Analyzing quality control at input quality control in zeder viet nam plant

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 CONTROL AT INPUT QUALITY CONTROL IN ZEDER VIET NAM PLANT LECTURER: MASTER NGUYEN THI ANH VAN STUDENT : PHAM TUAN HUNG SKL010175 Ho Chi Minh City, April 2023 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING THESIS GRADUATION ANALYZING QUALITY CONTROL AT INPUT QUALITY CONTROL IN ZEDER VIET NAM PLANT Student Implement: PHAM TUAN HUNG Student ID: 19124001 Major: INDUSTRIAL MANAGEMENT Advisor: Master NGUYEN THI ANH VAN Ho Chi Minh City, April 2023 COMMENTS OF ADVISOR HCM City, …./…./…… Advisor Van Nguyen Thi Anh Van Trang i COMMENTS OF REVIEWER HCM City, …./…./…… Reviewer Trang ii ACKNOWLEDGEMENTS Before starting my thesis, the author would like to sincerely thank the dedicated and enthusiastic teaching lecturers in the Facility of High-Quality Training at Ho Chi Minh City University of Technology and Education during the course This has brought the author really useful knowledge and conveyed the practical experience distilled during the work of the teachers Thanks to that, it helped me have a deeper insight and valuable knowledge to help me in my future career development path The author would also sincerely thank Ms Nguyen Thi Anh Van for her enthusiastic guidance in helping the author write my thesis so that the author could complete the report the best way The author has consecutive hope with her in defense of my graduate thesis in this equally challenging and exciting field of Quality In addition, the author wants to thank the Board of Directors of Zeder Vietnam Company for giving me a great opportunity to accompany the company Moreover, the author also wants to say thank you to all of colleagues in the Quality department at the Zeder Vietnam factory Especially all the brothers on the Input Quality Control Team have greatly supported me during my internship It has helped me have a deeper perspective on my future career path This is the first time the author has experienced a real working environment, the thesis is hard to avoid errors and mistakes The author hopes to receive comments from teachers and companies Finally, the author would like to wish Lecturer and Zeder company a lot of health and success in the future HCM City, …./…./…… Student Name Hung Pham Tuan Hung Trang iii LIST OF ABBREVIATION Abbreviation Explanation ZVN Zeder Viet Nam Plant IQC Input Quality Control QMS Quality Management System NCR Non-Conformative Report QC Quality Control EHS Environment-Healthy-Safety ISO 9001:2015 International Organization for 9001:2015 AQL Acceptable Quality Level AHP Analytic Hyerarchy Process IAF International Accreditation Forum FMEA Failure Mode and Effect Analysis AQL Acceptable Quality Level SQE Supplier Quality Engineer SCAR Supplier Corrective Action Report OD Outside Dimension ID Inside Dimension L Length CNC Computerized Numerical Control Trang iv Standardize LIST OF TABLE Table 1.1: The Basic Information about Zeder Viet Nam Table 3.1: Some Basic Measurement Quality Product Methods in Zeder Viet Nam………………………………………………………………………………… 32 Table 3.2: Incoming Material Scorecard in Input Quality Control at Zeder Viet Nam………………………………………………………………………………… 37 Table 3.3: The Six Quality Insection Levels in Input Quality Control at Zeder Viet Nam…………………………………………………………………………… ……42 Table 4.1: The Profile of Panelist Profile survey the Criteria in ZVN………….…….61 Table 4.2: The 10 Factors affect the most criteria for choosing a supplier in ZVN and recommend people………………………………………………………………… 61 Table 4.3: The Criteria to evaluate criteria QMS Overview with redundant factors in AHP Method……………………………………………………………………… …61 Table 4.4: The Results of Analyzing ten factors in the AHP Method……………………………………………………………………………… 62 Table 4.5: The weight of each criterion in choosing a supplier in Input Quality Control 63 Table 4.6: The Schedule to implement audit supplier and responsible people 65 Table 4.7: The Risk Priority Number follows severity, occurrence, and detection 66 Table 4.8: The Failure Mode and Effect Analysis Table for each high defect rate of raw material in Input Quality Control……………………………………………… 68 Table 4.9: The corrective and recommended action in each defect the author recommends