Quality Defect Management Software with Rejection RCA

The record

From a defect to a root cause: the record

Most plants record rejections somewhere. Fewer connect them to what the equipment was doing. The quality maintenance pillar asks which conditions of the equipment, material and method produce good product, and how to keep them. That starts with a consistent record of each defect: what, where, when, how many and on which equipment, then an analysis of why.

MaintWiz records each rejection with its equipment, shift, phenomenon and defect class, and the rejection RCA classes the reason by 4M, so equipment-caused defects go to maintenance (Figure 2).

From a defect to a standard

The quality maintenance loop in the QM module

1. 1

   Record the defect

2. 2

   Run the rejection RCA

3. 3

   Read the QD matrix report for repeat defects

4. 4

   Set the 4M conditions as checks in the CIL or PM standard

5. 5

   Verify with defect data

maintwiz.comAI CMMS built for TPMWhatsApp us+91 93459 29168Book a demo

JIPM, the Japan Institute of Plant Maintenance, lists quality maintenance among the four core pillars of TPM, the pillars it describes as directly related to reducing loss in the production process.

Module scope

What does the QM module include?

A quality defect matrix is a table that relates each defect type to the process steps or equipment conditions that can cause it, so that the team knows which conditions to control. The QD matrix report counts rejections by phenomenon and area (Figure 3), and the free QM matrix sets the 4M condition, its value and its check frequency for each quality characteristic (Figure 4).

A QA matrix: quality characteristic to 4M condition

ILLUSTRATION: example conditions for a filler; each cell is a condition to hold and how often to check it

Quality characteristic	Machine	Method	Material	Man
Fill weight	Nozzle wear in limit, check each shift	Fill set point held, check at start-up	Product temperature in range, each batch	Operator trained on set-up, check yearly
Seal integrity	Seal bar clean and flat, check each shift	Seal dwell time held, check at start-up	Film lot approved, each reel	Operator trained on seal check, check yearly

ILLUSTRATION: wording of the conditions is an example, set the values for your own line

maintwiz.comAI CMMS built for TPMWhatsApp us+91 93459 29168Book a demo

Paper vs system

Paper and spreadsheets versus a system for defects

How fast can we start?

The MaintWiz roll-out takes 6 to 8 weeks, with easy Excel uploads of equipment, defect types and people, and guided project management by the MaintWiz implementation team. Defect categories, RCA formats and report layouts are set up with each plant, and the QM module holds the defect, analysis and complaint records next to the other TPM records.

Who uses it

Who uses the QM module?

From defect record to equipment condition

• Record the defect with its phenomenon, the equipment and the quantity.
• Run the rejection analysis and record the root cause.
• Update the QD matrix: which process conditions affect this defect?
• Turn the conditions into standards that operators and maintenance can check.
• Track the action to closure and watch whether the defect recurs.

Corrective actions are tracked like other abnormalities in the abnormality register, with an owner and a target date.

Walk a complaint from register to closed action in a demo

What you will see in the demo

• A defect recorded against equipment with its phenomenon and quantity.
• Rejection root-cause analysis and the QD matrix report.
• Complaints tracked by status in the complaint register.
• The QM dashboard: rejection RCA compliance, rejections by facility, complaints by status and defect phenomena.
• Data exported to XLS and PDF.

Book a demo and see this module on your own records.

FAQ

Frequently asked questions