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1、SINGAPORE PRODUCTIVITY AND STANDARDS BOARDNational Cost of Quality National Cost of Quality Programme Programme Zephyr Silkscreen Co (Zephyr Silkscreen Co (PtePte) Ltd) LtdSINGAPORE PRODUCTIVITY AND STANDARDS BOARDPresentation OutlinePresentation OutlineIIAn introduction to Zephyr SilkscreenAn intro
2、duction to Zephyr SilkscreenIIWhat is COQWhat is COQIIHow we carried out COQHow we carried out COQIIThe analysisThe analysisIIThe improvement actionThe improvement actionIIThe benefitsThe benefitsSINGAPORE PRODUCTIVITY AND STANDARDS BOARDAn Introduction to Zephyr SilkscreenAn Introduction to Zephyr
3、SilkscreenIspecializing in the printing of high quality nameplates, panel fronts, labels, overlays, scale-windows, tape seals, self-adhesives etc. ,Iincludes the fabrication of insulated parts and resilient materials.SINGAPORE PRODUCTIVITY AND STANDARDS BOARDAn Introduction to Zephyr SilkscreenAn In
4、troduction to Zephyr SilkscreenIS$14M in sales revenue and a fully owned factory in Changi South. IMachinery including 27 semi-automated screen-printing machinery and fully-automated screen-printing machinery with UV ink-printing and curing capabilities. $14,000,00027UVSINGAPORE PRODUCTIVITY AND STA
5、NDARDS BOARDWhat is COQWhat is COQThe obvious answer is to look inwards at cost reduction. The bigger question is HOW. ?The obvious answer is to look inwards at cost reduction. The bigger question is HOW. ?RevenueCostProfit,?Is it possible to increase profits in an economic downturn, when revenues a
6、re either flat or on the decline ?,?Is it possible to increase profits in an economic downturn, when revenues are either flat or on the decline ?RevenueLossesCostSINGAPORE PRODUCTIVITY AND STANDARDS BOARDFailure CostFailure Cost (External) = (External) = 40%40%Failure CostFailure Cost (Internal) =(I
7、nternal) =30%30%Prevention Cost = Prevention Cost = 10% 10% ( ( Eg Eg Quality Training )Quality Training )Appraisal Cost = Appraisal Cost = 20%20% ( ( Eg Eg Inspection )Inspection )P PA AF(I)F(I)F(E)F(E)Cost of Cost of ConformanceConformanceCost of Non Cost of Non ConformanceConformanceWhat is COQ W
8、hat is COQ - - The PAF ModelThe PAF ModelFocus on Non Conformance Cost( : )(: )PAFSINGAPORE PRODUCTIVITY AND STANDARDS BOARDHow We Carried Out COQ1. Identify Cost2. Collect Data3. Identify Opportunities4. Makes Things Better5. Share Gains1.2.3.4.5.SINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe Analys
9、isThe AnalysisIn-coming InspectionIn-process Inspection (SPC)Out-going QC InspectionHigh rate of OQC rejects and low detection rate at in-processSINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe Improvement ActionThe Improvement ActionIVerify OQC rejectsIProblem solving ( QC 7 Tools ) and SPC trainingIL
10、ook at contributors for OQC rejects,SPCSINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe Analysis The Analysis - - Long Process Cycle TimeLong Process Cycle TimeSemi Auto Printing Process55%51%14%Productive TimeSet-up TimeBreak TimeSINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe Improvement Action The Imp
11、rovement Action Long Process CycleLong Process CycleIIInk Test is the main contributor to setInk Test is the main contributor to set- -up time.up time.IIA high proportion of ink test time is taken up by the long A high proportion of ink test time is taken up by the long search for the right ink.Stor
12、age of ink was not search for the right ink.Storage of ink was not organised organised well.well.IIAction items include Action items include reorganising reorganising ink storage and ink storage and appointing a dedicated person for ink issue and trackingappointing a dedicated person for ink issue a
13、nd tracking.SINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe BenefitsThe BenefitsQuality Rejects0.00%2.00%4.00%6.00%8.00%10.00%12.00%JunJulAugSepOctNovDecJanFebMonth% RejectOQCIn-process Clean Rm, Clean Area, ShikiSINGAPORE PRODUCTIVITY AND STANDARDS BOARDThe BenefitsThe BenefitsCOQ Savings(20,000)020,00040,00060,00080,000100,000120,000JunJulAugSepOctNovDecJanFebMonthSavings ($)Cost Savings - CumCost Savings - MonthlyOQC S$300K Savings in Yr 1 !