MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING CAPSTONE PROJECT INDUSTRIAL MANAGEMENT ANALYZING QUALITY
Introduction
Quality management remains a critical focus for businesses amid today's intense competition It plays a vital role in enhancing an enterprise's reputation and market position, as high product quality not only boosts credibility but also attracts more orders.
Reducing costs and boosting long-term profits is essential for multinational manufacturing corporations, as maximizing production output and enhancing profitability remain their primary objectives.
My experience as an intern at Zeder Vietnam has deepened my understanding of the critical role quality control plays in manufacturing, particularly for companies that demand high product accuracy Preventing defects in product quality from the raw material stage is essential for meeting these stringent requirements.
Strict quality control from raw materials to final products is a primary objective for companies Ensuring the quality of input materials is a key priority for the quality management department to facilitate seamless production.
Minimizing the influx of defective materials into production is a primary objective of the IQC department, particularly in mechanical manufacturing firms like Zeder Viet Nam, where precise equipment assembly is crucial Consequently, there is a strong emphasis on enhancing the control of input materials This article focuses on "Analyzing the Quality Control at Input Quality Control in Zeder Viet Nam Plant."
Objective
This study was carried out with the following main purposes:
- Define the current reality of input quality control in the Input Quality Team at Zeder Viet Nam
- Propose some solutions to improve and improve the efficiency of quality control of input materials at the Input Quality Control department.
Scope and object
- Object: The process of controlling input materials at Input Quality Control at Zeder Vietnam
- Space Research Scope: Input Quality Control Process in Zeder Vietnam
- Time Research Scope: From February 2022 to September 2022.
Research methodology
- Secondary data: Refer to Quality and Production documents from factory departments, documents, thesis, and information on the Internet
- Primary data: Information collected from personal interviews directly with production and databases at Input Quality Control and related departments of Input Quality Control at the Zeder Vietnam factory
AHP method: The AHP method is used to rank the importance of each factor, thereby indicating the most influential factors causing the error situation encountered at Input Quality Control.
Structure of Thesis
The Thesis Graduation has 4 chapters includes:
INTRODUCTION ABOUT COMPANY
General Information
1.1.1 Historical Foundation and Development Zeder Corporation
Figure 1.1: The Zeder Corporation Logo
Sources: The Administrative- Human Resources Department in Zeder
Figure 1.2: Zeder Location in the World
Sources: The Administrative- Human Resources Department in Zeder
Zeder Corporation is the merged entity of Fulcrum Suspensions &
Fulcrum and Redranger combine decades of expertise in the Automotive Aftermarket, establishing a strong leadership presence both locally and globally ZEDER stands out as the largest and foremost manufacturer of automotive polyurethane bushings and related accessories worldwide.
Zeder Corporation, the largest automotive steering and suspension business in the country, is focused on global expansion through mergers and acquisitions, alongside investments in innovation, IT, manufacturing, logistics, and marketing to enhance its leadership role Named after Frederick Zeder, a pioneering engineer who co-designed the groundbreaking 1924 “Chrysler Six,” Zeder Viet Nam embodies the spirit of innovation and technical leadership that defined the automotive industry The Chrysler Six introduced key features like shock absorbers and bushings, which were crucial to Chrysler's success This legacy of engineering excellence continues to inspire Zeder Viet Nam's vision, mission, and core values as it evolves from its historical roots to meet contemporary challenges.
Vision: Enhance your driving experience on every journey
Mission: To be the selective supplier of chassis, shock absorbers, and resilient solutions
Survive Reason: Delivering superior and sustainable elastic products
Zeder has five core brands in the aftermarket, with some name list below:
Figure 1.3: The fire bands belong to Zeder Corporation
Sources: Zeder Corporation Websites 1.1.2 General Information about Zeder Viet Nam
ZEDER Vietnam, a branch of the ZEDER Group from Australia, is situated in Long Thanh Industrial Park, Dong Nai Province This facility marks the ZEDER Group's inaugural factory established outside of Australia.
Some basic information about Zeder Viet Nam in the table below:
Table 1.1: The Basic Information about Zeder Viet Nam
International Name ZEDER VIETNAM COMPANY
Brief Name ZEDER VIETNAM CO., LTD
Address Street 10, Long Thanh Industrial Zone,
Tam An Ward, Long Thanh District, Dong Nai Province, Viet Nam
Representative Person NICOLAS SCUDAMORE – SMITH
Manage by Dong Nai Provincial Tax Department
Type Enterprise Limited Liability Company
Sources: Dong Nai Provincial Tax Department
The Zeder Vietnam factory features five workshops, each covering an area of 5*23,000 ft², separated by wide breezeways With a workforce of over 500 employees across various departments including Factory, Warehousing, Kitting, Engineering, and Administration, the facility operates efficiently It utilizes a globally integrated ERP system that connects all operations Specializing in the production of swaybars, spare parts, and car accessories, the factory achieves an impressive output of over 10 million bushings and 40,000 swaybars annually, supported by advanced machinery.
Sources: The Administrative- Human Resources Department in Zeder 1.1.3 Organizational Structure
The Zeder Vietnam factory consists of two main sections: the production support department and the direct production department, both overseen by a general manager The HR department is led by an HR director, while each department is managed by engineers and supervisors who ensure smooth operations through practical processes and an ERP system Communication among departments is facilitated by Microsoft Teams, enhancing collaboration Engineers and supervisors in production directly manage their teams to ensure optimal performance throughout the factory.
Figure 1.4: The Front of Image about Zeder Plant Viet Nam
Sources: The Administrative- Human Resources Department in Zeder
The Core Product of Zeder Viet Nam
Our control arm kits are equipped with pre-installed bushings and all necessary components for easy installation Designed as a time-saving repair and upgrade solution, our expanding range of replacement control arms simplifies the installation process Zeder offers both adjustable and fixed upper control arm options to enhance wheel alignment, especially for lifted vehicles used in off-road conditions.
Figure 1.5: The Organizational Structure of Zeder Viet Nam
Figure 1.6: The Control Arm with brand Whiteline in Zeder Viet Nam
The swaybar, located in the engine compartment and connecting the front shock absorbers, plays a crucial role in enhancing vehicle performance By linking the two ends of the fork, the swaybar minimizes chassis bending during cornering, resulting in improved grip and handling Our selection of sway bars significantly enhances vehicle stability, ensuring cornering loads are distributed evenly across the tires for better traction This not only leads to improved tire wear, as the tires remain flatter and more upright, but also enhances comfort by reducing movement inside the vehicle during bends.
Figure 1.7: Products Swaybar in Zeder Viet Nam
Bushings connect your vehicle to its springs, struts, and shock absorbers, playing a crucial role in the suspension system They serve as movement or mounting points that significantly affect ride quality, steering feel, tire grip, brake performance, and shock absorber stability Worn suspension bushings can lead to unpredictable and unsafe driving conditions Unlike traditional rubber bushings, polyurethane suspension bushings are not bonded by compression; instead, Zeder bushings are designed with a mechanical fit that minimizes urethane crush, allowing the center pin to pivot freely with lubrication.
