine…

Third party cannot judge as

[Abnormal] and secondary
disaster occurs.
Impact to customer
Parts not meeting required quality standard flow ・Stop line, call, wait for
out leading to direct loss and lines stopping management and allow
them to resolve the problem
【Declaration to follow today’s rule！】
⑫If support must be brought in, clarify work
delegations with associate before beginning work

If delegation is not clear・・・ Can’t keep up Support Screw assy Support Door assy

Since supporter works with a

side job mentality, work
precision is not good.
Impact to customer
Assembly defect （Tightening defect) and
process skip (missing parts) may flow out ・Stop line once instead
and lead to direct loss and lines stopping of bringing in support
and recover delay
【Declaration to follow today’s rule！】
⑬Do not react or reply when
talked to during 1 cycle You,
tell me…
1 cycle complete！
If you react when talked to・・・ Ignore until
Fitting 1 cycle is
complete！ completed!
If results are bad, you will be blamed.
The person that reacted becomes the bad Operation check
guy, not the one who initiated the talk complete！

Screw assembly
Impact to customer complete！
・Even if it is a manager,
Assembly defect （Tightening defect) and stress not to talk while in
process skip (missing parts) may flow out middle of cycle
and lead to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑭If work speed cannot keep up with the designated
man-hours (line tact), do not continue working and
report to manager.

If you continue and struggle to keep up・・・

・Stop line once and
I won’t make it recover delay
Work will become hurried and
・Discuss with manager
mistakes will be induced, corners
will be cut, and steps omitted

Impact to customer
Quality drops due to hurried work
leading to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑮Do not change rules （Work, Process）
on selfish judgments!
Even if good results are obtained from
It would be easier if we
changes you made on your own・・・ did this differently…

A good result was by chance.

If it is against the rules, you will not be praised.
You will be scolded twice as much if found later.
・Bring it up to the circle
・Discuss with management
Impact to customer
Assembly defect （Tightening defect) and
process skip (missing parts) may flow out and
lead to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑯Do not rework anything, any part other
than those designated to yourself
If you rework anything beyond
Something like this, I
your responsibility range・・・ could rework myself
instead of calling and
Even if you help someone out, if waiting…
results are bad, you get scolded.
Person that relied on you will
look the other way.

Impact to customer ・Call, wait, and let

Assembly defect （Tightening defect) person responsible
and process skip (missing parts) may
flow out and lead to direct loss and
handle the problem
lines stopping
【Declaration to follow today’s rule！】
⑰Do not make any judgments beyond
your responsibilities
If you make judgments for other people・・・ If only this extent, it can be
passed on to the preceding
processes without a problem…

You will be scolded if results are bad.

Other person did not request you to so
will look the other way.
Impact to customer ・Call off line and
get judgment
Parts not meeting required quality standard flow
out leading to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑱If it is difficult to work as designated in the
standard procedures, report to management

Even if you continue in the difficult work situation・・・

Working according to the
standard procedures is
No one will compliment awkward and difficult…
“You are very good with this process.”
You will only get irritated.

Impact to customer
・Bring it up to the circle
Assembly defect （Tightening defect) and ・Discuss with management
process skip (missing parts) may flow out
and lead to direct loss and lines stopping
【Declaration to follow today’s rule！】
⑲Master checks・blade replacements
must be done at designated intervals
If you don’t follow the １／Ｄ check
designated intervals・・・ completed！

If you skip out on checks and replacements

mandatory by process capability,
chronic/massive defects will occur

Impact to customer
Parts not meeting required quality standard flow ・Clarify reasons why master
out leading to direct loss and lines stopping check cannot be done and
report to management
【Declaration to follow today’s rule！】
⑳If rules are unclear or you are questioning a
rule, do not neglect it, do not work

If you keep working with doubts in your mind・・・

Why is it?
Oh well…
Lead to less focus and ？
work will become unstable

Impact to customer
Quality drops due to unstable work and ・Bring it up to the circle
leads to direct loss and lines stopping ・Discuss with management
 ０３年度 冷製３部ＰＱ活動

｢Declaration to follow rules!｣ Status ｢全員参加のルール遵守活動｣

－ Will [Follow] and [Have followed] rules today Personal organizer －

31 Dec
Production Section Team
30 1
29 2 Name
28 Nov 3
27 Oct
4
26 5 ：Was followed
Sep
：Was not followed
25 6

24 7

23 8

22 9
21 10
20 11
19 12
18 13
17 16 15 14
Rules that could not be followed
S/L
Rule № Date Why could it not be followed? Oath in order to follow the rule in future check