福特8D报告.ppt

1,FORD8DMethodology/DMAICApproach&PDCA,2,PDCAintroduction8DintroductionDMAICbriefintroductionCITintroduction,3,PDCA,PDCACycle:Plan计划Do执行Check检查Action纠正活动,4,PDCA改进模式,PDCA是一个持续的品质改善的螺旋上升循环,5,优质企业,客戶满意,PDCA持续改进,PDCA不是一个平面环，它是阶梯式上升的，这个循环走完一遍应该就已经解决一部分问题，取得一部分成果，到了循环的下一个周期，在范围上就应该产生了变化，所以说它不是一个平面环。,6,Ford-8DPractice,Followthistemplate!,7,使用Ford8D的时机,Consequencesidentified因果关系的鉴别,Causeunknown原因不明时用8D来找原因,Resourcesforproblemsolution&recurrencepreventionmanagement-approved解决问题的资源和防止再发生措施的批准,Single-personcapacityforproblem-solvingexceeded不是一个人能解决的，需要通过脑力激荡和团队合作来解决,Symptomsdefined异常状况已经出现，并很明显,Symptomquantifiedwithmeasurement异常状况可量化,8,Ford-8DWorkflow,DescribetheProblem,D1:主题选定及小组成立,D2:问题描述及原因确认,D3:展开暂时防堵措施,D4:定义及验证真因,D5:列出,选定及验证永久对策,D6:执行永久对策及效果确认,D7:预防再发及标准化,D8:恭贺团队及未来方向,PreventRecurrence,ImplementPermanentCorrectiveAction,RecognizeTeam&IndividualContributions,Y,N,EstablishaTeam,DevelopInterimContainmentAction,Define&VerifyRootCause,Choose&VerifyPermanentCorrectiveActions,9,D1:TeamBuilding,Establishateamwithpeople:与此project或工作相关的人有crossfunction的人一起参与有相关的knowledgeexperience定期（每周/每月）review进度,10,D2:ProblemDescription,Whatiswrongwithwhat?Howcantheproblembequantified?What?When?Where?Howmuch?Cause&Effect?Somethingchanged/neverbeensuccessful?,11,D3:DevelopmentofICA,ICA=InterimContainmentAction(暂时防堵措施)QuickfixesTemporarydetectiveactionsIsolationfromharmfuleffects.Short-termactionbeforePCAaretaken.PCA=PermanentCorrectiveAction,12,D4:Definition&VerificationofRootCause,Identify“realproblem”-5why,Testeachpossiblecause.,Systematicuseofresources.,Ideality(Whatitisinbestway),NO?,YES?,13,RootCauseIdentification-Sampling,Problem:BipolartransistorgaininBiCMOSprocessout-of-spechighate-test(WAT).在WAT测试中发现BiCMOS工艺中的双极晶体管增益高出规范的要求Why#1Whywasthebipolartransistorgaintoohigh?为什么这个双极晶体管的增益太高？Answer#1:Emitterjunctionwastoodeep.发谢极太深,Howdoyouknowwhenyouhavefoundthetruerootcause?,theremustbesomeelementofhumandecision.,14,Why#2:Whywastheemitterjunctiontoodeep?为什么发谢极太深？Answer#2:Actualfurnacetemperaturewasslightlyhigh.(confirmedbymanualprofiling)炉管的实际温度偏高了一点Why#3:Whywastheactualfurnacetemperatureslightlyhigh?为什么实际的温度会偏高一点？Answer#3:Furnacecontrollerspikethermocouples(T/Cs)didnotextendfarenoughintotheheatzone.炉管的热电偶控制器不能够控制到炉管加热的整个区域,RootCauseIdentification-Sampling,15,RootCauseIdentification-Sampling,Why#4:Whydidntthespikethermocouplesnotextendfarenoughintotheheatzone?为什么炉管的热电偶控制器不能够控制到炉管加热的整个区域？Answer#4a:Thermocoupleswereslightlyshorterthanpreviousones.这个热电偶比之前的一个短Answer#4b:T/Cpositionwasnotcheckedafterinstallation.安装后热电偶的位置没有检查（热电偶的位置偏移了）,16,D4:Definition&VerificationofRootCause,Why#5a:WhywerethespikeT/Csslightlyshorterthanpreviousones?为什么这个热电偶比之前的一个短？Answer#5a:SpikeT/Cswerebeingpurchasedfromanewvendor.这个热电偶是从一个新的供应商那里采购的Why#6a:WhywasanewspikeT/Cvendorbeingused.