Figure 1.8: The Bushing Product from Zeder with brand Nolathane in Amazon
Figure 1.9: The Bushing Product in Zeder Plant Viet Nam
LITERATURE REVIEW
Quality
Quality is a multifaceted concept relevant across various professions, including service, commerce, and manufacturing It serves as a benchmark for evaluating a corporation's processes, workforce, and standards According to the ISO 9000:2015, quality is defined as the degree to which inherent characteristics of an object meet specified requirements Additionally, the American Society for Quality describes quality as the fulfillment of commitments regarding service or product expectations.
From the manufacturer's perspective, quality encompasses the complete set of characteristics of a product that reflects how well it meets predetermined requirements under specific economic and social conditions.
Edward Deming (1982) emphasized that concentrated efforts lead to the efficient production of quality that meets market expectations He connected quality with management, stating that improved quality through better management of design, engineering, and testing results in reduced costs and increased productivity.
Peter Ducker (2009) defines Quality in a product or service as not what the supplier puts in It is what the customer gets out and is willing to pay for
According to ISO 9001:2015, we have seven principles of Quality Management
ISO 9001:2015 defines as a formalized system that documents processes, procedures, and responsibilities for achieving quality policies and objectives
Implementing a quality management system (QMS) in manufacturing companies is essential for enhancing organizational performance and achieving compliance with regulations A well-documented QMS helps meet customer requirements, fostering trust and leading to increased sales and repeat business Additionally, it promotes cost-effective and resource-efficient operations, paving the way for growth and profitability Establishing strong customer relationships is crucial; companies can utilize surveys, review processes, or call centers within their QMS to gather valuable customer data This documentation enables businesses to monitor and maintain quality standards effectively within their quality departments.
ISO 2859:2015 outlines quality inspection as the process of measuring, examining, testing, or gauging various characteristics of a product This involves comparing the results against specified requirements to determine if each characteristic meets conformity standards.
Buyers have three primary tools available to assess the quality of their suppliers' products, and it is essential for each buyer to select the option that aligns best with their specific requirements.
In quality control, there are four key types of inspections: pre-production, during-production, pre-shipment, and container inspection, each serving a distinct purpose in supply chain management The applicability of one or more of these inspection types depends on the specific product, the relationship with your supplier, and various other factors relevant to your business needs.
Quality assurance (QA) refers to the systematic efforts in both manufacturing and service industries aimed at ensuring that products meet customer expectations regarding performance, design, reliability, and maintainability The primary goal of QA is to prevent mistakes and defects during the development and production processes It functions as a distinct part of a company, overseeing quality assurance for each product's production process Given that different product types have unique characteristics, QA must incorporate specific criteria and technical requirements tailored to each product, emphasizing process focus and distinguishing itself from quality control.
Quality assurance is based on two key principles: ensuring that products are "fit for purpose" and achieving "right first time" to eliminate mistakes It encompasses the management of quality across raw materials, assemblies, products, components, and services, as well as overseeing production and inspection processes.
Quality auditing involves a systematic and independent evaluation of an organization's quality management system (QMS) to ensure compliance with strategic objectives This process is carried out by internal or external auditors who assess the effectiveness of quality activities and results As outlined in term 9.1 of ISO 9001 standards, quality audits are essential for maintaining high standards in Quality Management.
Quality audits play a vital role in quality management by ensuring products are safe for consumers and compliant with regulations (Xiao et al., 2020) They provide essential evidence for identifying and addressing problem areas, enabling timely corrective actions to prevent issues Furthermore, audits are critical for meeting regulatory and compliance standards, as well as assessing the success of an organization’s products, systems, and processes.
An auditor must be educated on the ins and outs of industry standards and conducts audits according to these standards Quality auditors can be either internal or external:
• An internal auditor is an employee who understands company policies, procedures, and practices but is not directly involved in the product, system, or process audit
• An external auditor is an outside source hired from an approved agency, client, or customer with a complete understanding of the same policies, procedures, and practices of the industry
Quality control (QC) is essential for businesses to ensure that products and services meet established quality standards and customer requirements (Lakshminarayan et al., 2020) While QC focuses on the end products, quality assurance emphasizes the manufacturing process QC involves testing samples from the production line, finished goods, and raw materials to identify potential issues early By analyzing data from quality inspections, engineers can implement preventive measures to avoid production problems Additionally, non-manufacturing businesses can utilize customer service reviews, surveys, inspections, and audits as part of their quality testing procedures Ultimately, companies must adopt various techniques to guarantee that their final products or services are safe, compliant, and aligned with consumer expectations.
One of the key principles in Quality Management is the process approach, which aligns with the seventh principle of ISO 9001:2015 According to Saida and Taibi (2021), the Quality Control approach focuses on three essential aspects.
• Elements such as controls, job management, defined and well-managed processes, performance and integrity criteria, and identification of records
• Competence, such as knowledge, skills, experience, and qualifications
• Soft elements include personnel, integrity, confidence, organizational culture, motivation, team spirit, and quality relationships
Quality control significantly influences both employees and customers by fostering a safe work environment and ensuring that products are safe and meet customer expectations This field offers a fulfilling career for individuals who are passionate about problem-solving and enhancing results.
During the industrial revolution, factories established quality control departments to oversee production processes The author identifies three key types of quality control in manufacturing and service industries: input quality control, which focuses on the quality of raw materials; process quality control, which monitors work-in-progress products; and output quality control, which ensures the quality of finished goods Today, various quality control methods are employed, including x-bar charts, Six Sigma, 100% inspection mode, and the Taguchi Method Each method has its own advantages and disadvantages, requiring quality specialists and engineers to select the most suitable approach for specific situations This informed decision-making enables the implementation of corrective actions to mitigate potential issues within the company.
Some Quality Control Tools
A Pareto chart is a bar graph that displays frequency or cost, with the longest bars on the left and the shortest on the right, highlighting the most significant situations The Pareto Principle, also known as the 80-20 rule, focuses on identifying and efficiently utilizing an entity's best assets to maximize value Additionally, a cumulative frequency line illustrates the overall contribution of individuals.
Recognizing the significance of each issue is crucial for effective problem-solving It is essential to prioritize the issues that require immediate attention By implementing quality improvement activities, we can observe the positive outcomes that follow these enhancements.
Steps to build a complete Pareto chart
Step 1: Identify errors or causes of errors and collect data
Step 2: Sort the data in the table in order from largest to smallest
Step 3: Calculate the percentage of each type of error
Step 4: Determine the cumulative error percentage
Step 5: Plot a bar chart with the percentages of the error types just calculated above Step 6: Draw a cumulative line according to the calculated cumulative percentage Step 7: Write the title of the content and write a summary of the features of the error on the graph
Figure 2.1: The Example of Pareto Chart
A check sheet is a customizable form utilized for data collection, encompassing quantitative, frequency, and qualitative data It serves as one of the seven fundamental tools of Quality Control, allowing users to tailor the form to meet their specific data collection needs.
In addition, it is sometimes known as a defect concentration diagram
The check sheet serves to analyze the distribution of data for an indicator throughout the production process, while also identifying defect locations to trace the sources of product defects.
