The mechanic must know 10 quality indicators
Mechanical work will touch a lot of indicators every day, but every day in the mouth of the indicators you really know it, and know why? Before the explanation to do a survey to see if we are not aware of the following concepts of the definition, purpose, calculation formula and which related to the technical terms.
First, the rejection rate
definition:
The percentage is determined by dividing the cost of the waste material by the total production cost or by the total quantity of the waste divided by the total production quantity of the product.
purpose:
Used as a measure of the results to determine whether the process is in accordance with the standardization of parts production and assembly.
formula:
Percentage of rejects = (amount of waste material / total production cost) × 100% or (total amount of waste / total production quantity) × 100%.
the term:
Waste Material Amount: The value of the material used for the waste.
Total production costs: the sum of labor, materials and factory burden (water, electricity, etc.).
Application / information: waste calculation is directly from the unit's financial system to get its value. If the company's financial system can not be separated from the labor and the burden of waste material value, should be resolved with the relevant departments as soon as possible.
Second, the rework rate
definition:
The proportion of time spent in the rework period is divided by the total number of workers who divide the working hours by the total number of workers who produce labor or rework (rework).
Purpose: Used as a measure of the results to emphasize those operating stations that need to be improved in the first quality.
formula:
Rework rate% = (total working hours / total production hours) × 100% or (total number of rework (rework) products / total production quantity) × 100%.
the term:
Back to work hours: refers to the re-processing, sorting, repair those who will become waste parts of the time spent. These times can be used in products, finished products and purchased parts or materials. Rework time includes such as repair, repackaging, re-sorting, additional inspection activities and containment. Rework time includes internal or external activities. Should include the direct time plus the direct time part of the overtime.
Production labor hours: the sum of the working hours of direct / productive labor workers (including direct time plus the direct time part of overtime).
Application / Information: The occasional inspection of direct workers should not be considered rework. Any product that enters the production process should be considered reworked. Part of the total labor content of the production line should be considered rework. This part will be determined according to the reworked product. For example, in the final inspection, the paint production line 10% of the product failed, and the paint production line a total of 20 operators, rework products (10%) need to paint again, paint production line total working hours of 10% Is considered to be used for rework. 10% × 20 people × 8 hours = 16 rework hours.
Third, the product storage inspection pass rate
definition:
The number of qualified items stored in the warehouse is divided by the total amount of the inspection.
purpose:
Used as a process measure, used to measure the quality of the entire production process.
formula:
Product acceptance test pass rate% = (product storage inspection qualified quantity / total number of storage inspection) × 100%.
Four, the number of substandard goods (customer return rate or product non-performing rate)
definition:
The number of customers who return / reject or the number of nonconforming products in each million products represents the total number of shipments or the total production.
purpose:
Used as a result of measurement, to fully show the impact of product dissatisfaction, making the focus on solving the problem.
formula:
Customer Return Rate = Number of Returned / Number of Products Total Quantity * 1,000,000 or Product Nonperformity = Total Number of Unqualified / Total Products * 1,000,000.
Fifth, the quality of the accident
definition:
The number of production stops per year due to product failure. Causing the company to stop shipping, stop production or require that the manufactured product be amended.
purpose:
Used as a measure of the overall results, the reaction caused by the quality of the company caused by the number of products are not satisfied, in order to help focus on solving the problem.
formula:
Quality Accident = Number of factory production pauses caused by a company-defined quality accident each year.
6, parts processing non-performing rate (inspection pass rate or process pass rate)
definition:
Inspection pass rate or process pass rate that is part of the production process a qualified quantity divided by the total number of parts of the total income or weighted average income; parts processing non-performing rate for the total number of parts out of the total number of production proceeds from the production.
purpose:
Used as a process measure to determine the quality level of a production process.
formula:
Patrol pass rate or process pass rate = (number of qualified products / total number of parts production) × 100%
Parts processing defect rate = (number of parts failed / parts production input) × 1,000,000.
Seven, customer inspection pass rate once
definition:
Refers to the quantity delivered by the customer, one by the number of products received by the customer, divided by the total quantity delivered.
purpose:
Used as a measure of the quality of the finished product.
formula:
Customer inspection pass rate% = (total number of products received through customer acceptance / total number of products delivered) × 100%.
