《FTQ中英》PPT課件.ppt

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1、Company Confidential First Time Quality PPM TIME 2 First Time Quality Training Module Training Objectives 培訓(xùn)目標(biāo) : To Understand 理解 What First Time Quality Is 什么是一次下線合格率 ? Why It Is Important 一次下線合格率的重要性 Why We Need to Measure It 為什么需要對(duì)一次下線合格率進(jìn)行測(cè)量 ? How to C

2、alculate It 如何計(jì)算 ? What the FTQ Deployment Process is 怎樣進(jìn)行 FTQ? What the Basic Quality Tools Are 基本質(zhì)量工具是什么 ? How to Apply the Quality Tools 怎樣運(yùn)用基本質(zhì)量工具 ? What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 每個(gè)工廠應(yīng)該監(jiān)控和匯報(bào)什么 ? 3 First Time Quality Training Module

3、 What is First Time Quality? 什么是一次下線合格率 ? First Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted 一次下線合格率是測(cè)量制造過(guò)程中不合格品數(shù) 與總產(chǎn)品數(shù)的比值 . REJECTS 4 First Time Quality Training Module Why is FTQ important? 一次下線合格率的重要性 Beca

4、use if we dont make good parts the first time, we have to inspect in quality 因?yàn)槿绻覀兊谝淮螞](méi)有生產(chǎn)出好的產(chǎn)品 ,我們就必須進(jìn)行檢驗(yàn) . We know inspection is at best 85% effective 我們知道檢驗(yàn)最多只 有 85%的有效性 . Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因而 ,如果任何時(shí)候一次下線合 格率大于 0,我

5、們都需要依賴檢驗(yàn)來(lái)保護(hù)客戶 . To reduce manufacturing costs 降低制造成本 To eliminate waste through the value stream and meet customer requirements (take time) 通過(guò)價(jià)值流和滿足客戶要求來(lái)消除浪費(fèi) . 5 Catch Defects Filter Inspection misses some defects 檢驗(yàn)會(huì)遺漏一些缺陷 Defects not caught 漏網(wǎng)缺陷 Voice of the Customer 客戶的聲音 Problem問(wèn)題 D D

6、The Role of Inspection D Inspection is like a filter 檢驗(yàn)好比一個(gè)篩子 6 1 2 Catch & Count defects 抓住并計(jì)算缺陷 React to ALARM LIMITS 超過(guò)警戒線的反應(yīng) Follow Reaction Plan 執(zhí)行反應(yīng)計(jì)劃 Voice of the Customer客戶的聲音 The Role of First Time Quality Process Reaction Plan ZERO Defects Forward 7 Analyze Data分析數(shù)據(jù) Understand Defe

7、cts and Decide the Order of Priority: 理解缺陷并決定優(yōu)先次序 Assign problems to Cross-Functional Group: 向跨功能小組提出問(wèn)題 Select and Plan the Improvement: 1.Right Information 2.Right Cause 3.Right Timing 選擇并計(jì)劃改善問(wèn)題 正確的信息 正確的原因 正確的時(shí)間選擇 Fix the Biggest Problems First: 首先找到最大的問(wèn)題所在

8、1 2 A B C D Problems 1 2 1 2 Responsible Team Works Problems 相關(guān)團(tuán)隊(duì)負(fù)責(zé)解決問(wèn)題 DEFECT 1. ---------------------- 2. ---------------------- 3. ---------------------- Hour Glass The Role of First Time Quality Process 4 3 2 3 2 2 1 1 1 1 8 Inspection Exercise THE NECESSITY OF TRAINING FARMHANDS FOR FIRST

9、 CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH THE FAMILY TRADITION

10、 OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT. Count the Number of Fs contained in the paragraph below (60sec) 數(shù)一下下面總共出現(xiàn)了幾個(gè)“ F”（ 60秒） 9 Inspection Exercise THE NECESSITY OF TRAINING

11、 FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH

12、THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT. Total of 36 Fs 10 First Time Quality Training Module Why does FTQ need to be measured? 為什么需要測(cè)量 FTQ Main Reason

