Approved by Reveiewed byPrepared by

KOYAMA INDIA Quality Improvement Activity - (July 2018 - May 2019)　 Takebayashi Matsuura Kumar

Reflection from the past 　 : 　

■Run out & length rejection rootcuase not found out (Major contribution)
■Reduction of handling damages .
■Reduction of weight u/s.
■Non recurrance of custumer complaints

Target : < 0.5 %(Last year 1.0 Target : 3 (Last year

%) 8)
Activity policy 　 :
■ Worst Two Defects root cause found and reducing
■ Monozukuri Audit and control
■ Skill enhancement of next level people
Supplier ■Supplier Audit & Improvement
Supplier Crack
Crack

Achieve Goal: 　
■Reduce the rejection ratio to 0.5% by the end of Mar 2019.
■Keep customer complains to three or less.

This month actual : 　

■Inhouse Rejection % 1.17,when we remove runout 0.63 % .
■This month Customer Complaint 1 no (Supplier crack)

PLAN Jun 2018 - May 2019

Purpose　目的 Goals and activities　目標と活動の進め方 Content of the activity　活動内容 Incharge
ACT June July August September October November December January February March April May
Perform audit by QA head and person responsible for
Preventive measure of recurrance of customer complaints Confirm countermeasure implemented for past complaints problem and keep record and take action if not QA,Kumar and respective P □ □ □ □ □ □ □ □ □ □ □ □
and check the effectiveness satisfactory HOD,operators

A Completed

Preventive measure of recurrance of Major Inhouse Confirm countermeasure implemented for past complaints Perform audit by QA head and person responsible for
problem and keep record and take action if not QA,Shyam,Damu and respective P □ □ □ □ □ □ □ □ □ □ □
issues and check the effectiveness satisfactory HOD,operatos

Do analysis and find out root cause for each model runout By continously doing Quality circle activity activity and Quality circle Team
Worst two Defects reduce rejection and reduce as per plan update as QC story (Mani,Kumar,Shyam,George,vignesh,Ram P □ □ □ □ □ □ □ □ □ □ □ □
adoss) Facilitator Matsuura

will start
A from next
month

Effective Die maintanence,monitoring and effective

Reduction of die related problem Do analysis and take action to prevent recurrance countermeasure George,Sujeeth P □ □ □ □ □ □ □ □ □ □ □ □

2GS AD silver
A coating solved

Small group activity (workmen

Do analysis and find out root cause for each model and By continously doing small activity activity and update as -Natiya,sundar,Rajasekar, Velayutham)
Spline Outer damages and handling damages reduction reduce as per plan QC story Facilitator
P □ □ □ □ □ □ □ □ □ □ □ □
- Manikandan
will start
A from next
month
Small group activity (workmen)
Do analysis and find out root cause for each model and By continously doing small activity activity and update as (Gnaiyah,Prasanth,Karthik ,Vetri)
Weight U/S reduction reduce as per plan QC story
P □ □ □ □ □ □ □ □ □ □ □ □
Failitator - Shyam
will start
A from next
month

Do analysis and find out root cause for each model By continously doing small activity activity and update as Small group activity (workmen)
Runout Rework Rejection Reduction rework and reduce as per plan QC story (Damu,anbu,venkatesh,Kishore) P □ □ □ □ □ □ □ □ □ □ □ □
Facilitator -kumar

will start
A from next
month

Effective implementation of Basic principles of Monozukuri Doing Monzukuri audit monthlly Findout the areas where rule not followed and insist to Shyam & Responsible Heads P □ □ □ □ □ □ □ □ □ □ □ □
follow and adhere
audit
A done,oberva
tion closed

Improve supplier performance By doing Supplier audit as per plan Find out the gaps at supplier end try to improve the Dilli,Shyam, Kumar P □ □ □ □ □ □ □ □ □ □ □ □
supplier performance with help of yamaha
sunflag
A audit
completed
Monitor and do Comparison trend for Japan die and local If more than 10% variation informed to die suplier and
Die localisation to reduce cost and lead time die correct it and get the correct die George,Sujeeth , Kumar P □ □ □ □ □ □ □ □ □ □ □ □

A
2FS AM
completed

close observations and train employees to follow all basic

Create Quality Awareness among employees doing Gemba audit with the production and keep records rules without failure Kumar/Mani/Anbu P □ □ □ □ □ □ □ □ □ □ □ □

A
Bonde
completed

validate employee awareness after three months ,if not ok

Create Quality Awareness among employees By preparing case study videos and explain to employees again train them Praveena, Kishore, Suresh P □ □ □

Customer complaints POKE YOKE Try to prevent customer complaints by making pokeyoke work as a team and find out the best way to prevent Dilli,anbu,suresh,kumar P □ □ □ □ □ □
recurrance