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Product Safety and Quality

Basic Policy

Promoting quality in products and services based on the basic quality policy

OMRON considers safety to be the most important consideration, even before functionality, performance, and cost. As such, OMRON strives to maintain and enhance the safety of its products and services at every stage of its business process from product planning and development through production, all the way up to sales, after-sales service, and disposal.

To realize maximum customer satisfaction, OMRON continually seeks to improve the quality of its products and services, in accordance with the basic quality policy that puts quality first. To this end, all employees are working hard to raise quality in their daily work.

Basic Quality Policy

  • Achieve quality levels that satisfy our customers.
  • Establish, maintain and improve quality management systems based on ISO quality standards.
  • Promote quality assurance activities through the participation and cooperation of all employees.

Product Safety Policy

  • Safety should come first, above functionality, performance, and cost.
  • Maintain at least a level of safety that is accepted in general social terms.*
  • If industry standards for safety are higher than the generally accepted level, however, maintain industry-standard or higher levels of safety.
  • * Even in cases of use not intended by OMRON, ensure product safety based on assumed risks pertaining to generally foreseen ways of use.

Refer to OMRON Group Rules for Ethical Conducts 4. Safe Products and Services 5. Protection of Customers

Quality Assurance System

Establishment of a quality management system and strict implementation of the PDCA cycle

To live up to its basic quality policy, OMRON has established a quality management system that requires meeting the OMRON Group’s own provisions in addition to the requirements of the international standard ISO 9001.

Across the OMRON Group, each organization has been strictly implementing a PDCA cycle. In this cycle, an improvement plan is formulated, the plan is implemented, and the degree of achievement is evaluated. This evaluation leads to the next improvement, and the cycle is repeated. Strict implementation of a PDCA cycle helps ensure the safety and quality of products, enabling continuous improvement of quality and prevention of quality-related problems. Concurrently, auditing has been conducted to measure the efficacy of quality management systems since fiscal 2011.

As for substances that may adversely impact the environment or society, OMRON has constructed a chemical substances management system in order to quickly respond to customer inquiries and provide necessary information.

The Global Manufacturing Innovation HQ, a corporate headquarters division, has a well-established structure to support quality enhancement on a global scale, through reinforcement of development organization capabilities, quality approval for purchased parts, and advancement of failure analysis technologies. As for purchased parts, for example, a system of evaluating and certifying suppliers’ process quality is implemented to ensure the highest possible product quality throughout the world.

In fiscal 2017, OMRON strengthened its efforts to avoid silent changes* that the company started in fiscal 2016, increasing the number of processed items to purchase integratedly. OMRON will continue the efforts.

  • * Silent change refers to changes in material composition or alteration of specifications for parts that suppliers make, without notification to clients.

Clarifying a system to maintain product safety in order to supply highly safe products

In accordance with its Product Safety Policy, OMRON Group companies clearly determine safety management systems to be implemented at each stage of its business process, from product planning and development through production, and all the way up to sales, after-sales service, and disposal. By so doing, the OMRON Group strives to ensure the supply of highly safe products.

ISO 9001-certified sites

Quality Assurance Activities

Conducting quality audits to maintain effective quality assurance activities

At OMRON Group companies, quality audits are performed on a regular basis. The objective is to continuously improve the compatibility and effectiveness of quality management processes and upgrade their level by implementing their PDCA cycle. The Global Manufacturing Innovation HQ is committed to resolving issues faced by each Group company through the implementation of quality management systems.

Objective evaluation for assurance of safety

To ensure product safety, OMRON Group companies verify and review designs and check the appropriateness and validity of the designs while developing new products. By taking these steps, the nature and completeness of risk prevention measures related to the products being developed are objectively evaluated.

Continuous quality education based on the concept of "all employees assume an important role in quality"

OMRON believes that quality must be supported by all OMRON members, whether they belong to sales, planning, R&D, procurement, manufacturing, or quality assurance. This applies even to directors and officers.

Based on this belief, OMRON continuously offers quality education targeting various ranks, from new employees to managerial-level employees, in order to nurture quality leaders.

In China, where many of OMRON’s production sites are located, an "OMRON classroom" has been set up at the local technical colleges to provide education regarding OMRON’s product manufacturing philosophy, including quality assurance. With the classroom, OMRON has been developing personnel who will potentially lead OMRON’s manufacturing and quality management activities in the future. Since fiscal 2011, a priority has been placed on nurturing leaders who would consistently promote quality improvement. To this end, the quality leader qualification system is being promoted.

Especially in China and Indonesia, Quality Control (QC) education equivalent to Level 2 and Level 3 of Japan’s Quality Management and Quality Control Examination* is offered.

  • * Quality Management and Quality Control Examination: An examination to assess the level of knowledge regarding quality management (QM) and quality control (QC), and certify those who meet QM/QC standards required for those who work in any organization.

OMRON Group Quality Training Programs

  • Product safety/environment-related training 
    (Training for product safety engineer nurturing, product safety and product assessment, etc.)
  • Quality management/technology-related training
    (Quality/environment contracts training, quality engineering<Taguchi Method>training, etc.)
  • Quality training for new employees
  • Other quality-related training
    (5S <Sort, Straighten, Scrub, Stabilize and Sustain> training, site-specific quality training, etc.)
  • Personnel training through collaboration with local technical colleges in China
  • Implementation of the quality leader qualification system in China
  • Training of core personnel in Chinese production sites

Qualtiy Risk Management

Establishment of a system for quick detection and response to serious complaints

OMRON manages customer inquiries and complaints on defects in order to quickly detect serious quality problems that may affect customers’ safety and prevent the recurrence of similar problems. To convey serious quality problems to top executives rapidly and correctly, OMRON has established the OMRON Group Rules for Product Quality Risk Management.

Along with agile response to customer complaints, quick detection of serious complaints and preventing the recurrence of similar complaints are sought by the corporate headquarters division in charge of quality assurance. This is done in collaboration with the quality assurance departments of business companies and divisions. OMRON Group Rules for Integrated Risk Management are also available to appropriately and rapidly take necessary countermeasures in the event of serious accidents such as those that involve bodily injury, death, and fire.

OMRON has also formulated OMRON Group Guidelines for PLP *, which stipulate the implementation of four activities listed below.Based on these rules, OMRON seeks to prevent PL accidents involving defects of products manufactured and sold by OMRON that cause damage to customers’ lives or possessions, while also ensuring the supply of highly safe products.

The four activities are:
  1. Activities for maintaining product safety
  2. Actions to take in the event of PL accidents, and measures to prevent the spread of damage and recurrence of similar accidents
  3. Activities necessary to avoid PL risk
  4. Education and information release related to PLP, and inspection of PLP activity status
  • * PLP (Product Liability Prevention)
    PLP stands for Product Liability Prevention, and refers to the implementation of countermeasures to prevent PL accidents, i.e., product defects that impede the use of the product or put the health/life of a person or property at risk.

Product Safety Assessment Implementation Rate

Indicator Target Results
FY2015 FY2016 FY2017
Serious PL accidents *1 None None None None
Serious violations of laws/ regulations *2 None None None None
  • *1 Number of accidents that can seriously harm the life or health of consumers (death, serious illness or injuries, residual disabilities, monoxide poisoning, fire, etc.)
  • *2 Number of serious violations of laws or regulations relating to product safety that require external reporting Indicator Target Results

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