13、s 主要原因 : It is the first signal that a process is out of control 它是過(guò)程失控最先發(fā)出的信號(hào) It allows us to respond to problems internally before they reach our customers 它使我們能夠在問(wèn)題到達(dá)客戶之前先在內(nèi)部作出反應(yīng) . It measures improvement from corrective actions implemented 通過(guò)執(zhí)行糾正措施后來(lái)衡量問(wèn)題改善的情況

14、. If we dont fix our quality problems internally, we will never be able to fix our external customer issues 如果我們不能在 內(nèi)部找到質(zhì)量問(wèn)題 ,我們就不能確定外部客戶的問(wèn)題 . 11 First Time Quality Training Module How is First Time Quality calculated? 如何計(jì)算 FTQ FTQ is reported in parts per million (PPM) defective FTQ反映每一百萬(wàn)個(gè)產(chǎn)品中的

15、缺陷產(chǎn) 品數(shù) . It can be measured at any step in the manufacturing process where parts are rejected 可以 在有拒收產(chǎn)生的制造過(guò)程的任何一步測(cè)量 FTQ. It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 通過(guò)以不合格品數(shù)除以總數(shù)來(lái)計(jì)算 . The total number of pieces attempted includes all go

16、od pieces produced plus all pieces rejected 總的產(chǎn)品數(shù)包括生產(chǎn)出來(lái)的所有合格品數(shù)和不合格品數(shù)之和 . Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不合格品數(shù)包括所有報(bào)廢和經(jīng)過(guò)返工后合 格的產(chǎn)品數(shù) . 公式 : Number of Pcs. Rejected不合格品數(shù) Total Number of Pcs. Attempte

17、d總產(chǎn)品數(shù) X 1,000,000 = FTQ PPM 12 First Time Quality Training Module How is First Time Quality calculated?如何計(jì)算 FTQ? An example at the cell level: Cell “A” has six operations A單元有 6個(gè)操作工序 Reject data is collected at operations 3 and 6 在第三和第六工序收集到不合格品數(shù)據(jù) Cell “A” produced 1040 good pieces d

18、uring the first hour of production. 第一個(gè)小時(shí) A單元共生產(chǎn)良品 1040件 At OP.3, 28 pcs. were rejected. 第三工序發(fā)現(xiàn) 28件不合格品 At OP.6, 16 pcs. were rejected. 第六工序發(fā)現(xiàn) 16件不合格品 What is the FTQ in PPM for Cell A? A單元 FTQ的 PPM是多少 ? 28 + 16 1040 + 28 + 16 1 2 3 4 5 6 X 1,000,000 = 40590 PPM FTQ 28 16 Tally Sheet 13

19、First Time Quality Training Module What is the First Time Quality Improvement Process? 什么是 FTQ改善過(guò)程 ? FTQ process defines a common process to be used by all Delphi manufacturing plants to meet the business plan requirements and drive defect-free manufacturing FTQ是 Delphi 工廠常用的以達(dá)到商業(yè)計(jì)劃要求和 無(wú)缺陷生產(chǎn)要求的

20、一個(gè)方法 . The FTQ process defines FTQ定義 : Process Steps 流程步驟 Stakeholders 有關(guān)系的人 Deployment Chart (functional flow chart) for identifying lead functions 用于識(shí)別重要功能的布置圖表 (功能流程圖 ) Control Plan for Tracking Implementation 控制計(jì)劃和跟蹤執(zhí)行 14 IDENTIFY & COUNT DISCREPANT PARTS IMPLEMENT IMPROVEMENT 執(zhí)行改善

21、EVALUATE 評(píng)估 INSTITUTION- ALIZE LESSONS LEARNED 系統(tǒng)化經(jīng)驗(yàn)教訓(xùn) TOOLS FOR IDENTIFICATION用于識(shí)別的工具 : - PROCESS CONTROL PLAN過(guò)程控制計(jì)劃 - BOUNDARY SAMPLES邊界樣品 TOOLS FOR COUNTING用于計(jì)數(shù)的工具 : - PARTS COUNTERS產(chǎn)品計(jì)數(shù)器 - TALLY SHEETS計(jì)數(shù)表 - SIZED CONTAINERS有尺寸大小的容器 TOOLS工具 : - PARETO直方圖 - CAUSE & EFFECT