Step 1: Identify events or issues to be observed
Step 2: Determine when data will be collected and for how long
Step 3: Design the template Set up the data to be rewritten simply using a search mark ( Example: Symbol “x,” tick mark, circle, )
Step 4: Test the Check sheet again after the test run to ensure it collects the correct data and is easy to use
Step 5: Monitor when the target event occurs, and record the data in the Check sheet
A flowchart, as defined by the American Society for Quality, visually represents the sequential steps of a process and can be adapted for various applications, including manufacturing, administration, and project planning This versatile tool not only serves as a quality control mechanism but is also easy to create and understand Flowcharts present information in a concise manner, facilitating effective communication and guidance in the workplace By utilizing flowcharts instead of complex and costly A4 documents, businesses can enhance their presentations, engage a broader audience, and gain a competitive advantage in attracting potential customers.
We have six steps to create a flow chart involves:
1 Define the process to be diagrammed Write its title at the top of the work surface
2 Discuss and decide on the boundaries of your process: Where or when does the process start? Where or when does it end? Discuss and decide on the detail level to include in the diagram
3 Brainstorm the activities that take place Write each on a card or sticky note
4 Arrange the activities in proper sequence
5 When all activities are included, and everyone agrees that the sequence is correct, draw arrows to show the flow of the process
6 Review the flowchart with others involved in the process (workers, supervisors, suppliers, customers) to see if they agree that the process is drawn accurately
The Fishbone Diagram, developed by Dr Ishikawa in 1960, is a crucial quality management tool utilized in modern businesses This diagram systematically organizes potential causes of a problem, aiding in the identification of its root cause for timely corrective and preventive actions While it helps list and categorize these causes, it does not provide a method for their elimination The analysis of the Fishbone Diagram involves five elements, starting with the letters M and E, which influence the operational and functional labor of individuals involved in product design and delivery.
The method encompasses both the production process and the associated service delivery processes Often, these processes are overly complex, featuring excessive steps, signoffs, and activities that fail to add significant value.
Machines encompass the systems, tools, facilities, and equipment essential for production However, these machines and their supporting systems are frequently mismanaged or unable to achieve the desired output due to technical or maintenance challenges.
Effective management of materials, including raw materials, components, and consumables, is crucial for producing a desired end product Common issues such as incorrect specifications, mislabeling, improper storage, and outdated materials can lead to significant mismanagement.
Environmental factors, such as unpredictable weather events, floods, earthquakes, and fires, can significantly impact facilities While many of these factors are manageable and predictable, some remain unavoidable, leaving certain facilities unprepared for their consequences.
Measurement involves both manual and automatic inspections, as well as physical measurements such as distance, volume, temperature, and pressure However, inconsistencies in measurements can complicate the process, making it challenging to draw reliable conclusions from the data.
Figure 2.2: The Example of Fishbone Diagram
Failure mode and effect analysis (FMEA)
Failure Mode and Effects Analysis (FMEA) is a widely recognized methodology in manufacturing and engineering that aims to identify potential failures in the design, manufacturing, and assembly processes of a product or service This approach focuses on effective presentation and prioritizes the reduction of risks associated with these failures.
FMEA is an acronym for Failure Mode and Effects Analysis, which includes the meanings of each symbol as follows:
Failure is an undesirable outcome that everyone wishes to avoid, yet it can arise from a love affair The failure identified in the FMEA represents a latent failure, indicating that while it has not yet occurred, there is a potential for it to happen in the future.
Many individuals often confuse the terms "failure mode" and "defect," despite their distinct meanings Failure mode pertains to the mechanism and cause of a failure, while the effect refers to the impact of that failure on the final product It is essential to understand how failures influence the product's appearance and material quality.
Analysis: We must understand the cause and analyze the risks and consequences From there, prioritize to give directions for improvement
Originally rooted in the military, the automotive industry has established the standard for Failure Mode and Effects Analyses (FMEAs), leading various other sectors to adopt its risk analysis best practices.
To effectively implement Failure Mode and Effects Analysis (FMEA) in a business, it is essential to follow key steps: identify potential failure modes (what could go wrong?), analyze the causes of these failures (why would the failure happen?), and assess the effects of each failure (what would be the consequences?).
FMEA (Failure Mode and Effects Analysis) systematically identifies potential failure modes in products or processes and prioritizes them for attention This prioritization is achieved through a scoring model that evaluates each failure mode based on its Severity (S), Occurrence (O), and Detectability (D).
Formular: RPN( Risk Priority Number) = S*O*D
AHP Method
The Analytic Hierarchy Process (AHP) is a decision-making framework that combines mathematical and psychological principles to effectively organize and analyze complex choices Developed by Thomas L Saaty in the 1970s, AHP has undergone continuous refinement and remains a valuable tool for decision analysis today.
The Analytic Hierarchy Process (AHP) is a powerful decision-making tool that helps solve complex problems by breaking them down into manageable components It involves three key elements: defining the ultimate goal, exploring various alternatives, and establishing criteria for evaluating these options By quantifying both the criteria and alternatives, AHP provides a rational framework that aligns decision-making with the overall objective According to Saaty, this technique effectively organizes and assesses intricate choices, allowing for a clear hierarchical representation of the problem's importance.
The authors used pairwise compared assessments to establish the relative value of each component and indicator level in this study Respondents were asked to rank variables
To evaluate the importance of factors A and B, assign scores from 1 to 9 based on their preference Use a score of 1 if factors A and B are equally important If factor A is more important, select a score between 2 and 9, favoring A Conversely, if factor B holds greater significance, choose a score between 2 and 9, favoring B The maximum score of 9 indicates the highest level of importance.
The consistency and dependability of the obtained data will be verified using the consistency index (CI) Accordingly, consistency is determined by the formula:
CI = (λmax - number criteria) / (number criteria - 1)
RI: random index is defined in the table below:
According to (Darko et al., 2019), the evaluation is considered reliable if the
The CR value is below 0.1, indicating a strong model fit Subsequently, the relative weights of each indicator and factor were integrated to produce a final weighted score, effectively quantifying the implementation of the TQM model in organizations following the assessment of the CR value.
REALITY ABOUT THE QUALITY CONTROL AT INPUT
Quality Department in Zeder Viet Nam
3.1.1 The Quality Assurance at Zeder Viet Nam Plant
Zeder Vietnam's Quality Department is structured into two key teams: Quality Control and Quality Assurance The Quality Assurance team establishes the standards that the Quality Control team follows, ensuring alignment with ISO standards Currently, the Quality Assurance processes are managed through the Netsuite ERP system and stored on the Box cloud platform Zeder Vietnam's quality control system is certified to ISO 9001:2015 by the IAF, emphasizing the company's commitment to quality consistency This consistency allows customers to have clear expectations and receive uniform quality with every purchase, ultimately attracting more clients Additionally, the data generated by the company's systems enables engineers and managers to analyze operations and identify potential compliance issues.
