1.
Quality Maintenance
© Operational Excellence Consulting. All rights reserved.
Quality Maintenance means figuring out the equipment conditions in which
defects won’t occur, setting them up as the standards, monitoring and
measuring actual equipment conditions over time, and confirming the
actual conditions are within the standards.
§ Determine standard values for checks
§ Create Quality Maintenance matrix
§ Increase reliability of checks, simplify
them, and reduce number of people
involved
§ Revise materials standards, checking
standards and work standards
§ Identify quality (“Q”) components so
that standards are kept
§ Monitor trends and confirm results
8. Determine Standard Values
for Checks & Revise Standards
§ Find ways to consolidate and fix the
checking methods
§ Carry out improvements to make
checking easier
7. Consolidate Checking Methods
§ Expose flaws in 4M conditions
§ Carry out restoration or improvements
§ Evaluate results
§ Establish 4M conditions that allow good
product to be achieved
6. Eliminate Flaws in 4M
Conditions and Finalize
§ Analyze situations where the conditions
for building in quality are unclear
§ Establish defect causes
§ Optimize settings, processing conditions
and setup procedures
§ Evaluate
5. Establish Conditions that Allow
Good Products to be Achieved
§ Create deficiencies chart and identify
countermeasures
§ Verify state of equipment and
restore/improve it
4. Plan Action to Correct
Deficiencies
§ Check quality standards and quality
characteristics
§ Create a flow diagram of individual
processes for building in quality
§ Investigate defect situation and stratify
defect phenomena
1. Verify the Existing Situation
§ Draw up a Quality Assurance (QA)
matrix
§ Investigate individual processes where
defect modes occur
2. Investigate the Processes
where Defects Occur
§ Investigate 4M conditions in each
process. The 4Ms are:
• Men/Women
• Materials
• Machines
• Methods
§ Identify lapses in these conditions
through on-site investigation
3. Identify & Analyze 4M
Conditions
Identify & Analyze 4M Conditions
3
Investigate the Processes where Defects Occur
2
Verify the Existing Situation
1
Plan Action to Correct Deficiencies
4
Consolidate Checking Methods
7
Eliminate Flaws in 4M Conditions and Finalize
6
Establish Conditions that Allow Good Products to be Achieved
5
Determine Standard Values for Checks & Revise Standards
8

2.
Quality Maintenance
© Operational Excellence Consulting. All rights reserved.
Quality Maintenance means figuring out the equipment conditions in which
defects won’t occur, setting them up as the standards, monitoring and
measuring actual equipment conditions over time, and confirming the
actual conditions are within the standards.
§ Determine standard values for checks
§ Create Quality Maintenance matrix
§ Increase reliability of checks, simplify
them, and reduce number of people
involved
§ Revise materials standards, checking
standards and work standards
§ Identify quality (“Q”) components so
that standards are kept
§ Monitor trends and confirm results
8. Determine Standard Values
for Checks & Revise Standards
§ Find ways to consolidate and fix the
checking methods
§ Carry out improvements to make
checking easier
7. Consolidate Checking Methods
§ Expose flaws in 4M conditions
§ Carry out restoration or improvements
§ Evaluate results
§ Establish 4M conditions that allow good
product to be achieved
6. Eliminate Flaws in 4M
Conditions and Finalize
§ Analyze situations where the conditions
for building in quality are unclear
§ Establish defect causes
§ Optimize settings, processing conditions
and setup procedures
§ Evaluate
5. Establish Conditions that Allow
Good Products to be Achieved
§ Create deficiencies chart and identify
countermeasures
§ Verify state of equipment and
restore/improve it
4. Plan Action to Correct
Deficiencies
§ Check quality standards and quality
characteristics
§ Create a flow diagram of individual
processes for building in quality
§ Investigate defect situation and stratify
defect phenomena
1. Verify the Existing Situation
§ Draw up a Quality Assurance (QA)
matrix
§ Investigate individual processes where
defect modes occur
2. Investigate the Processes
where Defects Occur
3. Identify & Analyze 4M
Conditions
§ Investigate 4M conditions in each
process. The 4Ms are:
• Men/Women
• Materials
• Machines
• Methods
§ Identify lapses in these conditions
through on-site investigation
Identify & Analyze 4M Conditions
3
Investigate the Processes where Defects Occur
2
Verify the Existing Situation
1
Plan Action to Correct Deficiencies
4
Consolidate Checking Methods
7
Eliminate Flaws in 4M Conditions and Finalize
6
Establish Conditions that Allow Good Products to be Achieved
5
Determine Standard Values for Checks & Revise Standards
8

