The material industry is an important infrastructure field that uses process technology to produce parts applied to the final product and determines the quality of the finished product. However, the
market environment has deteriorated recently and has been recognized as a 3D industry, losing competitiveness compared to other material industry countries.
This study analyzes the characteristics of open die forging company and sets up the definition of quality cost to develop processes for quality cost management and continuous quality improvement process specialized in the company concerned. The study found that three characteristics of open die forging industry; capital-intensive, front-demanded, and technology-centered areexisted, and internal failure cost and external failure cost are set as the criteria of quality improvement tasks selection.
And a quality cost management process and continuous improvement process were developed for the open die forging company only. The detailed quality cost management process steps include organizing an improvement team and setting the final goal, analyzing the status of the quality system, defining the quality cost, designing the quality cost input system and formula, and developing the monitoring system. In addition, a series of quality processes such as continuous improvement and quality activity have been developed and implemented. The continuous quality improvement process has 5 steps as quality cost measurement and analysis, improvement tasks selection, improvement activity plan and execution, and performance result check, and standardization and process repetition.
A total of six quality improvement tasks were selected by applying the quality cost management system and the continuous quality improvement process developed for the large-scale A open die forging company. And the improvement activities proved its effectiveness by checking the reduction of quality costs by 63.4%
compared to the previous year. The research helps open die forging company establishes the direction of quality management strategy by systematically managing and analyzing quality cost.