Figure 3.1: The Certificate of ISO 9001:2015 at Zeder Viet Nam
The Quality Management System (QMS) at Zeder Vietnam regulates audit documents related to product quality and establishes specific standards for each product code across various inspection areas Given that each product type has unique characteristics and materials, the standards vary according to the item's price and significance The QMS encompasses the entire process, from raw material input to finished products at the factory All quality management data and standards are stored in Box software within the Quality room The system initiates with QA-01, while specific standards for each quality management process commence with QC-01.
Zeder Vietnam's quality management system is overseen by QMS Admins, who develop tailored quality management frameworks for each production area and process All quality procedures are securely stored on Box, and the quality control system undergoes annual audits in accordance with the ISO 9001:2015 standard issued by IAF By utilizing a diverse range of data from the Document System on Box, standardized to ISO 9001:2015, Zeder Vietnam effectively meets customer requirements and fosters trust among its clients.
Figure 3.2: Document System at Box Platform in Zeder Viet Nam
3.1.2 The Quality Control at Zeder Viet Nam
Zeder's quality management department at the Vietnam factory is structured to oversee the entire production process, from the warehouse to product packaging Each product unit undergoes rigorous checks based on established standards within the Quality Management System Given the high precision required for Zeder's mechanical products, quality control stations are staffed by skilled Technicians and Operators who ensure compliance with these standards Strategically located throughout the production process, these stations are equipped with specialized tools to assess the quality of each product effectively.
The Quality Control department features six control stations, each designated for specific tasks The metal quality control station focuses on assessing the quality of shortcut steel bars, while the Swaybar quality control station ensures that steel bars are bent according to molds and meet quality standards Additionally, the Powder Coating quality control checks the paint quality of products like Swaybars and Control Arms The packaging quality control area oversees the packaging of Control Arm and Swaybar products at the Pressing stage The Poly area is dedicated to the quality control of Bush components, and the Incoming Quality Control (IQC) area evaluates the quality of all incoming materials.
Figure 3.3: The Flowchart of Quality Control in Zeder Viet Nam
At the Zeder Vietnam factory, all input materials, semi-finished products, and final products undergo rigorous quality control in accordance with the Quality Management System on the Box platform Each quality control area is equipped with specialized equipment tailored to the specific production processes, ensuring that products are meticulously checked for size, material, and other unique characteristics.
Table 3.1: Some Basic Measurement Quality Product Methods in Zeder Viet Nam
Figure 3.4: Caliper with brand Mitutoyo in Zeder Viet Nam
At the Zeder Vietnam factory, products that necessitate testing for specific characteristics are equipped with dedicated measuring instruments at each quality control station For instance, products undergoing the powder coating process are evaluated for hardness using either manual or mechanical hardness testers, with mechanical measurements enhancing the accuracy of the results.
Figure 3.6: Manual mechanical hardness Tester
Figure 3.5: Infrared laser heat gun used to measure powder coating thickness
The quality control process at Zeder Vietnam begins with inspection requirements from the planning and production departments, documented through NCR papers included with the goods to be inspected Each production unit's quality department then evaluates the product against its specific standards If the product meets the quality criteria, it is stamped and released into the system.
The images depict wood markings that comply with the standard material specifications of the ZVN factory, serving as evidence that these materials meet high-quality standards and are approved for the Input Quality Control area Additionally, we possess a non-conforming report that details the inspection of input materials, ensuring adherence to the specific requirements outlined in that report.
Figure 3.7: Non-Conforming Report Paper in Zeder Viet Nam
Figure 3.8: Seal suitable quality standards
Products failing to meet quality standards are marked with isolation cards and await further processing At the Zeder Vietnam factory, the QA01-F05 card is utilized to temporarily hold defective items in the goods detention area.
Figure 3.9: Detention Card QA01-F05 in Zeder Viet Nam
The Input Quality Control in Zeder Viet Nam
3.2.1 Overall about Input Quality Control in Zeder Viet Nam
The IQC department at Zeder Vietnam is responsible for ensuring the quality of input materials before they enter production This department conducts thorough checks on raw materials stored in the warehouses, directly collaborating with suppliers to maintain high standards By verifying the quality of materials, the IQC department minimizes potential errors in production According to Allion Labs, "Input Process Quality Control (IQC) refers to quality control in the input process of raw materials, production, and packaging." The department focuses on two main objectives: verifying the first product from a new or switched product line and establishing product standards within the production department Inspection standards are based on the initial sample, ensuring that raw materials are validated before production commences.
Figure 3.10: The Quantity of incoming material overall in Input Quality Control at
Jan Feb Mar Apr May Jun Jul Aug Sep
Sum of FAILED Q'TY Sum of RECEIVING Q'TY Defect Rate
Table 3.2: Incoming Material Scorecard in Input Quality Control at Zeder Viet Nam
At the Zeder Vietnam factory, the objective of Input Quality Control is to maintain a monthly error rate of only 1% However, the rate of defective goods from suppliers remains significantly high, particularly for items like tubes and forging gears, which are susceptible to damage This leads to stringent accuracy requirements for processed items, resulting in a monthly error rate on the incoming material scorecard that exceeds the established target.
At the Zeder Vietnam factory, there are numerous suppliers, both domestic and international, contributing to tens of thousands of imported product codes and hundreds of thousands of raw material units each month This high volume has led to a significant number of errors in Input Quality Control Each product code has varying acceptance levels defined by the Quality Management System on the Box Platform Data collected from January to September indicates a substantial quantity of imported goods alongside a notable number of defects, highlighting the pressing issues within the quality control stage of input materials that require urgent attention.
At the Zeder Vietnam factory, we collaborate with over 80 global suppliers to ensure a diverse range of materials for our manufacturing processes Currently, our localization rate for materials stands at approximately 87%, and we are actively seeking domestic suppliers to fulfill the majority of our material requirements Our factory produces a variety of components, including Bush, Control Arms, and Swaybars, with different suppliers providing specialized goods for these three main product lines.
Month Jan Feb Mar Apr May Jun Jul Aug Sep
Zeder Vietnam's Incoming Material Scorecard encompasses a range of products, including tube products, hot forged gears, shell products, and finished steel items With over 87% of suppliers being domestic, the company enhances its resilience against supply chain disruptions from foreign sources This domestic focus allows for easier exchanges and reworking, significantly reducing lead times However, certain critical materials are sourced from a limited number of foreign suppliers, making it challenging to replace them without risking an increase in defects from substandard domestic alternatives To address this, Zeder Vietnam's Input Quality Control division is actively working to boost the localization rate of input materials, thereby decreasing reliance on foreign raw materials As a result, domestic suppliers are gradually being entrusted with key ZVN product codes, fostering greater cohesion between the Zeder Vietnam Plant and its suppliers, both domestic and foreign.
Figure 3.11: The percentage of domestic and abroad suppliers in Zeder Viet Nam
The percentage of domestic and abroad supplier in
Figure 3.12: The process inspection of the raw material in Input Quality Control in
Sources: Database from Input Quality Control Team
The material quality control process at the Zeder Vietnam factory follows a structured flow chart It begins with the receipt of materials from suppliers in the warehouse, where items are documented Subsequently, the materials are categorized into two groups: those that require inspection and those that do not need testing.
