We endeavor to prevent quality issues by engaging in risk management activities for reducing quality risks at Group companies both in Japan and overseas. We aim to prevent quality risks from materializing and provide stable quality to customers.
In order to ensure that delivery time and cost are not prioritized over quality, we have established the order of priority for decision making in the performance of duties as SCQDE*. By repeatedly informing and educating employees, we are fostering an environment that encourages consistent judgments. The same concept is applied in product R&D, and is a fundamental principle in all decisions that require problem solving or response to potential risks. Furthermore, we have established a front-loading system guideline, whereby the design and development, manufacturing, quality assurance, research, and sales departments identify risks and problems to be considered at each stage from design to mass production, deliberate on improvements and countermeasures, and ensure the execution of new projects through expert review and customer evaluation. This process is reviewed by experts and evaluated by customers to ensure the execution of new business.
In order to deliver safe, high-quality products to customers as a manufacturer, we ensure product quality and safety based on a precautionary approach, in addition to complying with laws and regulations. We have also formulated a set of regulations for the control of hazardous chemical substances contained in our products. As well as thoroughly ensuring that we do not release any products containing hazardous substances to customers, including via Group companies, we are committed to disclosing product information as necessary.
We make every effort to guarantee safety when transporting products that require additional safety measures in transit, such as sulfuric acid.
Specific measures include ① avoiding contact with other substances, ② wear protective equipment when filling and unloading products, ③ take measures to prevent leaks or dispersal from containers, and ④ providing drivers with SDS clearly outlining measures in the event of an accident.
Providing safety information on our own products is vitally important, to ensure product safety further along the supply chain. We therefore attach Safety Data Sheet (SDS) to Mitsubishi Materials products so as to effectively disclose and convey information on chemical substances.
We have formulated a set of regulations for the control of hazardous chemical substances contained in our products, and continue to reinforce management and ensure legal compliance in relation to chemical substances contained in our products. In Japan, we register, maintain and manage chemical substances based on the Chemical Substances Control Law*1. Overseas, we successfully completed the registration of chemical substances in accordance with REACH regulations*2, which apply within EU regions, by September 2017, and currently maintain and manage those substances. Also note that new REACH regulations have come into effect in the UK (commonly known as UK-REACH) in response to the UK’s departure from the EU, and we are making the necessary preparations to comply. We are also gathering information on and responding to chemical-related laws and regulations in other countries as needed.
We provide Group companies with the latest information through quality liaison conferences and quality meetings, and give them advice on compliance with all applicable legislation.
We carry out reviews during four key stages of the R&D process, when exploring areas of R&D, conducting R&D and prototyping, conducting mass production trials, and commercializing products. While continually taking safety in our processes and products into account, we implement checks and careful examination regarding the use of hazardous chemical substances, compatibility with customer requirements and compliance with various laws and regulations. From the initial stages of the R&D process we repeatedly check these aspects.
The Group had declared November 1 of each year to be our Group-wide Quality Review Day so that the quality issues that occurred in 2017 will not be forgotten and the same issue will not occur again. In the fiscal year ended March 2024, this was an opportunity to review quality issues by watching a video message from the CEO and a video of lessons learned from the series of quality issues. It is also an opportunity to once again verify that the products and services provided to customers at each site do not have quality issues. We have also implemented various initiatives, including the verification of the effectiveness of the measures for preventing the recurrence of complaints, and a review of the standards and procedures.
We operate in accordance with the "Fundamental Quality Provisions at Mitsubishi Materials Group" in order to enhance governance relating to quality. Under the quality provisions, we have formulated a Group-wide "Quality Policy" that aims to provide first-class products and to obtain customer satisfaction, and established and operate the "Quality Control Guidelines at Mitsubishi Materials Group" to complement the Group Quality Policy. We have established and are working to maintain our quality management, from design and development to production, shipping and sales, for the processes involved in quality improvement of products and services provided by us.
The Group handles a wide variety of products at its domestic and overseas sites, and it is important to share the latest information related to quality management. For this purpose, we hold quality officers meeting regularly attended by parties involved in the Group's quality management. The objectives of these meetings are as follows.