22、 (FISHBONE) 原因和結(jié)果 (魚(yú)骨圖 ) - CONCENTRATION DIAGRAM集合表 - FLOW CHART流程圖 - HISTOGRAM柱狀圖 - SCATTER DIAGRAM散布圖 - CHECK SHEET檢查表 - 5 WHYS 5個(gè)為什么 EXAMPLES例子 : - CROSS-FUNCTIONAL TEAMS跨功能小組 - CHANGE BOARDS變化看板 - RPN REDUCTION降低 RPN - STATISTICAL ENGINEERING PROJECTS統(tǒng)計(jì)工程

23、方案 ACTION PLAN行動(dòng)計(jì)劃 : - WHAT, WHEN, WHO事件 ,時(shí)間 ,人物 TOOL工具 : - ACTION PLAN 行動(dòng)計(jì)劃 TOOLS工具 : - PFMEA過(guò)程流程圖 - PROCESS CONTROL PLAN 過(guò)程控制計(jì)劃 - LOOK-ACROSS-CHART 瀏覽表 - 5 WHYS 5個(gè)為什么 SELECT & PLAN IMPROVEMENT 選 擇和計(jì)劃改善 NEW LEVEL OF QUALITY? 新的質(zhì)量水平 DEFINE REACTION PLAN & ALARM LIMITS

24、定義反應(yīng)計(jì) 劃和警戒線 RECORD DATA 記錄數(shù)據(jù) TOOLS工具 : - CONTROL CHART控制圖 ANALYZE DATA 分析數(shù)據(jù) TOOL工具 : - RUN CHART 運(yùn)行圖 - GATE CHART 門圖 ALARM EXCEEDED 是否超過(guò)警戒 ? IMPLEMENT ALARM REACTION PLAN 執(zhí)行報(bào)警反應(yīng)計(jì)劃 YES NO NO YES IDENTIFY確認(rèn) ANALYZE分析 PLAN計(jì)劃 EVALUATE評(píng)估 IMPLEMENT執(zhí)行 FTQ Improvement

25、Process 識(shí)別和清點(diǎn)有 差異的產(chǎn)品 15 FTQ Improvement Process Stakeholder Footprint Plant A Plt B Plt C CELL 1 2 3 4 5 7 8 N 6 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 TEAM LEADER 小組領(lǐng)導(dǎo) CROSS- FUNCTIONAL TEAM 跨功能小組 MEMBERS成員 : - TEAM LEADER小組領(lǐng)導(dǎo) - OPE

26、RATIONS/MANUFACTURING操作 /制造人員 - QUALITY ENGINEER質(zhì)量工程師 - PROCESS ENGINEER 工藝工程師 - INDUSTRIAL ENGINEER工業(yè)工程師 - MAINTENANCE設(shè)備維護(hù) - PRODUCT ENGINEER產(chǎn)品工程師 - SUPPLIER QUALITY供應(yīng)商品質(zhì)人員 PRODUCT ENGINEERING MANAGER 產(chǎn)品工程經(jīng)理 QUALITY MANAGER 質(zhì)量經(jīng)理 MAINTENANCE MANAGER 設(shè)備維護(hù)經(jīng)理 OPERATIONS MANAGER 制造經(jīng)理

27、 PROCESS ENGINEERING MANAGER 工藝工程經(jīng)理 PLANT MANAGER 工廠經(jīng)理 PC&L MANAGER 物流經(jīng)理 CELL 工作站 16 First Time Quality Improvement Process Deployment Flow Chart CFT 跨功能 小組 PROCESS過(guò)程 QUALITY ENGINEER 質(zhì)量經(jīng)理 OPERATIONS 操作人員 PROCESS ENGINEER 工藝工程師 PRODUCT ENGINEER 產(chǎn)品工程師 MAINTENANCE 設(shè)備維護(hù) INDUSTRIAL ENGINEER

28、 工業(yè)工程師 DEFINE REACTION PLAN & ALARM LIMITS 定義反應(yīng)計(jì)劃和警戒線 IDENTIFY & COUNT DISCREPANT PARTS 識(shí)別和清點(diǎn)異常產(chǎn)品 IMPLEMENT ALARM REACTION PLAN 執(zhí)行警戒反應(yīng)計(jì)劃 (如果超過(guò)警戒線 ) RECORD DATA 記錄數(shù)據(jù) ANALYZE DATA 分析數(shù)據(jù) SELECT & PLAN IMPROVEMENT 選擇和計(jì)劃改善 IMPLEMENT IMPROVEMENT 執(zhí)行改善 EVALUATE 評(píng)價(jià) INSTITUTIONALIZE LESSONS LEARNED 系

29、統(tǒng)性經(jīng)驗(yàn)教訓(xùn) LEAD 負(fù)責(zé) SUPPORT 支持 17 First Time Quality Training Module Process Step 1 第一步 Define reaction plan and alarm limits 定義反應(yīng)計(jì)劃和警戒線 You have to start someplace Alarm limits must be based on current process reject data or available data from Run at Rate, historical data, etc. 警戒線必須基于在當(dāng)前工藝

30、下生產(chǎn)的不合格品數(shù)據(jù) , 或源于按節(jié) 拍生產(chǎn) ,歷史數(shù)據(jù) ,等 . Alarm limits must be statistically calculated 警戒線必須進(jìn)行統(tǒng)計(jì)計(jì)算 . Alarm limits must be communicated to operators so they can react 警戒線必須與操作人 員進(jìn)行交流溝通 . If alarm limits are exceeded, there must be a reaction plan to implement 如果超過(guò)警戒 線 ,必須有一個(gè)可執(zhí)行的反應(yīng)計(jì)劃 . The reaction p

31、lan must clearly define what actions are to be taken 反應(yīng)計(jì)劃必須明確定 義所需采取的行動(dòng) . I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N T I F I C A T I O N

32、 : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C

33、E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C

34、 A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M P R O V E M E N

35、T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M P L E M E N T A

36、 L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T DEFINE REACTION PLANS & ALARM LIMITS 定義反應(yīng)計(jì)劃 和警戒線 18 First Time Quality Training Module Process Step 2 第二步 Identify and count discrepant parts 識(shí)別和計(jì)算有差異的產(chǎn)品數(shù) Operators must h

37、ave sufficient tools and skills in order to identify product discrepancies 操作人員必須有足夠的途徑和技能來(lái)確認(rèn)產(chǎn)品的差異 . Tools to enhance the operators ability to identify product discrepancies include 用于加 強(qiáng)操作人員確認(rèn)產(chǎn)品差異的途徑有 : Boundary Samples 極限樣品 Illustrations 圖表 Photographs 照片 Gages 量具 Tools for counting di

38、screpant parts include 用于清點(diǎn)差異產(chǎn)品的工具有 : Parts Counters 產(chǎn)品計(jì)數(shù)器 Tally Sheets 計(jì)數(shù)表 Sized Containers 容量固定的容器 I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F

39、 O R I D E N T I F I C A T I O N : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T (

40、 F I S H B O N E ) - C O N C E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U

41、C T I O N - S T A T I S T I C A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T &

42、 P L A N I M P R O V E M E N T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E

43、E D E D ? I M P L E M E N T A L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T IDENTIFY & COUNT DISCREPANT PARTS 識(shí)別和清點(diǎn) 有差異的產(chǎn)品 19 First Time Quality Training Module Process Step 3 第三步 Implement Alarm Reaction Plan if Limit Exc

44、eeded 超過(guò)警戒線時(shí)反應(yīng)計(jì)劃的執(zhí)行 Reaction Plan 反應(yīng)計(jì)劃 : I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N T I F I C A T I O N : - P R O C E S S C O N T R

45、 O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C E N T R A T I O N D I A G R

46、A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C A L E N G I N E E R I N G P

47、 R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M P R O V E M E N T N E W L E V E L O F Q U A L I

48、 T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M P L E M E N T A L A R M R E A C T I O N P L A N

49、YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T IMPLEMENT ALARM REACTION PLAN 執(zhí)行警戒反應(yīng)計(jì)劃 Alarm Limit Exceeded 是否超過(guò)警戒線 ? Contain 遏制 Investigate 調(diào)查 Implement Containment Plan Until Problem Fixed 執(zhí)行遏制計(jì)劃直到找到問(wèn)題 Yes Containment Plan遏制計(jì)劃 20 First Time Quality

50、Training Module Process Step 4 第四步 Record Data 記錄數(shù)據(jù) Data must be recorded and plotted over time 必須按時(shí)間記錄數(shù)據(jù) : What chart should be used 應(yīng)使用什么圖表 ? Since the area of opportunity varies from sample to sample, the reject count must be converted into a rate prior to charting 如果單位時(shí)間內(nèi)生產(chǎn) 的樣品數(shù)有很大不同，在

