TDR (TOTAL DEFECT REDUCE)
By MUSTAFIJUR RAHMAN
Theory & Application
Author
Mustafijur Rahman
QA, Technical Services Specialist & Consultant
LSSGB, ISO QMS 9001:2015, QM, OM, PM Certified
Mail:mustafijcertifiedaudit@[Link]
Mobile: +8801954577058 (WhatsApp/IMO)
LinkedIn: MUSTAFIJUR RAHMAN
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Dedication
This book is dedicated to publish TDR (Total Defect Reduce) Method in all over
the world and spread this method in everyone so that people can apply this
method and benefited by reducing defect. This books is one kinds of research
paper where I mention TDR method with application and example.
Hopefully, I say it help the man to reduce defect.
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Total Defect Reduce
TDR is the very easy way to reduce defect in short time by
easy analyses. Only 3 person is enough to do this method but
project leader must be talent, technical and active to drive this
method. This method not only reduce defect, ensure Goods
quality and good working environment, this method reduce
product making cost and wastage also. TDR is so much effective
method for reducing every kinds of defect by hour by hour.
Total Defect Reduce
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TDR method follow LP-PDOR roles
LP-PDOR :
[Link]
[Link] plan
3. Defect Overview
4. Review .
That is:
1. Leadership
I. Leader selection
II. How to lead for TDR plan setup
III. Study and research about full project plan and
Customer requirement for getting Customer
satisfaction.
IV. Process plan analyses and follow-up plan
V. Have good communicational skills English and
Computer skills
VI. Must have managing, presentation skill & train up
skills.
VII. Keep all kinds of record
VIII. Keep skills of any kinds of problem solution hand over
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2. Process plan
I. Train up section wise manpower to do right things.
II. Ensure working environment by OMDC method
(OMDC Method for making smart working place
1 .Order for need
2 .Missing find out
3 .Decorate everything
4 .Clean work place)
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[Link] & Waste reduce by IM3P method
(IM3P is for Cost and waste reduce
1. Inventory manage first
2. Manpower manage
3. Process measure and use for need
4. Process time reduce
5. Production Balance)
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IV. Follow-up check-sheet analyses
V. Category wise produce first 1 pcs and output than
measure and match everything customer standard if it
okay then start bulk
VI. Hourly Sample match method & Customer requirement
matching
(Hourly Sample match method is that one person who expert
at customer requirement and sample matching, he full
reviews 1 or some pcs products for matching customer
requirement and sample 1 hour later to later.)
VII. Follow Ambulance method
(Ambulance method is an emergency method.
If some where any problem arise, hare section wise sound
ringing by indicating this sound top management can
guesses, who need to go there for fix this problem as
much as possible. For this problem, this topic specialist
need to go there because of giving lifetime solution.)
[Link] Defect Overviews
I. 1st Hour DHU, defect research how to stop completely.
II. 2nd Hour DHU, defect research, some defect why repeat
analyses & Take CAP
III. 3rdHour DHU, defect research & some defect why repeat
analyses
IV. 4thHour DHU, defect research & some defect why repeat
analyses
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V. Day wise defect record analyses & some defect why not
stop at root point research.
VI. Buyer requirement matching for approve to transfer
products into Okay method.
[Link] finally
I. Okay/Not Okay method
(Okay/Not Okay method is the method of last stage
custom standard meeting method here project leader do:
1. Day wise Record view
2. Approve view for transfer into okay method
3. All process appearance review
4. All process quality review
5. Get-up check
6. Ensure products quality
7. Ensure labeling
8. Ensure Packaging
9. Product status check
10. Customer satisfaction test
11. Final summary Make
12. Okay Sign /Not Okay result publish,
13. Finally, Project leader and project owner sign as
approve to hand over all product to customer.
TDR method end by this way. TDR project leader handle every
this and every process step by step. Hare Top Management
engagement to give hourly defect CAP so that this defect
cannot on going.
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Hourly Defect Analyses sheet
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TDR method project summary
Example:
X Customer all goods defect rate 80%
Hare, we apply TDR method for reduce 99.9999999996%
defect rate.
TDR method follow LP-PDOR roles
LP-PDOR : Leadership, Process plan, Defect Overview &
Review .
Company authority select One for leading this TDR
project.
He setup all plan and manage manpower and ensure
working environment as OMDC method.
(OMDC Method for making smart working place
[Link] for need
2 .Missing find out
3 .Decorate everything
4 .Clean work place)
Every people have own working record list, He follows up
how they monitoring their record is it/ mind made nor
actual. Beside, follow up that Top Management how to
monitor every man power record.
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He train up and setups manpower for manage first
inventory to drive process.
He train up and setup operator to operate his process
without defect by giving process sample and good
instruction that which defect appear in his operation .
He manage production, manpower, inventory & quality
by his nominated person by following IM3P method.
(IM3P is for Cost and waste reduce
1. Inventory manage first
2. Manpower manage
3. Process measure and use for need
4. Process time reduce
5. Production Balance )
After bulk every category wise 1 pcs produce by matching
customer requirement based. Review all process, if it
okay, then start it bulk.
Select one person who expert at customer requirement,
he full reviews 1 or some pcs by matching customer
requirement 1 hour later to later.
Follow ambulance method it like emergency method if
some where problem appear, this problem specialist
need to come here like ambulance to give proper
solution .
(Ambulance method is an emergency method.
If some where any problem arise, hare section wise
sound ringing by indicating this sound Top Management
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can guesses, who need to go there for fix this problem as
much as possible. For this problem, this topic specialist
need to go there because of giving lifetime solution.)
When checker and nominated person follow hourly
sample match method , he have to overview all process
and all materials, he cannot skip single process and single
materials, which on this produced goods and he should
keep accurate record from hour to hour.
When nominated person and hourly checker when he
found so many defect, keeps record for defect reducer
analyses, Nominate someone gives CAP & some tips that
how they use cap for defect reduce.
1 hour left they again check and if any defect found than
again they analyses those defect, if some defect repeat,
only for that team leader discuss with nominated person
who maintain it, ask him why some defect repeated .
This process on going chain wise in full day. After hole
day keeps day wise defect record.
Analyses and compare hour to hour defect reduce
variation such as
1sthour 70% and 15 defect found (analyses and give
so much effective cap so that those defect cannot
find in 2nd hour.
2nd hour 55% and 10 defect found in 10 defect old 6
defect repeated than analyses why 6 defect repeat.
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3rd hour 40% and 6 defect found in 6 defect 2 defect
repeated, again take strong action that why previous
defect on going still now.
Same to way , analyses day wise report, if some
defect on going day to day, take strong action to
reduce this defect.
After sample method check post, Quality Specialist check
and match Customer requirement, ensure all process
appearance, quality, labeling, packaging & other
customer requirement so that factory can submit this
goods with no defect and no fault.
Finally, apply hare okay or not okay method, this method
drive Team leader, after apply this method, he reviews
total record, if all record is okay then he reviews finally
okay goods. If team leader approved as okay. Then it pass
to customer. If not okay, team leader makes decision to
make ensure all goods okay quality. Then, he transfers its
to The Customer.
END
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