8D介绍.doc

COMAX TECHNOLOGY CO., LTD. Customer Complaint Corrective & Preventive Action Report (8D) - FILE NO.: T-DSL-02-001B2 - CAR NO: CAR-030411-E -Customer Name 客戶名稱JIAN TAY Shipping Qty 出貨數量180K pcs Part No.產品料號C121 Failure rate 不良率1.0% / FQC Shipping Date 出貨日期04-03-2003 Complaint Date 抱怨日期04-07-2003 DISCIPLINE 1: Use Team Approach (團隊組成) DATE: 04-08-2003 Team Leader: Edwin Lai Team member(s): Morgan Jair; Stanley Ji; Rambo Chao; Hence Huang; Leo Liu; Leo Lu; Teawe Zhang; Victor Zhou 執行者不列入DISCIPLINE 2: Describe The Problem (問題描述) DATE: 04-08-2003 There is a break or crack on the left ear of body of connector product C121 (Discovered by customer) DISCIPLINE 3: Implement And Verify Containment Action (防堵措施) DATE: 04-08-2003 1. Sorting out the defected product from the rejected lot and the stock of customer. 2. Sorting out the defected product from the assembly lines of customer by Comax inspectors 3. Sorting out the defected product from the assembly lines of Comax. 4. Returning all of the stored products of Comax to assembly lines to sort out the defected product (it has been finished on 9 Apr) 防堵五要客倉、在途、客線、我線 & 我倉。DISCIPLINE 4: Define and Verify Root Cause (定義及驗證根本原因) DATE: 04-08-2003 1. The conner of ear of body has been hit by the head of push-bar of the sub-auto assembly machine. 2. In the continuous assembly procedure, the head of push-bar will hit the conner of ear of the next body, because the width of the head of push-bar of the assembly machine is same as the height of the C121 body. (Attached file NO.1: the photo of the assembly machine, and push-bar is before improved) 3. The inspection with 100% for cracked product is failed on picking the defects out, it make some defected product flew out to the customer. DISCIPLINE 5 Choose and Verify Permanent Corrective Action (永久對策) DATE: 04-08-2003 1. Cutting off 2 m/m of the width of the head of push-bar of the sub-auto assembly machine to protect the next body from hitting by the push-bar. (Attached file NO.2: the photo of the assembly machine, and push-bar is after improved ) 2. The inspector for appearance checking will according to SOP and SIP to execute it strictly, avoiding the defected products be judged in wrong or leakage than flew out to customer. (Attached file NO.3: the criteria of Appearance inspection ) 3. For the better guarantee of the products quality, Comax Technical Center to enhance the strength to protect the ear of body from break or crack, and to change the thickness of ears from 0.6mm to 0.8mm. At the same time, we push logo as “COMAX” on the body. ( Attached fileNO.4 , the products drawing after enhance) 4. Pushing a break test inspection on the injection process, and the specification of the break force of the both ear is more than 2.0kg. ( Attached file NO.5 , the SIP of this inspection) 5. Adding a sensor on the entry gate of sub-auto assembly machine to avoid the next body getting into machine too early then be hit by push-bar ( Attached file NO.6 , the photo of the added sensor) 對策六要起點改善、工治具替助、判定標準、辨識標記、隔離處置、產品設計改善。DISCIPLINE 6: Implement Permanent Corrective Action (執行永久對策及效果確認) DATE: 04-17-2003 1. The enhanced body of C121 is on mass production from Apr 14, and there isnt any defect again in lot of 35K pcs. 2. According to the reading of thermal shock test, the strength of enhanced body is better than before. (Attached No.7: The thermal shock test) DISCIPLINE 7: Prevent Recurrence & Standardization (預防再發生及標準化) DATE: 04-17-2003 1. Attached No 2 : The sub-auto assembly machine be improved 2. Attached N0.4: The enhanced body of C121 3. Attached No.5: The SIP for the break test inspection on the injection process 4. Attached No.6: The added sensor DISCIPLINE 8: Congratulate Our Team (恭賀團隊) DATE: QA Manager: Rambo Chao QA: Hence Huang Checked By: Victor Zhou Prepared By:Hence Huang 8D方法,又称团队导向问题解决方法,是福特公司处理问题的一种方法,亦适用于制程能力指数低于其应有值时有关问题的解决,它提供了一套符合逻辑的解决问题的方法,同时对于统计制程管制与实际的质量提升架起了一座桥梁. 8D工作方法的介绍 主要步骤包括： D1：小组成立目的:成立一个小组,小组成员具备工艺/产品的知识,有配给的时间并授予了权限,同时应具有所要求的能解决问题和实施纠正措施的技术素质。小组必须有一个指导和小组长。关键要点:成员资格，具备工艺、产品的知识 D2：问题说明目的:用量化的术语详细说明与该问题有关的内/外部顾客抱怨,如什么、地点、时间、程度、频率等。“什么东西出了什么问题”方法：质量风险评定，FMEA分析关键要点: 收集和组织所有有关数据以说明问题问题说明是所描述问题的特别有用的数据的总结审核现有数据，识别问题、确定范围细分问题，将复杂问题细分为单个问题问题定义，找到和顾客所确认问题一致的说明，“什么东西出了什么问题”，而原因又未知风险等级 D3：实施并验证临时措施目的:保证在永久纠正措施实施前，将问题与内外部顾客隔离。（原为唯一可选步骤，但发展至今都需采用）方法：FMEA、DOE、PPM关键要点: 评价紧急响应措施找出和选择最佳“临时抑制措施”决策实施，并作好记录验证（DOE、PPM分析、控制图等） D4：确定并验证根本原因目的:用统计工具列出可以用来解释问题起因的所有潜在原因，将问题说明中提到的造成偏差的一系列事件或环境或原因相互隔离测试并确定产生问题的根本原因。方法：FMEA、PPM、DOE、控制图关键要点: 评估可能原因列表中的每一个原因原因可否使问题排除验证控制计划 D5：选择并验证永久纠正措施目的:在生产前测试方案，并对方案进行评审以确定所选的校正措施能够解决客户问题，同时对其它过程不会有不良影响。方法：FMEA关键要点: 重新审视小组成员资格决策，选择最佳措施重新评估临时措施，如必要重新选择验证管理层承诺执行永久纠正措施控制计划 D6：实施永久纠正措施目的:制定一个实施永久措施的计划，确定过程控制方法并纳入文件，以确保根本原因的消除。在生产中应用该措施时应监督其长期效果。方法：防错、统计控制关键要点: