[Seminar] Introduction to Quality Management - Advancing with the Five Gen Principles and Quality Response
Quality creates the future. A serious commitment to quality starts today.
Understanding the essence through the "Five Gen" principle The first step in quality assurance is to have the right mindset. By thoroughly implementing the "Five Gen" principle, which incorporates the actual site, actual items, and reality along with points of change and fundamental principles, we can discern the essence of problems. Let's aim for quality improvement through the dual approach of "quality assurance," which creates a system to prevent defective products, and "quality control," which focuses on early detection and correction. Furthermore, collaboration with related departments, from development to manufacturing and sales, is essential. We will establish a preventive system through "front-loading," which incorporates quality from the design stage, not just responding after problems occur. Enhancing problem-solving capabilities with a framework When a quality issue arises, the first step is to understand the current situation and implement "temporary measures," followed by identifying the root cause and planning "permanent measures." A powerful tool in this process is "5 Whys analysis." We must consciously avoid blaming others and objectively pursue the true cause. The problem-solving process can be effectively advanced using a systematic framework like DMAIC (Define, Measure, Analyze, Improve, Control). Let’s acquire practical skills through specific case studies.
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1. Quality Response / Mindset: Five Gen Principles 1-1. Five Gen Principles / Three Gen Principles 1-2. Quality Assurance and Quality Control 1-3. Importance of Interdepartmental Collaboration 1-4. Aim for the Introduction of Front-Loading Process 2. Examples of Quality Response / Basics: Use and Combination of Frameworks 2-1. Situation Confirmation: Temporary Measures / Permanent Measures 2-1-1. Let's Advance the Why-Why Analysis: The Key is Not to Blame People! 2-1-2. How to Organize After Conducting the Why-Why Analysis 2-1-3. Let's Analyze Using the Why-Why Analysis 2-2. Be Aware of the Order of Progression: Using DMAIC as an Example 2-2-1. Case Study: Defective Case Screws / Use of Insert Nuts 2-2-2. Case Study: Defective Appearance at Panel Edges / Variation Due to Changes in Processing Specifications 2-3. What is the Latest Hou-Ren-Sou? / Organizational Building and Communication 3. Summary: Important Aspects of Quality Response (How to Act as a Whole Company) 3-1. People, Processes, Systems (Environment)
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You can systematically understand the overall picture of quality management: From the mindset when quality issues arise to the formulation of specific solutions and the implementation of recurrence prevention measures, you can comprehensively learn the entire flow. You can acquire practical frameworks: Through actual case studies, you can practically learn effective problem-solving frameworks such as the "5 Whys" analysis and DMAIC. You will develop the ability to identify root causes: You can cultivate a thought process to pinpoint true causes without being distracted by superficial phenomena and to establish permanent countermeasures. You will understand the importance of interdepartmental collaboration and improve communication: You will recognize the significance of collaboration with other departments in quality management and gain insights to contribute to overall quality improvement in the organization through smooth communication. You can seize the opportunity to transform your company's quality culture: By understanding the concept of front-loading and the importance of people, processes, and systems, you can enhance the overall quality awareness of the organization and take the first step towards building a better quality culture.
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A Challenge to Transform "Impossible" into "Possible" in Design Quality One day, we received a development project for a new wearable device that pursued unprecedented thinness and lightness. The client's request was, "It must be completely waterproof while not compromising on design at all." The project initially ran aground due to this conflicting challenge. The thickness of the casing was just a few millimeters. With conventional waterproofing technology, it was not only difficult to protect the internal precision instruments but also to maintain design integrity. While many engineers threw in the towel, declaring it "impossible," the challenge at Kamigami Corporation began. Our team first thoroughly utilized 3D data as part of our DX promotion, repeatedly conducting simulations in a virtual space. This was a crucial process to eliminate rework and improve development productivity. Drawing on the experience and insights that our representative, Suzuki, had cultivated over many years in developing some of the world's thinnest waterproof designs for smartphones, we meticulously analyzed every possible water intrusion route, leaving no 0.1 millimeter gap unchecked. We pursued the highest design quality and devised a new waterproof structure that overturned conventional wisdom.