(1) Sharing of various up-to-date information on the Group's quality, which is transmitted from the Safety, Environment and Quality Dept.
(2) Sharing of examples of improvements at each site and group discussions on themes to promote understanding among participants.
(3) Promotion of improvements at each site based on the shared information.
We have also set up a Quality Liaison Conference comprised of the persons in charge of quality from Safety, Environment & Quality Dept., each in-house Company, and others, in our efforts to enhance our governance system. At the Quality Liaison Conference, the progress and status of quality initiatives at each in-house Company, including Group companies, are reported. The necessary information is then shared by participants.
Further, where necessary, Safety, Environment & Quality Dept. and the Company holds quality holds quality meetings that are aimed at sharing quality information. At quality meetings, we provide detailed support to each site, such as checking the status of quality management with each site individually and exchanging views. Quality audits are conducted as part of themed audits led by the Internal Audit Dept. The purpose of the quality audit is to confirm the lack of quality fraud and the implementation of effective quality initiatives based on objective evidence. It also aims to identify issues and improvements related to quality, and to provide an opportunity for the audited sites to make continuous improvements.
We have established a database of quality issues that have occurred in the Group , which we use to look back on past quality issues and to prevent similar events from recurring.
Given the reflection that crisis sharing within the Group was not working and a poor sense of ownership was seen when the quality issues occurred, quality training is conducted for each level of younger employees, middle employees and managers, to continue to change their mindset on quality. The quality management system (QMS) based on ISO 9001 is fundamental to our quality management and quality assurance. ISO9001 internal auditor training is conducted regularly for newly appointed auditors. In the fiscal year ended March 2024, ten classes were held with a total of 93 participants. Furthermore, we also held five classes aimed at maintaining and improving the auditing skill and capabilities for the experienced internal auditors. A total of 22 people participated in these classes.
Total of 9 manufacturing sites in Europe, the US and Asia of our Metalworking Solutions Company produce high-quality products in cooperation with the domestic sites and receive continuous technical advice from domestic sites on equipment maintenance, production technology and inspection standards in order to improve quality. As a result of multi-year efforts, local employees now lead improvement meetings and quality control reviews, and their motivation to learn new skills is a driving force for quality improvement.
In order to achieve further quality improvements, quality awareness through repeated training and improved quality documentation are implemented.
Also, the Electronic Materials & Components business, a part of Advanced Products Company, has five manufacturing sites (including subsidiaries and partners) in Southeast Asia and has established a production and quality control system in close cooperation with Ceramics Plants in Japan. The Copper & Copper Alloy business has a total of 12 sites in Europe, the United States, South America and Asia, and is working to maintain and improve the level of quality management by strengthening coordination with Japanese sites and head office. To reduce customer complaints about product quality and maintain governance, we encourage the sharing of information and conduct a wide range of activities aimed at further raising awareness and improving the skills of local staff and personnel posted overseas, including quality supervisor meetings, small group activities and presentation meetings, quality audits conducted by the in-house Company, and web conferences held on a timely basis.
As a result of the Group’s efforts to implement and strengthen prevention measures for recurrence in quality management, we have improved both quality awareness and control level across the Group and various measures have been disseminated across the Group. To prevent the recurrence of quality issues going forward, we will incorporate a series of measures to prevent quality issues into our quality management systems such as the systems that comply with the ISO 9001 standard, and continuously implement them.
Currently, as part of our "proactive quality management" efforts, we are also working to realize designs, facilities, and processes that prevent the occurrence of out-of-specification products. Each Company and base sets quality targets and promotes various improvement activities to achieve them.
Currently, as part of our "proactive quality management" efforts, we are also working to realize designs, facilities, and processes that prevent the occurrence of out-of-specification products. Each Company and base formulates activity plans and promotes various improvement activities to achieve them.
Since quality is the brand asset of our Group, we will continuously improve the level of quality through quality education and quality improvement activities, and continue to provide products that satisfy our customers.