8, feed inspection pass rate (incoming inspection pass rate)
definition:
For a certain period of time, the quantity of the feed inspection is divided by the quantity of the feed inspection.
purpose:
Used as a measure of the results used to monitor supplier supply quality levels.
formula:
Feed inspection pass rate% = (total number of qualified inspection / quantity of feed inspection) × 100%.
Nine, quality cost
definition:
It is simply defined as the cost of failure (loss) for a certain period of time.
purpose:
Used as a result of measurement, used to reflect the effectiveness of the company's quality management system to run the results of the comprehensive results.
formula:
Quality Cost = Internal Failure (Loss) Cost + External Failure (Loss) Cost;
Internal failure (loss) cost = retirement loss + rework or return loss;
External failure (loss) cost = customer return loss fee + product liability fee + complaint fee;
Quality Cost Ratio to Sales Ratio = (Quality Cost ÷ Sales) × 100%.
the term:
Internal failure (loss) Cost: the product can not meet the quality requirements caused by the loss before delivery;
External failure (loss) cost: the product can not meet the quality requirements after delivery caused by the loss;
Scrap loss: due to finished products, semi-finished products, products in the quality requirements and can not be repaired or not economically worth repair damage caused by the cost of scrap;
Reimbursement or rework costs: fees for repairing nonconforming products to meet quality requirements or anticipated use requirements;
Customer return loss: customer return of the cost of waste loss;
Product liability fee: The cost of compensation for damage caused by product quality failure;
Complaint fee: The cost of repairing or replacing a product that has a quality problem with a customer.
Ten, batch failure rate
Definition: refers to the proportion of the number of batches of the total inspection lot required for rework (or rework or scrapped) of the entire inspection lot in all inspection lots for a certain period of time.
Purpose: Used as a measure of the results used to monitor the overall quality of the process.
formula:
Batch Unqualified Rate = Unqualified Batch / Total Inspection Batch * 100%.
Inspection batch: is submitted to test a number of products, but also as a test object and brought together a number of products. Usually the inspection lot should be the same type, the same level and the same type (size, characteristics, composition, etc.), and the production conditions and production time is basically the same unit product composition.
Production batch: refers to the production plan determined by the production of a certain number of products.
Mechanical work will touch a lot of indicators every day, but every day in the mouth of the indicators you really know it, and know why? Before the explanation to do a survey to see if we are not aware of the following concepts of the definition, purpose, calculation formula and which related to the technical terms.
First, the rejection rate
definition:
The percentage is determined by dividing the cost of the waste material by the total production cost or by the total quantity of the waste divided by the total production quantity of the product.
purpose:
Used as a measure of the results to determine whether the process is in accordance with the standardization of parts production and assembly.
formula:
Percentage of rejects = (amount of waste material / total production cost) × 100% or (total amount of waste / total production quantity) × 100%.
the term:
Waste Material Amount: The value of the material used for the waste.
Total production costs: the sum of labor, materials and factory burden (water, electricity, etc.).
Application / information: waste calculation is directly from the unit's financial system to get its value. If the company's financial system can not be separated from the labor and the burden of waste material value, should be resolved with the relevant departments as soon as possible.
Second, the rework rate
definition:
The proportion of time spent in the rework period is divided by the total number of workers who divide the working hours by the total number of workers who produce labor or rework (rework).
Purpose: Used as a measure of the results to emphasize those operating stations that need to be improved in the first quality.
formula:
Rework rate% = (total working hours / total production hours) × 100% or (total number of rework (rework) products / total production quantity) × 100%.
the term:
Back to work hours: refers to the re-processing, sorting, repair those who will become waste parts of the time spent. These times can be used in products, finished products and purchased parts or materials. Rework time includes such as repair, repackaging, re-sorting, additional inspection activities and containment. Rework time includes internal or external activities. Should include the direct time plus the direct time part of the overtime.
Production labor hours: the sum of the working hours of direct / productive labor workers (including direct time plus the direct time part of overtime).
Application / Information: The occasional inspection of direct workers should not be considered rework. Any product that enters the production process should be considered reworked. Part of the total labor content of the production line should be considered rework. This part will be determined according to the reworked product. For example, in the final inspection, the paint production line 10% of the product failed, and the paint production line a total of 20 operators, rework products (10%) need to paint again, paint production line total working hours of 10% Is considered to be used for rework. 10% × 20 people × 8 hours = 16 rework hours.