51、制表時(shí)，需將拒收數(shù)轉(zhuǎn)換為比率 . We do this by measuring FTQ in PPM 用 PPM計(jì)算 FTQ PPM is a rate PPM是一個(gè)比率 . I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N

52、T I F I C A T I O N : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N

53、 E ) - C O N C E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N -

54、S T A T I S T I C A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M

55、P R O V E M E N T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M

56、P L E M E N T A L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T RECORD DATA 記錄數(shù)據(jù) 21 Hour s or Day s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Non- c on f or m i ng 8 10 9 11 9 8 6 8 7 11 12 11 13 18 17 12

57、 9 10 7 8 5 9 11 8 7 Sa m pl e S i z e ( Av g) 18 Def ec ts w i ng m ar k 2 1 5 4 2 1 3 4 2 2 1 3 1 2 1 1 2 1 1 1 w i ng / bo dy f ol d 3 2 1 2 5 1 2 2 2 5 2 3 4 5 1 2 4 5 6 7 1 1 2 2 3 w r on g p ai nt d ot 2 2 1 5 1 2 3 5 4 3 3 6 8 1 1 3 1 4 3 3 pa i nt l oc ati on 3 4 2 1 2 3 7 2 2 2 2 4 w r on g

58、 o r no c l i p 1 2 2 1 1 1 3 1 1 3 2 6 1 2 1 1 4 3 T o t al no n con f o r m in g : 8 10 9 11 9 8 6 8 7 11 12 11 13 18 17 12 9 10 7 8 5 9 11 8 7 Produ c ti on 18 18 19 18 20 18 17 18 18 19 18 19 19 18 17 18 18 19 18 20 18 18 20 18 19 PP M Def ec ti v e np 1+ np 2+ ? .np k w he r e n p= nu m be r no

59、 nc on f or m i n, k = s ub gr ou ps k = SUM( C3:AA 3) /25 UCL np = 0 UCL np = 0 LCL np = 0 LCL np = 0 0 5 10 15 20 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 UC L= LCL= N o n c o n f o r m i n g a v g= NP Ch ar t in g f o r F T Q Sub g r o u p s ( Day s) np np 0 10 20

60、 30 40 50 60 70 80 90 100 Def ec ts Pa r eto U C L =n p + 3 * ( n p ( 1 - n p / n ) ) L C L =n p - 3 * ( n p ( 1 - n p / n ) ) n = avg sample size (18) np = number nonconforming k = subgroups (25) __ np = np1+np2+ ..npk k 0 2 4 6 8 10 12 14 16 18 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1

61、6 17 18 19 20 21 22 23 24 25 U C L = 1 6 . 1 L C L = 3 . 4 avg= 9.8 Alarm Limit Calculation using np Chart 22 First Time Quality Training Module Process Step 5 第五步 Analyze Data 分析數(shù)據(jù) The basic quality tools are 基本質(zhì)量工具 : Flow Charting 流程圖 Check Sheets 檢查表 Pareto 柏拉圖 Cause and Effect 原因和結(jié)

62、果 Run Chart 運(yùn)行圖表 Histogram 柱圖 Scatter Diagram 散點(diǎn)圖 Control Chart 控制圖 I D E N T I F Y & C O U N T D I S C R E P A N T PARTS I M P L E M E N T I M P R O V E M E N T EVALUATE I N S T I T U T I O N - A L I Z E L E S S O N S LEARNED T O O L S F O R I D E N T I F I C A T I O N : - P R O

63、 C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C E N T R A T I

64、 O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C A L E N G I

65、N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & PLAN I M P R O V E M E N T N E W L E V E L

66、 O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D DATA T O O L S : - C O N T R O L C H A R T ANALYZE DATA T O O L : - R U N C H A R T - G A T E C H A R T ALARM EXCEEDED ? I M P L E M E N T ALARM R E A C T I O N PLAN YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T ANALYZE DATA 分析數(shù)據(jù) 23 First Time Quality Training Module Process Step 5 第五步 Analyze Data 分析數(shù)據(jù) Problem Identification 確認(rèn)問(wèn)題 Prob