3.
Quality Maintenance
© Operational Excellence Consulting. All rights reserved.
Quality Maintenance means figuring out the equipment conditions in which
defects won’t occur, setting them up as the standards, monitoring and
measuring actual equipment conditions over time, and confirming the
actual conditions are within the standards.
§ Determine standard values for checks
§ Create Quality Maintenance matrix
§ Increase reliability of checks, simplify
them, and reduce number of people
involved
§ Revise materials standards, checking
standards and work standards
§ Identify quality (“Q”) components so
that standards are kept
§ Monitor trends and confirm results
8. Determine Standard Values
for Checks & Revise Standards
§ Find ways to consolidate and fix the
checking methods
§ Carry out improvements to make
checking easier
7. Consolidate Checking Methods
§ Expose flaws in 4M conditions
§ Carry out restoration or improvements
§ Evaluate results
§ Establish 4M conditions that allow good
product to be achieved
6. Eliminate Flaws in 4M
Conditions and Finalize
§ Analyze situations where the conditions
for building in quality are unclear
§ Establish defect causes
§ Optimize settings, processing conditions
and setup procedures
§ Evaluate
5. Establish Conditions that Allow
Good Products to be Achieved
§ Create deficiencies chart and identify
countermeasures
§ Verify state of equipment and
restore/improve it
4. Plan Action to Correct
Deficiencies
§ Check quality standards and quality
characteristics
§ Create a flow diagram of individual
processes for building in quality
§ Investigate defect situation and stratify
defect phenomena
1. Verify the Existing Situation
§ Draw up a Quality Assurance (QA)
matrix
§ Investigate individual processes where
defect modes occur
2. Investigate the Processes
where Defects Occur
3. Identify & Analyze 4M
Conditions
Identify & Analyze 4M Conditions
3
Investigate the Processes where Defects Occur
2
Verify the Existing Situation
1
Plan Action to Correct Deficiencies
4
Consolidate Checking Methods
7
Eliminate Flaws in 4M Conditions and Finalize
6
Establish Conditions that Allow Good Products to be Achieved
5
Determine Standard Values for Checks & Revise Standards
8
§ Investigate 4M conditions in each
process. The 4Ms are:
• Men/Women
• Materials
• Machines
• Methods
§ Identify lapses in these conditions
through on-site investigation

4.
Quality Maintenance
© Operational Excellence Consulting. All rights reserved.
Quality Maintenance means figuring out the equipment conditions in which
defects won’t occur, setting them up as the standards, monitoring and
measuring actual equipment conditions over time, and confirming the
actual conditions are within the standards.
§ Determine standard values for checks
§ Create Quality Maintenance matrix
§ Increase reliability of checks, simplify
them, and reduce number of people
involved
§ Revise materials standards, checking
standards and work standards
§ Identify quality (“Q”) components so
that standards are kept
§ Monitor trends and confirm results
8. Determine Standard Values
for Checks & Revise Standards
§ Find ways to consolidate and fix the
checking methods
§ Carry out improvements to make
checking easier
7. Consolidate Checking Methods
§ Expose flaws in 4M conditions
§ Carry out restoration or improvements
§ Evaluate results
§ Establish 4M conditions that allow good
product to be achieved
6. Eliminate Flaws in 4M
Conditions and Finalize
§ Analyze situations where the conditions
for building in quality are unclear
§ Establish defect causes
§ Optimize settings, processing conditions
and setup procedures
§ Evaluate
5. Establish Conditions that Allow
Good Products to be Achieved
§ Create deficiencies chart and identify
countermeasures
§ Verify state of equipment and
restore/improve it
4. Plan Action to Correct
Deficiencies
§ Check quality standards and quality
characteristics
§ Create a flow diagram of individual
processes for building in quality
§ Investigate defect situation and stratify
defect phenomena
1. Verify the Existing Situation
§ Draw up a Quality Assurance (QA)
matrix
§ Investigate individual processes where
defect modes occur
2. Investigate the Processes
where Defects Occur
3. Identify & Analyze 4M
Conditions
§ Investigate 4M conditions in each
process. The 4Ms are:
• Men/Women
• Materials
• Machines
• Methods
§ Identify lapses in these conditions
through on-site investigation
Identify & Analyze 4M Conditions
3
Investigate the Processes where Defects Occur
2
Verify the Existing Situation
1
Plan Action to Correct Deficiencies
4
Consolidate Checking Methods
7
Eliminate Flaws in 4M Conditions and Finalize
6
Establish Conditions that Allow Good Products to be Achieved
5
Determine Standard Values for Checks & Revise Standards
8

5.
© Operational Excellence Consulting. All rights reserved. 5
Operational Excellence Consulting is a management training and consulting
firm that assists organizations in improving business performance and
effectiveness. Based in Singapore, the firm’s mission is to create business
value for organizations through innovative design and operational excellence
management training and consulting solutions. For more information, please
visit www.oeconsulting.com.sg