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    18.1 Cost of Poor Quality

    Uploaded by

    Vikas Kashyap
    The document contains data on the cost of poor quality for a company from April 2007 to March 2008. It includes tables tracking metrics like customer returns, in-house rejections, rework costs, and the cost of poor quality as a percentage of sales each month. A line graph shows the trend of the cost of poor quality as a percentage of sales over this time period, which remained around 0-2% each month. The document was prepared to analyze the company's cost of poor quality metrics and trends over a one year period from 2007-2008.

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    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd

    18.1 Cost of Poor Quality

    Uploaded by

    Vikas Kashyap
    226 views11 pages
    The document contains data on the cost of poor quality for a company from April 2007 to March 2008. It includes tables tracking metrics like customer returns, in-house rejections, rework costs, and the cost of poor quality as a percentage of sales each month. A line graph shows the trend of the cost of poor quality as a percentage of sales over this time period, which remained around 0-2% each month. The document was prepared to analyze the company's cost of poor quality metrics and trends over a one year period from 2007-2008.

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    18.1 Cost of Poor Quality.xls

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    The document contains data on the cost of poor quality for a company from April 2007 to March 2008. It includes tables tracking metrics like customer returns, in-house rejections, rework costs, and the cost of poor quality as a percentage of sales each month. A line graph shows the trend of the cost of poor quality as a percentage of sales over this time period, which remained around 0-2% each month. The document was prepared to analyze the company's cost of poor quality metrics and trends over a one year period from 2007-2008.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    226 views11 pages

    18.1 Cost of Poor Quality

    Uploaded by

    Vikas Kashyap
    The document contains data on the cost of poor quality for a company from April 2007 to March 2008. It includes tables tracking metrics like customer returns, in-house rejections, rework costs, and the cost of poor quality as a percentage of sales each month. A line graph shows the trend of the cost of poor quality as a percentage of sales over this time period, which remained around 0-2% each month. The document was prepared to analyze the company's cost of poor quality metrics and trends over a one year period from 2007-2008.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 11
    At a glance
    Powered by AI
    The document tracks various quality and performance metrics for suppliers over multiple months. Metrics like customer PPM, supplier PPM, productivity, inventory turns, 5S score etc are being monitored on a monthly basis against set goals.

    Metrics like customer PPM, supplier PPM, productivity, inventory turns, 5S score, breakdown hours, quality audit percentage etc. are being tracked for suppliers on a monthly basis.

    Some metrics like customer PPM, supplier PPM show fluctuations over time but generally trend downwards indicating improved performance. 5S score and quality audit percentage have remained steady but below set targets. Inventory turns and productivity show slight improvements over the period.

    Cost of Poor Quality ( 2014-15 )

    Month

    Apr.,07

    May.,07

    Jun.,07

    Jul.,07

    Aug.,07

    Sep.,07

    Oct.,07

    Nov.,07

    Dec.,07

    Jan.,08

    Feb.,08

    Mar.,08

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    Feb.,08

    Mar.,08

    Dispatch Value
    Cost Of Poor
    Quality
    COPQ % of sales

    Cost of Poor Quality Trend ( 2007~08 )

    % of sales

    12.00

    10.00

    8.00

    6.00

    4.00

    2.00

    0.00
    Apr.,07

    May.,07

    Jun.,07

    Jul.,07

    Aug.,07

    Sep.,07

    Month
    Prepared By :-

    Oct.,07

    Nov.,07

    Dec.,07

    Jan.,08

    Prepared By :-

    Cost of Poor Quality


    Apr.,07

    May.,07

    Jun.,07

    Jul.,07

    Aug.,07

    Sep.,07

    Oct.,07

    Nov.,07

    Dec.,07

    Jan.,08

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    #DIV/0!

    Inhouse Rejection
    Value
    Customer Returned
    Rejection value
    (including
    transportation and any
    penalty by customer)
    Inhouse Rework value
    (part replaced+reprocessing
    cost+manpower cost)
    Rework cost at
    customer end (if any)
    Travelling Cost for
    review and analysis
    Cost of Poor Quallity
    Dispatch Value
    COPQ % of sales

    Feb.,08

    Mar.,08

    #DIV/0!

    #DIV/0!

    Sr. No.