Input materials that do not need to be inspected will be transferred directly to the
Warehouse for storage Materials that need to be checked will be checked by
Operators and technicians at Input Quality Control manage standard materials for carpentry, which are released into the system Non-standard materials are redirected to the processing area for rework or returned to the supplier Addressing defects at Input Quality Control necessitates the involvement of engineers and higher management to ensure timely measures are taken to resolve any issues effectively.
3.2.2 Six-Level Quality Inspection at Input Quality Control in Zeder Viet Nam Plant
In the Input Quality Control Area, the Engineer categorizes input materials into six inspection levels, ranging from low to high At the Zeder Vietnam factory, nearly all materials undergo inspection based on these levels The extent of inspection is determined by factors such as material quantity, historical failure data from the Input Quality Control database, and material cost The system automatically determines the necessity of quality checks for input materials Currently, the quality control protocol mandates a 100% inspection of the first three batches of each product code, with subsequent batches subject to sampling tests.
Figure 3.13: Defective Goods Retention Area with "QA01-F05" tags in Input Quality
Table 3.3: The Six Quality Insection Levels in Input Quality Control at Zeder Viet
The Quality Control for five core materials in Input Quality Control Area
3.3.1 The Quality Control for Tube Material
Tubes are short steel bars that are modified according to technical drawings to meet various product specifications These pipes are produced from defective steel sourced from both domestic and international manufacturers The flawed wire undergoes cutting and processing as dictated by the design requirements At Zeder Vietnam, most tubes are treated through heat processing and plating by external suppliers The primary suppliers for raw material pipes, which are subject to input quality control at ZVN, include domestic companies like Hung Dat and Cong Ngang, known for their heat pipe supply, while Nhat Phat Tuan specializes in plating tubes.
Figure 3.14: The inspection length tube by caliper rule
At the Warehouse's Input Quality Control (IQC) department, Tube codes are initially assessed using the Visual Check method, focusing on the inner dimension (ID), outer dimension (OD), and length (L) measured with a caliper Before sealing, tubes must undergo hardness testing with a hardness tester in the IQC area, prior to re-galvanization for surface polishing, which minimizes friction in automobile engine operations Tube materials frequently contribute to high error rates due to substantial monthly imports in various forms, including original, hardened, and plated tubes Common issues include discrepancies in OD, ID, and L sizes, as well as rust and impurities, making these errors prevalent in the IQC process.
3.3.2 The Quality Control for Control Arm Material
The Control Arm is a crucial component installed beneath the chassis of imported vehicles, meticulously molded and CNC machined to meet the standards set by ZVN's Research and Development department Priced at over 2,000,000 VND per unit, these components are primarily sourced from established foreign suppliers like Young Industrial and Yinzhou in China and Taiwan Notably, the delivery time for imported Control Arm components is the longest among materials tested at ZVN, ranging from 1 to 2 months After thorough inspection, these components are assembled into complete upper or lower control arm systems before being exported to customers Consequently, ZVN implements a stringent quality control process, ensuring a 100% inspection rate at the input quality control department, which adheres to the highest standards across six levels of inspection.
Figure 3.15: The inspection of control arm material in car system
In the Input Quality Control department, each Control Arm undergoes meticulous inspection, where threads are evaluated using gauges and dimensions are verified against technical drawings This process focuses particularly on critical dimensions essential for assembling bush codes and thread codes within the complete control arm The quality check of the input control arm is rigorously performed by operators and subsequently validated by a technician.
A Quality Control Engineer plays a crucial role in ensuring timely handling of Control Arm products, which are primarily imported from overseas Due to the lengthy return times associated with these product codes, efficient management is essential to minimize lead times for production orders.
Figure 3.16: The inspection space between two holes of the control arm
Sources: Input Quality Control Dashboard 3.3.3 The Quality Control for Forge Gear Material
Forging Gear (FG) is a crucial material used in the assembly of steel rods for swaybars and threaded hole steels at the ZVN factory This hot-stamped product is crafted from solid iron through CNC and welding processes The Zeder Vietnam factory currently stores various FG product codes, ranging from FG0001-000001 to FG0060-00015, which are accessible on the Box platform FG is primarily utilized to assemble steel bars with holes, which are then welded to the Forging Gear, creating a dynamic balancer for the swaybar Inspections of FG focus on checking its eccentricity against standard drawings provided by the Research and Development department on the Box platform Reputable domestic suppliers, such as ANCL, Profor, and Tin Dung, specialize in hot stamping goods like Forging Gear for the ZVN factory.
3.3.4 The Quality Control for Shell Material
Shells are essential for creating the finished bush that encases its exterior, with polyethylene resin poured into them At Zeder Vietnam's Poly factory, two types of shells are utilized: metal and plastic Metal shells are sourced from domestic suppliers like Van Kim Bao, Apro, and Chimasa, while plastic shells are imported from foreign suppliers such as Ningbo The choice between plastic and metal shell codes is determined by customer specifications Both shell types undergo a common testing method that evaluates external dimensions and length, as the inner dimensions are typically irrelevant for mold fitting during the resin filling process Additionally, plastic shells are assessed for thermal expansion at the Quaster 3 testing center for chemical components In the warehouse, shell codes are organized in bins, with the first bin designated by the letter 'S' for easy identification.
Figure 3.17: The inspection outside dimension in Shell
3.3.5 The Quality Control for Steel Material
Steel is the primary material used to manufacture sway bars, which are installed beneath vehicles and play a crucial role in balancing Zeder Vietnam imports two main types of steel: solid steel from traditional suppliers like Hoa Phat and Global, and perforated steel from MTS The specific requirements for the steel, including whether it needs to be threaded, are detailed in the drawings provided to the suppliers based on the order specifications.
The input steel inspection process at the ZVN factory varies for solid steel and steel with holes Solid steel is measured for outside dimensions using calipers, length with a tape measure, and hardness to ensure it meets specifications In contrast, steel with holes undergoes checks for both outside and inside dimensions based on item code requirements, with thread gauges used for thread verification This steel is primarily utilized in the production of dynamic balancers for swaybars, a key product of ZVN.
The Reality of Input Quality Control at Zeder Viet Nam
3.4.1 The High Defect Rate comes from Supplier
The majority of errors in Input Quality Control at Zeder Vietnam stem from external suppliers, who account for over 90% of imported goods Only about 10% of the inspected items are self-manufactured An analysis of the database reveals that certain suppliers, including Nhat Phat Tuan, Hung Dat, and NNLT, are responsible for the highest number of errors The Pareto chart highlights that Nhat Phat Tuan, a major supplier of tube plating products, has the largest number of non-conformities due to the high volume of goods received Additionally, suppliers of heat-treated products like Hung Dat and Cong Nang, as well as shell product suppliers such as NNLT and Van Kim Bao, also exhibit significant failure rates Other suppliers, including ANCL, Tin Dung, and Profor, who provide hot stamping goods, are similarly prone to errors.
Figure 3.18: The Pareto Chart of Defect Supplier per Quantity in Input Quality Control at Zeder Viet Nam
The Input Quality Control department has identified that over 50% of defects originate from four key suppliers: Nhat Phat Tuan, Hung Dat, NNLT, and ANCL, who primarily provide raw materials such as tubes and forging gear These suppliers' production processes do not align with the standards of the Zeder Vietnam factory, indicating a need for improvement The analysis highlights Nhat Phat Tuan as a supplier of galvanized tubes, Hung Dat as a provider of heat-treated tubes, ANCL for forging gear materials, and NNLT for shells, emphasizing the importance of addressing these quality issues to enhance overall product standards.
We utilize the Pareto rule (80/20 Principle) to identify suppliers contributing to faults at the ZVN Vietnam factory By employing the cause-and-effect diagram method, we pinpoint factors leading to supplier failures within the 5M and 1E categories This analysis allows us to identify the primary causes of errors, enabling timely prevention and resolution to ensure no issues arise in the Input Quality Control department Notably, supplier Nhat Phat Tuan accounts for 27% of defects, followed by Hung Dat at 11%, NNLT at 8%, and ANCL at 7%, collectively representing over 50% of total supplier errors in the Input Quality Control department A detailed analysis reveals that Nhat Phat Tuan, the supplier with the highest error rate, specializes in providing plating tubes.
Figure 3.19: The Fishbone Diagram about the defect rate of supplier Nhat Phat Tuan
Analysis of root causes makes defects in supplier Nhat Phat Tuan
The error at supplier Nhat Phat Tuan is partially attributed to human factors, as workers exhibit subjectivity in operating CNC machines Their insufficient skills hinder their ability to address issues that arise during machine operation, and a lack of close monitoring further exacerbates the problem.
The CNC machine used for processing finished tubes at the Zeder Vietnam factory suffers from inadequate maintenance, resulting in reduced accuracy Additionally, the supplier Nhat Phat Tuan only replaces the milling cutter when it is worn or damaged, lacking a regular tool change schedule This practice contributes to size errors and surface scratches on the tubes.
Neglecting to monitor the CNC machine's screen regularly can result in improper control during operation, causing scratches and incorrect plating tube codes This oversight may lead to pressing the wrong buttons, resulting in grinding that deviates from the required specifications outlined in the technical drawings.
The quality of steel used in manufacturing plays a crucial role in the integrity of the final product Issues such as small hole sizes and poor-quality steel can lead to surface scratches and incorrect dimensions, particularly with the internal measurements of tubes sourced directly from suppliers Additionally, some steel materials may be too soft, resulting in CNC machines cutting larger than specified in the design, ultimately causing product failures.
In addition to our primary supplier, Nhat Phat Tuan, we also work with Hung Dat, a supplier specializing in heat-treated tube codes However, Hung Dat has reported a significant error rate, contributing to 11% of the total faulty tube codes among over 80 suppliers in Vietnam.
Figure 3.20: The Fishbone diagram about the defect rate of supplier Hung Dat
Analysis of the root cause makes defects in supplier Hung Dat
The issues at supplier Hung Dat stem from a lack of skills in furnace operation, resulting in inadequate handling during the steel heating process, which ultimately leads to cracking and damage.
Regular maintenance of the furnace machine is crucial, as neglecting it until problems arise can lead to significant errors Common issues occur when the furnace temperature exceeds safe limits, often due to delayed oil application to the cooling unit This overheating can compromise the steel's integrity, resulting in cracking of the billet and subsequent tube code errors.
Neglecting to monitor the hardening process of the plating tube code can result in delayed responses to issues with the furnace machine, leading to increased error rates due to improper control Additionally, failing to perform timely oiling and temperature adjustments during the steel hardening process further exacerbates the likelihood of errors occurring.
The primary material used in the hardening process is mild steel; however, inconsistencies in steel codes can result in uneven hardness across measurement points, causing some areas to exceed allowable hardness levels When these materials are heated in a furnace, they can become excessively hard, leading to brittleness and breakage of the finished tube codes Additionally, if the steel has significant rust prior to heat treatment, it can create a thin film that adheres to the inner dimensions of the tube after processing.
Figure 3.21: The Fishbone diagram about the defect rate of supplier NNLT
Analysis of the root cause makes defects in supplier NNLT
The issues at supplier NNLT stem from the operator's subjective attitude while operating the CNC machine, which has resulted in dimensional inaccuracies Additionally, operators often neglect to monitor the machine's display during operation, preventing immediate resolution of problems in the process.
The CNC machine at the Zeder Vietnam factory suffers from irregular maintenance and a failure to replace the cutting tool as scheduled, resulting in diminished accuracy during the processing of finished shells Additionally, the wear on the cutting tool from operator use further compromises the precision of shell dimensions measured by calipers.
Regularly monitoring the CNC machine's screen and avoiding incorrect control methods are crucial to prevent scratches and misalignment of shells in Zeder Vietnam Additionally, improper inspection points can lead to errors, as each shell requires checks at the first, central, and last points Misidentifying these inspection points can result in inaccurate conclusions about defect dimensions, ultimately causing product returns for Zeder Vietnam.
Achievements and Limitations in Input Quality Control in Zeder Viet Nam…
• Quality Assurance Procedure: Criteria for inspection of raw material from Box Platform are very clear and have a work instruction approach with reality
Quality engineers possess advanced qualifications, strong foreign language proficiency, and exceptional management skills They bring extensive practical experience and maintain excellent relationships with their subordinates Additionally, quality engineers demonstrate flexible coordination across departments to identify the quickest and most effective solutions.
Technicians and operators possess fundamental knowledge of quality standards and are well-versed in the technical specifications for each product code during Input Quality Control They demonstrate a strong sense of responsibility, diligence, and a commitment to continuous learning, enabling them to collaborate effectively with other departments to address basic issues within their own areas.
The Input Quality Control department is fully equipped with essential tools, including grinders and stun guns, to enhance labor productivity and alleviate the workload of Technicians and Operators This advanced equipment not only streamlines the inspection process but also minimizes errors during the quality checks of incoming goods.
Besides the achievements, there are limitations in the quality control in the Input Quality Control department as follows:
• The workload is quite large, while human resources are limited
• Zeder Corporation has a checklist with specific criteria to audit suppliers, but the company doesn’t have the weight of criteria to support auditors when deciding on the audit supplier process
The high defect rate in product units can be attributed to specific causes By implementing effective measures in the Input Quality Control area, we can prevent these defects before they occur.
• Employees arrange the workplace not neatly and reasonably, creating the risk of making mistakes and spending a lot of time searching for goods and inspection equipment
• Staff also have limited technical knowledge when performing goods inspection
• The device has not been updated to the latest equipment, and the error of the measuring device is still quite high at Input Quality Control
CHAPTER 4: SUGGEST SOLUTIONS IN INPUT QUALITY CONTROL AT
4.1 Audit Supplier using Analytic Hierarchy Process to select good suppliers for support raw material in Zeder Viet Nam
Input material failures from suppliers significantly contribute to errors in the Input Quality Control (IQC) department To mitigate these issues, it is essential to select quality suppliers whose defect rates are within acceptable limits and offer reasonable pricing This strategy helps reduce defects at IQC Suppliers with high defect rates undergo regular evaluations to minimize errors before their products reach the Zeder Vietnam factory Each product code at Zeder Vietnam has specific output quality control requirements, ensuring that suppliers maintain stringent quality checks prior to shipment The IQC department collaborates closely with supplier quality engineers and the quality control teams at the suppliers' factories to ensure thorough inspections before goods are delivered to Zeder Vietnam.
At Zeder Vietnam, the current supplier evaluation checklist lacks clarity regarding the significance of various inspection elements, making it difficult to determine which factors carry more weight The author suggests implementing the AHP method to assess supplier importance, enabling a more nuanced evaluation of supplier quality By incorporating weighted criteria, auditors can identify key factors that contribute to selecting high-quality suppliers capable of consistently providing raw materials for production This approach will also assist Zeder Vietnam in identifying suppliers that meet competitive pricing and maintain strong product quality control, ultimately enhancing supplier management.
In their 2019 study, Darko et al highlight the implementation of the Analytic Hierarchy Process (AHP) for supplier selection, emphasizing its effectiveness in aligning suppliers with ZVN's quality requirements The authors advocate for the AHP method to evaluate suppliers by gathering questionnaire data from relevant departments at the Zeder Vietnam factory This approach aims to identify key factors influencing supplier selection, ultimately minimizing errors and mitigating factors that could adversely affect the supplier selection process at Zeder Vietnam.
Table 4.1: The Profile of Panelist Profile Survey the Criteria in ZVN
No Profile of Panelist Quantity Average Experience
The author gathers insights from interviewees in the quality control and purchasing departments to identify the factors influencing the supplier quality control process and selection at Zeder Vietnam factory This analysis highlights key elements affecting supplier quality, enabling auditors to pinpoint errors originating from suppliers in the Input Quality Control department Consequently, this approach aims to minimize errors from major suppliers such as Nhat Phat Tuan, Hung Dat, and NNLT at the ZVN factory.
The author conducted a thorough analysis of the supplier evaluation process at Zeder Vietnam Plant by utilizing the company's existing checklist and gathering data through questionnaires from the quality management department and relevant personnel, particularly in the Input Quality Control and purchasing departments This research highlights key factors that can simplify the evaluation for assessors and guide auditors in focusing on critical elements during their assessments.
Table 4.2: The 10 Factors that affect the most in criteria choosing a supplier in ZVN and recommend people
Sources: Author Collection and ZVN Quality Department
We will examine these factors by gathering insights from experts in the quality management department to assess their ratings After compiling data from these professionals, we will create a table to evaluate the interrelationships and influence of each factor on one another.
2 Purchasing and Supplier Management Purchasing Specialist
5 Tooling and Equipment Supplier Quality Engineer
7 Corrective and Preventive Action Supplier Quality Engineer
9 Validation and Process Control IQC Engineer
Table 4.3: The Criteria to evaluate criteria QMS Overview with redundant factors in
The author utilizes Excel to analyze the factors influencing supplier evaluation and selection at the Zeder Vietnam factory This analysis highlights the most significant factors, applying the AHP principle to establish a hierarchy that impacts the quality of materials in the Input Quality Control department.
The author calculated the CR index using Excel, resulting in a value of 0.09, which is below the threshold of 0.1, indicating that the factors analyzed are consistent with one another.
Table 4.4: The Results of analyzing ten factors in the AHP Method
The article discusses the supplier evaluation process at the Zeder Vietnam factory, highlighting the importance of a weight table for each evaluation factor It details how suppliers are selected and how their average scores are calculated by multiplying their scores by their respective weights The weighted scores, along with the ranking of standards and appropriate pricing, emphasize the significance of traceability in identifying the source of defective goods This approach minimizes the risk of defective materials entering the Zeder Vietnam factory.
Table 4.5: The weight of each criterion in choosing a supplier in Input Quality Control
3 Material Control, Storage, and Traceability 0.18 1.00
8 Customer Order and Production Capacity 0.10 4.00
The author emphasizes the importance of utilizing a Checklist to gather data from suppliers during the audit process, enhancing it with more specific criteria This refined checklist will aid in selecting suppliers that offer competitive pricing and high-quality materials for Zeder Vietnam The quality control department will periodically send this checklist to suppliers based on their delivery frequency, aiming to minimize substandard deliveries to the Input Quality Control department By employing a weighted index for each selection factor, regular audits can facilitate timely corrective actions in case of supplier defects A tailored checklist for both domestic and international suppliers will significantly assist Zeder Vietnam's Quality Control, particularly in preventing defects before raw materials arrive Additionally, the author suggests scheduling audits for suppliers with the highest performance ratings, such as Hung Dat and Nhat Phat Tuan, to implement corrective and preventive measures for any material defects identified in the Input Quality Control area.
Table 4.6: The Schedule to implement audit supplier and responsible people
Order Task Name Duration Start Finish Resource Names
1 Prepare Checklist to audit supplier Three days Tue 4/12/22 Thu 4/14/22
IQC Engineer, Supplier Quality Engineer
2 Set Time with Supplier Four days Thu 4/14/22 Tue 4/19/22
Supplier Quality Engineer, Purchase Specialist
Engineer at Supplier One day Tue 4/19/22 Tue 4/19/22
4 Gemba Walk to Reality Area in Zeder Plant Three days Wed 4/20/22 Fri 4/22/22
IQC Engineer, Quality Manager, Supplier Quality Engineer
5 The Supplier announces a specific time Two days Wed 4/20/22 Thu 4/21/22 Supplier Quality
6 Prepare human resources have experienced to audit Two days Thu 4/28/22 Fri 4/29/22
7 Audit Group goes to Supplier Two days Tue 5/3/22 Wed 5/4/22
IQC Engineer, Quality Manager, Supplier Quality Engineer,Driver
Implement the Failure Mode and Effect Analysis at Input Quality Control
FMEA (Failure Mode and Effects Analysis) is a crucial tool for manufacturing companies, particularly in the automotive spare parts sector, to prevent potential failures by identifying and eliminating faulty input components before they enter the production process This proactive approach minimizes the need for rework and other corrective measures, ultimately streamlining the Input Quality Control process By employing FMEA, companies enhance their ability to manage issues effectively when they arise, allowing for timely detection and prevention of potential failure factors This leads to a significant reduction in material defects and ensures a smoother operational flow.
In the third chapter of the ongoing fault situation in the Input Quality Control department, the author employs failure mode and effect analysis to pinpoint potential defects in major products, focusing on high defect rates from February to September 2022 This approach aims to reduce the error rate and enhance the error correction capabilities of the Input Quality Control unit The analysis reveals that the most common defects at the Zeder Vietnam factory include incorrect dimensions, rust, impurities, and dents or offsets The author further investigates the root causes of these defects and establishes a risk priority number based on severity, occurrence, and detection indices.
