| Quality management is a very important section in business management. With avalanche of quality issues and better quality understanding by people, role of quality management becomes more and more important in business management. Toyota's recall in US market in Aug and Nov of 2009, reminded people to re-look into what quality meant for automobile industry. High quality can not only bring good reputation and enhance the competitiveness in market for a company, but reveal company's responsibility for customer safety.BD Product Ltd. Company is one of the biggest Valve suppliers for commercial vehicle manufacturers. By bloom of commercial vehicle market, BD created serial highest sales value in 2009 and 2010. But unfortunately, quality issue increased at the same time. In order to prevent defective part from slipping to customer side,100% check was assigned at many stations of production line, which was none-value-added, only huge waste of resources, broke basic Lean idea. Although ratio of customer claim went down, claim quantity was increasing indeed with recurrence. So, quality improvement on assembly line must be carried out to mitigate pressures from inner and outer customers.The paper focuses on process elements 4M1E (Man, Machine, Material, Method, and Environment). Based on factual cases in BD, by modern process methodology of process quality improvement, key elements were defined and investigated to find the root cause of quality issue. Consequently systematic corrective action plan and preventive action plan were set to improve assembly process quality.Modern quality management theory and methodology keeps signality for process quality improvement, reaction capability of quality improvement and quality capability of company. Production Operation Management, Lean, Six-Sigma, TPM theories were used together with quality tools to analyze process quality issue and to define improvement action plans, which would provide very good reference to most of manufacturing companies. |
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