for Zeder Viet Nam………………………………………………… …68 Table 4.10: The Schedule implement Failure Mode and Effect Analysis in Zeder Viet Nam Plant……………………………………………………………… ……………69 Trang v LIST OF FIGURE Figure 1.1: The Zeder Corporation Logo Figure 1.2: The Location of Zeder Corporation in the World Figure 1.3: The fire bands belong Zeder Corporation Figure 1.4: The Front of Image about Zeder Plant Viet Nam Figure 1.5: The Organizational Structure of Zeder Viet Nam Figure 1.6: The Control Arm with brand Whiteline in Zeder Viet Nam 10 Figure 1.7: Products Swaybar in Zeder Viet Nam 11 Figure 1.8: The Bushing Product from Zeder with brand Nolathane in Amazon Platform 12 Figure 1.9: The Bushing Product in Zeder Plant Viet Nam .12 Figure 1.10: The Functional Units in Quality Department at Zeder Viet Nam .14 Figure 2.1: The Example about Pareto Chart 22 Figure 2.2: The Example about Fishbone Diagram 25 Figure 3.1: The Certificate of ISO 9001:2015 at Zeder Viet Nam 29 Figure 3.2: Document System at Box Platform in Zeder Viet Nam………………….30 Figure 3.3: The Flowchart of Quality Control in Zeder Viet Nam………………… 31 Figure 3.4: Caliper with brand Mitutoyo in Zeder Viet Nam……………………… 32 Figure 3.5: Infrared laser heat gun used to measure powder coating thickness…… 33 Figure 3.6: Manual mechanical hardness Tester…………………………………… 33 Figure 3.7: Non-Conforming Report Paper in Zeder Viet Nam………………….… 34 Figure 3.8: Seal suitable quality standards……………………………………………35 Figure 3.9: Detention Card QA01-F05 in Zeder Viet Nam………………………… 35 Figure 3.10: The Quantity of incoming material overall in Input Quality Control at Zeder………………………………………………………………………………… 36 Figure 3.11: The percentage of domestic and abroad supplier in Zeder Viet Nam………………………………………………………………………………… 38 Figure 3.12: The process inspection the raw material in Input Quality Control in Zeder Viet Nam…………………………………………………………………………… 39 Figure 3.13: Defective Goods Retention Area with "QA01-F05" tags in Input Quality Control…………………………………………………………………………….… 40 Trang vi Figure 3.14: The inspection length tube by caliper rule……………………………………………………………… ……………….….42 Figure 3.15: The inspection of control arm material in car system………………… 43 Figure 3.16: The inspection space between two holes of the control arm………………………………………………………………………………… 44 Figure 3.17: The inspection outside dimension in Shell…………………………… 45 Figure 3.18: The Pareto Chart of Defect Supplier per Quantity in Input Quality Control at Zeder Viet Nam…………………………………………………………………….47 Figure 3.19: The Fishbone Diagram about defect rate of supplier Nhat Phat Tuan………………………………………………………………………………… 49 Figure 3.20: The Fishbone diagram about defect rate of supplier Hung Dat…………………………………………………………………………………….50 Figure 3.21: The Fishbone diagram about the defect rate of supplier NNLT ……………………………………………………………………………… ………52 Figure 3.22: The Pareto Chart of quantity per defects in Input Quality Control at Zeder Viet Nam…………………………………………………………………………… 53 Figure 3.23: The Defect of Outside Dimension Inside Dimension and Length (From Left to Right) in Zeder Viet Nam……………………………………………….….…54 Figure 3.24: The Fishbone diagram about wrong dimension OD, ID and L……………………………………………………………………………………….54 Figure 3.25: The Defect of Rust, Impure in Input Quality Control area……………………………………………………………………………………55 Figure 3.26: The Fishbone Diagram about Rust, Inputre Defect……………………………………………………………………………… 57 Trang vii Contents COMMENTS OF ADVISOR i COMMENTS OF REVIEWER ii ACKNOWLEDGEMENTS iii LIST OF ABBREVIATION iv LIST OF TABLE v LIST OF FIGURE vi INTRODUCTION TO THE THESIS 1 Introduction Objective Scope and object Research methodology Structure of Thesis CHAPTER 1: INTRODUCTION ABOUT COMPANY 1.1 General Information 1.1.1 Historical Foundation and Development Zeder Corporation 1.1.2 General Information about Zeder Viet Nam 1.1.3 Organizational Structure 1.2 The Core Product of Zeder Viet Nam 1.2.1 Control Arm .9 1.2.2 Swaybar 10 1.2.3 Bushing 11 1.3 Quality Department in Zeder Viet Nam 12 1.3.1 General Information 12 1.3.2 Input Quality Control in Zeder Viet Nam 14 CHAPTER 2: LITERATURE REVIEW 16 2.1 Quality 16 2.1.1 Definition of Quality 16 2.1.2 Quality Management System 17 2.1.3 Quality Inspection 17 2.1.4 Quality Assurance 18 2.1.5 Quality Audit 18 2.2 Quality Control 19 Trang viii