Table 4.7: The Risk Priority Number follows Severity, Occurrence, and Detection
RPN (Risk Priority Number) = Severity * Occurrence * Detection
Class Severity Occurrence Detection RPN
Table 4.8: The Failure Mode and Effect Analysis Table for each high defect rate of raw material in Input Quality Control
After identifying common errors in Input Quality Control, we will assess requirements and potential issues that may elevate the error rate for each product code The analysis will reveal the primary causes of potential errors leading to failures, allowing us to calculate impact factors based on severity, occurrence, and detection to establish the risk priority number For errors with a high risk priority number, we will implement preventive measures and develop contingency plans to proactively address these issues, ensuring timely interventions to prevent errors This approach aims to reintegrate raw materials into the production process swiftly, minimizing lead times and maintaining product quality.
Table 4.9: The corrective and recommended action in each defect that the authors recommend for Zeder Viet Nam
Satisfy the requirement about OD, ID, and L dimensions with engineering drawing
Wrong outside and Inside dimension
Schedule audit CNC machine in Supplier
Checking grinding machine and quality of knife before work
Raw Material must not have rust or impure before the production process
Consider the time transportation and maintenance status before receiving raw material
Raw Material must not have dents and offset
Inside dimension stick excess material
Add hardness criteria and require test results of steel's physical composition before use
The Failure Mode and Effect Analysis (FMEA) identifies key factors contributing to high error rates in the Input Quality Control (IQC) Area To effectively implement the FMEA plan, a schedule and designated responsibilities for each task are proposed This framework allows for the evaluation of the performer's completion level and the assessment of work progress before immediate deployment Below is a detailed implementation plan for the FMEA at the Zeder Vietnam factory.
Table 4.10: The Schedule implements Failure Mode and Effect Analysis in Zeder Viet
Task Name Duration Start Finish Resource Names
IQC Engineer, Supplier Quality Engineer
Open FMEA method courses for some related in
IQC Technician, Supplier Quality Engineer
Two days Sat 9/3/22 Sun 9/4/22 Supplier Quality
The engineer in the supplier makes an appointment with IQC
Two days Tue 9/6/22 Wed 9/7/22 IQC Engineer
Present high defect raw material of supplier in meeting and coordinator to solve the high defect rate
Three days Thu 9/8/22 Sat 9/10/22 IQC Engineer, IQC
Quality system management poses a significant challenge for businesses, particularly in the manufacturing sector For Zeder Vietnam, a major player in auto parts production, enhancing product quality is crucial for successfully entering the U.S market The company is committed to investing in product improvement to meet the demands of competitive global markets Zeder Vietnam aims to establish itself as a leading auto parts manufacturer worldwide by prioritizing top-quality products that resonate with customers.
The author, through university studies and an internship at Zeder Vietnam, has utilized acquired knowledge and experience to complete the thesis titled "Analysis of the Current Situation of Quality Control at the Input Quality Control Department in Zeder Vietnam Factory." Guided by Ms Nguyen Thi Anh Van and the quality management team, particularly the Input Quality Control Team, the author identified the primary causes of errors in the department Employing methods learned in university, such as the AHP Method, the author analyzed data from Input Quality Control and discovered that errors primarily stem from suppliers and insufficient detail in product quality inspection standards Consequently, the author proposes solutions to address these issues at Zeder Vietnam Factory.
Drawing from academic knowledge and practical experiences gained during an internship at Zeder Vietnam, the author aims to propose effective solutions for enhancing input quality control at the factory This opportunity to practice at a leading global auto parts company reflects the author's aspirations for professional growth The author expresses gratitude to Ms Nguyen Thi Anh Van and the Zeder Vietnam board of directors for their invaluable support in this journey toward improving quality sector knowledge.
1 Introduction about Zeder Viet Nam (12/12/2022) Retrieved from: https://zedercorp.com/
2 Thomas L Saaty (1980) Multicriteria Decision Making: The Analytic Hierarchy Process: Planning, Priority Setting, Resource Allocation
3 Leal, J E (2020) AHP-express: A simplified version of the analytical hierarchy process method MethodsX,https://doi.org/10.1016/j.mex.2019.11.021
4 Darko, A., Chan, A P C., Ameyaw, E E., Owusu, E K., Pọrn, E., & Edwards,
D J (2019) Review of application of analytic hierarchy process (AHP) in construction International Journal of Construction Management, 19(5) https://doi.org/10.1080/15623599.2018.1452098
5 Saida, E., & Taibi, N (2021) ISO 9001 Quality Approach and Performance Literature Review European Scientific Journal ESJ, 17(1) https://doi.org/10.19044/esj.2021.v17n1p128
6 Theofilou, P (2013) Quality of life: Definition and measurement Europe’s Journal of Psychology, 9(1) https://doi.org/10.5964/ejop.v9i1.337
7 Edward Demming( 1982) The Quality, Productivity, and Competitive Position
8 Peter Ducker (2009) The Innovative and Entrepreneurship
10 The Internation Organization for Standard 9000:2015(2015)
11 American Society for Quality, Quality Resources Retrieved from: https://asq.org/
12 Patyal, V S., & Koilakuntla, M (2017) The impact of quality management practices on performance: an empirical study Benchmarking: An International Journal, 24(2), 511-535 https://doi.org/10.1108/BIJ-11-2015-
13 Brugha C (1998) ‘Structuring and Weighting Criteria in Multi-Criteria Decision Making (MCDM),’ Trends in Multicriteria Decision Making:
14 My Nguyen, L T., Tran, T., van Pham, T., Nguyen, T T., Thu Le, H T., Phuong Trinh, T T., & Nghiem, T T (2021) Factors affecting successful quality assurance implementation in Vietnamese higher education: A qualitative study Qualitative Report, 26(2) https://doi.org/10.46743/2160-
Conversation between Junior IQC Engineer Tran Van Canh and me in the Input Quality Control area
Me: Can I suggest some solution for the improvement of the high defect rate of supplier and raw material codes in the Input Quality Control area now?
Mr Canh: Of course, you can do it, but I have some ideas for you You can research about 8D and FMEA methods to solve it
The data from the Input Quality Control Team's database indicates that the majority of defect rates in our area stem from primary suppliers and certain raw material issues I would like to propose a method to enhance the situation regarding these defect rates.
Mr Canh expressed that while the idea is promising, it is essential to address the challenges in input quality control He emphasized the need for a specific plan to enhance this area and inquired about the associated costs for implementation.
I will present a plan for implementing Failure Mode and Effect Analysis (FMEA) along with a checklist for auditing suppliers using the Analytic Hierarchy Process (AHP) method, which is cost-effective in our area.
Mr Canh: Ok Let us do it I am waiting for your proposal for planning
Me: Thank you very much I will have the results of it soon
E x tre mely Ver y S tro ng ly Str o ng ly M o dera tely E qu a lly M o dera tely Str o ng ly Ver y S tro ng ly E x tre mely B
QMS Overview and Management Responsibility
Material Control, Storage, and Traceability
Customer Order and Production Capacity
Material Control, Storage, and Traceability
Customer Order and Production Capacity
Customer Order and Production Capacity
Preventive Action 9 8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 Customer Order and
Preventive Action 9 8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 Validation and Process
Customer Order and Production Capacity
Process Control 9 8 7 6 5 4 3 2 1 2 3 4 5 6 7 8 9 Validation and Process