Third, the product storage inspection pass rate
definition:
The number of qualified items stored in the warehouse is divided by the total amount of the inspection.
purpose:
Used as a process measure, used to measure the quality of the entire production process.
formula:
Product acceptance test pass rate% = (product storage inspection qualified quantity / total number of storage inspection) × 100%.
Four, the number of substandard goods (customer return rate or product non-performing rate)
definition:
The number of customers who return / reject or the number of nonconforming products in each million products represents the total number of shipments or the total production.
purpose:
Used as a result of measurement, to fully show the impact of product dissatisfaction, making the focus on solving the problem.
formula:
Customer Return Rate = Number of Returned / Number of Products Total Quantity * 1,000,000 or Product Nonperformity = Total Number of Unqualified / Total Products * 1,000,000.
Fifth, the quality of the accident
definition:
The number of production stops per year due to product failure. Causing the company to stop shipping, stop production or require that the manufactured product be amended.
purpose:
Used as a measure of the overall results, the reaction caused by the quality of the company caused by the number of products are not satisfied, in order to help focus on solving the problem.
formula:
Quality Accident = Number of factory production pauses caused by a company-defined quality accident each year.
6, parts processing non-performing rate (inspection pass rate or process pass rate)
definition:
Inspection pass rate or process pass rate that is part of the production process a qualified quantity divided by the total number of parts of the total income or weighted average income; parts processing non-performing rate for the total number of parts out of the total number of production proceeds from the production.
purpose:
Used as a process measure to determine the quality level of a production process.
formula:
Patrol pass rate or process pass rate = (number of qualified products / total number of parts production) × 100%
Parts processing defect rate = (number of parts failed / parts production input) × 1,000,000.
Seven, customer inspection pass rate once
definition:
Refers to the quantity delivered by the customer, one by the number of products received by the customer, divided by the total quantity delivered.
purpose:
Used as a measure of the quality of the finished product.
formula:
Customer inspection pass rate% = (total number of products received through customer acceptance / total number of products delivered) × 100%.
8, feed inspection pass rate (incoming inspection pass rate)
definition:
For a certain period of time, the quantity of the feed inspection is divided by the quantity of the feed inspection.
purpose:
Used as a measure of the results used to monitor supplier supply quality levels.
formula:
Feed inspection pass rate% = (total number of qualified inspection / quantity of feed inspection) × 100%.
Nine, quality cost
definition:
It is simply defined as the cost of failure (loss) for a certain period of time.
purpose:
Used as a result of measurement, used to reflect the effectiveness of the company's quality management system to run the results of the comprehensive results.
formula:
Quality Cost = Internal Failure (Loss) Cost + External Failure (Loss) Cost;
Internal failure (loss) cost = retirement loss + rework or return loss;
External failure (loss) cost = customer return loss fee + product liability fee + complaint fee;
Quality Cost Ratio to Sales Ratio = (Quality Cost ÷ Sales) × 100%.
the term:
Internal failure (loss) Cost: the product can not meet the quality requirements caused by the loss before delivery;
External failure (loss) cost: the product can not meet the quality requirements after delivery caused by the loss;
Scrap loss: due to finished products, semi-finished products, products in the quality requirements and can not be repaired or not economically worth repair damage caused by the cost of scrap;
Reimbursement or rework costs: fees for repairing nonconforming products to meet quality requirements or anticipated use requirements;
Customer return loss: customer return of the cost of waste loss;
Product liability fee: The cost of compensation for damage caused by product quality failure;
Complaint fee: The cost of repairing or replacing a product that has a quality problem with a customer.
Ten, batch failure rate
Definition: refers to the proportion of the number of batches of the total inspection lot required for rework (or rework or scrapped) of the entire inspection lot in all inspection lots for a certain period of time.
Purpose: Used as a measure of the results used to monitor the overall quality of the process.
formula:
Batch Unqualified Rate = Unqualified Batch / Total Inspection Batch * 100%.
Inspection batch: is submitted to test a number of products, but also as a test object and brought together a number of products. Usually the inspection lot should be the same type, the same level and the same type (size, characteristics, composition, etc.), and the production conditions and production time is basically the same unit product composition.
Production batch: refers to the production plan determined by the production of a certain number of products.
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