    Indicator

    Data
    Source

    Metric

    Base
    Line

    Goal

    5S Score

    Supplier

    32%

    60%

    Customer Quality PPM


    (Talbros)

    Tallbros

    PPM

    1000

    Customer Quality PPM


    (Overall customer)

    Supplier

    PPM

    4356

    2178

    Supplier in house PPMQuality (scrap+ Rework)

    Supplier

    PPM

    7054

    3527

    Breakdown

    Supplier

    Hrs/month

    72

    30

    Productivity

    Supplier

    Sale/Salary

    13.89

    14.4

    Inventory Turns

    Supplier

    Turns

    12.37

    13.6

    Delivery schedule
    adherence (Overall)

    Supplier

    97.9

    97.9

    Accident frequency rate /


    MONTH

    Supplier

    Nos./ Month

    10

    Mfg Excellence Score


    (Quarterly)

    QGS Audit

    36%

    60%

    11

    No. of QW Kaizens

    Supplier

    Nos./ Month

    16

    12

    Visual Management

    QGS Audit

    Level

    13

    Vendor Performance
    rating-QHT

    Talbros

    14

    Delivery PerformanceQHT

    Talbros

    15-Apr 15-May 15-Jun

    15-Jul

    15-Aug 15-Sep

    15-Oct 15-Nov 15-Dec 16-Jan

    32%

    32%

    32%

    32%

    32%

    32%

    32%

    32%

    32%

    32%

    364

    6857

    9671

    5523

    12934

    7580

    199

    98

    272

    758

    431

    3434

    504.199

    1457

    2050

    555

    368

    1855

    546

    5462

    4398

    5477

    3695.3

    1245

    1852

    1996

    2700

    3101

    3677

    96.5

    139.5

    219.4

    170

    170

    155

    166

    149

    159

    62

    14.6

    15.8

    15.7

    14.3

    15.8

    15.9

    12.7

    13.7

    12.2

    15.23

    17.35

    32.28

    9.3

    11.78

    22.6

    12.8

    20

    18

    107

    98

    108

    96

    91

    97

    95

    88

    88

    100

    36%

    36%

    36%

    36%

    36%

    36%

    36%

    36%

    36%

    36%

    100

    52

    100

    89

    100

    99

    87

    90

    96

    100

    90

    100

    87

    100

    100

    98

    89

    73

    93

    86

    16-Feb 16-Mar

    16-Apr

    44%

    44%

    44%

    156

    248

    185

    723

    543

    458

    3254

    3165

    2956

    78

    49

    120

    11.7

    11.9

    12.35

    13.5

    15.8

    12.1

    99

    100

    100

    44%

    44%

    44%

    99

    100

    76

    100

    % SCORE

    A MJ JuA S ON D J F MApr'16
    5# # # # # # # # # # # # #
    Ta# # # # # # # # # # # # #

    PPM
    Target

    5'S Score

    70%
    PPM
    Target

    60%
    50%
    40%

    PPM
    Target

    30%
    20%
    10%
    0%
    Apr'1 May' Jun'1 Jul'15 Aug' Sep' Oct'1 Nov' Dec' Jan'1 Feb'1 Mar' Apr'1
    5
    15 5
    15 15 5
    15 15 6
    6
    16 6

    Customer Quality PPM (Talbros)


    PPM

    14000

    12934

    12000
    9671

    10000
    8000

    7580

    6857
    5523

    6000
    4000
    2000364

    199

    98

    272

    248

    185

    0
    Apr'1 May' Jun'1 Jul'15 Aug' Sep' Oct'1 Nov' Dec' Jan'1 Feb'1 Mar' Apr'1
    5
    15 5
    15 15 5
    15 15 6
    6
    16 6

    Axis Title

    Customer Quality PPM (Overall customer)


    4000
    3434
    3500
    3000
    2050
    2500
    1855
    2000
    1457
    1500
    758
    555
    546
    543 458
    1000
    504.199
    431
    368
    500
    0
    Apr'1 May' Jun'1 Jul'15 Aug' Sep' Oct'1 Nov' Dec' Jan'1 Feb'1 Mar' Apr'1
    5
    15 5
    15 15 5
    15 15 6
    6
    16 6

    Apr'15

    May'15

    Jun'15

    Jul'15

    Aug'15

    Sep'15

    Oct'15

    Nov'15

    Dec'15

    Jan'16

    Feb'16

    364

    6857

    9671

    5523

    12934

    7580

    199

    98

    272

    156

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    Apr'15

    May'15

    Jun'15

    Jul'15

    Aug'15

    Sep'15

    Oct'15

    Nov'15

    Dec'15

    Jan'16

    Feb'16

    758

    431

    3434

    504.199

    1457

    2050

    555

    368

    1855

    546

    723

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    Apr'15

    May'15

    Jun'15

    Jul'15

    Aug'15

    Sep'15

    Oct'15

    Nov'15

    Dec'15

    Jan'16

    Feb'16

    5462

    4398

    5477

    3695.3

    1245

    1852

    1996

    2700

    3101

    3677

    3254

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    1000

    Apr'16

    248

    185

    1000

    1000

    Mar'16

    Apr'16

    543

    458

    1000

    1000

    Mar'16

    Apr'16

    3165

    2956

    1000

    1000

    Supplier in house PPM-Quality


    AxisTitle

    Mar'16

    6000
    5000
    4000
    3000
    2000
    1000
    0

    5477

    5462
    4398

    3695.3
    1245

    1852 1996

    2700

    MONTH

    3101

    3677

    3165 2956

    (scrap+ Rework)

    scrap+ Rework)

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