DEFINITIONS OF EACH OF THE 20 TOOLS OF PROCESS CONTROL

1. Q.C. Process Sheet- This chart lists the Quality Control items- Standards,
Specifications, and characteristics of each process. It also includes the names
of the persons who are responsible for quality control and the Q.C.
2. Set Up Change Manual- This is used on the Assembly line as a guide to
correctly set up a machine and designates which parts are to be used for this
set up process.
3. Standard Worksheet A diagram displayed at each job site indicating the
flow of each operators process. It also indicates quality checkpoints, safety
warning signal and standard in process stock.
4. Abnormal Situation Rules Flow charts stating correct method of handling
unusual/abnormal situations at the assembly line.
5. Quality Control Points Used To Check Products Results These sheets are at
the work stations indicating the process and Quality Control points used to
check that particular process such as touch method, visual, and the use of
visual aids.
6. My Check Points-Machine Conditions-Factors - A check sheet used by
technicians to set parameters for the machines such as correct temperature,
correct press time, etc.
7. Group Leader Check Points A Group Leader Check Point Sheet is used to
monitor the 4 Ms which are Machine + Method + Man + Material. A group
leader checks and monitors the following:

1. All necessary check sheets are at the work station

2. Check sheets are filled out properly
3. Fail-safes are present and working properly
4. Jig surfaces are clean and not worn
5. All samples needed are present
6. Materials being used are correct and of acceptable quality
7. Educating the operators on proper procedure
8. Making sure the operators are following the process
9. Making sure operators are checking quality
10. Initial training and monitoring new operators
11. Making sure his\her operators are observing the 5 Ss
12. Making sure scrap and rework boxes are being utilized
13. Initial sampling of parts for quality checks

These items may be listed on a check sheet and are monitored and logged on a
Day to day basis.
8. Start Up and First Article Check Sheet A check sheet used by the operators
to check a process at the start of a production run or after a change in the
process. This corresponds to the Set Up Change Manual.
Example: 1. Bolt inserter OK
2. Glue machine Ok
3. Light test OK

9. Process Defect Data Sheet Sheets kept when a 100% inspection process is
being used on a particular product to determine problem areas.
10. Start Of Operation Check Sheet A sheet used to check particular factors
before the start of a process such as an equipment operation check, dies and
jigs check, safety equipment check, and failsafe functions check. This is
checking #6 and #7.
11. Abnormality Records Book located in an assigned location on the assembly
line used to log any abnormal/unusual conditions that may occur. Preventive
actions may also be logged along with the date and the action taken to correct
the abnormality.
12. Sealer Control Chart Chart used to monitor amount the sealer used to
bond lens to housing.
13. A Sign Stating That This Is A New Line A notification at the Start of
Production (S.O.P.) indicating a new production line and the date production
started. This New Line notification should remain posted for 6 months.
14. A Sign Posted Explaining That This Is A Critical Process A notification over
a particular workstation indicating an important step in the production
process.
15. Failsafe This refers to the low cost, highly reliable devices or innovations
that both detect abnormal situations before they occur at a production
process, or once they occur, will stop the machines or equipment and prevent
the production of defective products.
16. Actual Part To Test Failsafe Defective dummy sample used for checking a
failsafe process. These should be located in a cabinet next to the operating
line.
17. Boundary Sample Sample of a maximum acceptable level of a defect, which
is tagged and logged in a defect journal and used to determine acceptable or
rejectable defects. The Q.C. Supervisor, Q.C. Manager, Q.C. Director and the
Q.C. Process Engineer must approve boundary samples.
18. Measurement Tools Precision tools such as calipers, micrometers, scales,
etc. used to measure dimensions or weights.
19. Scrap or Repair Box A designated container (red for scrap, yellow for
repair) to hold parts that are not repairable and are classified as scrap and
items which are considered reworkable.
20. Call Light A signal, which lights up to show at a glance the current state of
work operations. A call light will allow speedy corrective action to be taken
when a problem arises.