为什么要从这个新的供应商处采购？Answer#6a:Reducedcosts.降低成本Why#7a:Whywasntthisproblemanticipated?为什么没有预料到这个问题？Answer#7a:Noguidelinesorproceduresforsuchchanges(nophysicalcomparisondoneandno“What-could-go-wrong?”analysis).对这样的变更没有程序规定（没有做对比试验，也没有“可能会引起什么样的错误”的分析）“没有程序文件或检查表”是一个经常导致问题发生的根本原因。,17,D4:Definition&VerificationofRootCause,Why#5b:WhywastheT/Cpositionnotcheckedafterinstallation?为什么安装后热电偶的位置没有检查Answer#5b:Equipmenttechdidnotexpectanyproblem.设备侦探没有预期有任何问题。Why#6b:WhydidtheEquipTechnotexpectanyproblem.为什么设备侦探没有预期有任何问题？Answer#6b:HewasnotinformedthatanewspikeT/Cvendorwasbeingused.没有告诉他使用了新厂商的热电偶Why#7b:WhywasEquipTechnotinformedthatanewspikeT/Cvendorwasbeingused?为什么没有告诉他使用了新厂商的热电偶Answer#7b:Noproceduretodosoforsuchmaterialchanges.对于这个材料的变更，没有程序规定要这样做。“没有程序文件或检查表”是一个经常导致问题发生的根本原因。,18,下面列举了一些在FAB重复发生的典型的根本原因没有程序、或程序不完善、或程序没有文件化或没有检查表文件化的程序不清楚、不明确、不完善或让人糊涂。跳跃式的程序以节省时间.,D4:Definition&VerificationofRootCause,19,D5:Choice&VerificationofPCA,PCA=PermanentCorrectiveActionEliminationofrootcause?Costs?Productionstop?Overtimeworknecessaryforimplementation?Overtimeworknecessaryformaintenance?,20,D5:Choice&VerificationofPCA,针对每一“为什么”的答案都应至少有一个措施这也就意味着一个充分的预防解决方案至少有57个措施,一种常犯的错误是把侦测措施作为预防措施。如检验、测量、检查、监控、做先行批等。,侦测措施是必需的，但不是充分的它们只是遏制了这个问题。侦测措施与生产没有直接的关系它们不能对产品增值只是增加了成本。它们就象买“保险”，保险是有成本的保险费,21,D6:Implementation&ValidationofPCA,ICAremovedLong-termresultmonitored,22,D7:PreventionofRecurrence,SystemmodificationaccordingtoPCAImprovementstandardization,Followme!,文件化的程序并进行适当的培训才是真正的预防措施,23,预防措施可采取以下的格式进行：建立或修改程序（针对没有程序或不完善程序）程序的文件化(建立/修改文件)培训（文件的执行）消除环境因素,D7:PreventionofRecurrence,24,D8:RecognitionofTeam&IndividualContributions,Appreciationforeverymemberseffort!,25,DEFINEthecustomer,theirCTQ(CriticaltoQuality)issues,andthecoreprocessinvolved.,MEASUREtheperformanceofthecoreprocessinvolved.,Stage1:定义改善机会,Stage2:测量运作水平,Stage3:分析改善机会,Stage4:改善运作水平,Stage5:控制运作水平,CONTROLtheImprovementstokeeptheprocessonthenewcourse.,IMPROVEthetargetprocessbydesigningcreativesolutionstofixandpreventproblems.,Changeoperations?,Re-definetheoperations,No,Yes,ANALYZEthedatacollectedtodeterminerootcauseofdefectsandopportunitiesforimprovement.,DMAICWorkflow,26,Stage1:Define,Definewhocustomersare,whattheirrequirementsareforproductsandservices,andwhattheirexpectationsareDefineprojectboundaries?ThestopandstartoftheprocessDefinetheprocesstobeimprovedbymappingtheprocessflow,27,Stage2:Measure,DevelopadatacollectionplanfortheprocessCollectdatafrommanysourcestodeterminetypesofdefectsandmetricsComparetocustomersurveyresultstodetermineshortfall,Data!Data!,28,Stage3:Analyze,IdentifygapsbetweencurrentperformanceandgoalperformancePrioritizeopportunitiestoimproveIdentifysourcesofvariation,Priority!,29,Stage4:Improve,CreateinnovatesolutionsusingtechnologyanddisciplineDevelopandde