Faurecia 7QB TRAINING (佛吉亚7QB培训教材).ppt

The7QBofproductionFAStrainingpresentation 2012V1 7QB Level1training 3 7QB TARGETSOFTHELEVEL1TRAINING Objective TounderstandthebasictoolsofQualityusedbyFaureciaandFAS Attheendofthemoduleyouwilldiscoverandbeabletoapplythe7QBintheplant Timeframe1 5hours Program Introduction BQPandRelationto7QBOK1stPartPokaYokeSelf InspectionFinalInspection TQWRedBinsReworkundercontrolQRCI Trainer s level4 whocanconduct Qualificationprocess Thetraineehasunderstoodallthe7QBtoolsandthemindsetbehindthem BreakthroughQualityPlan7QBofBQP 7QBinProduction 7QBinDevelopment TheBQPisatop downapproachsetting7practicalandsimplerulesdesignedtoaddressourmainweaknessesinproductionandindevelopment BQPindetail BQP 1 Capitalization Transversalizationof8D FinalcustomerneedsCustomerneedsPastproblemsKeyDimensionsKeyFunctionsSuppliers JobinstructionsDailychecksheetsPokayokechecksStatisticalProcessControl OK1stpiece PokaYoke keycharacteristicsincludingS R ControlPlan GoodParts BadParts ActionRules QRCI 7QUALITYBASICSOFPRODUCTION BQPAction 2 Strictapplicationofcontrolplan BQPAction 3 4 QuickresponseindailyQRCI Plant ProgramQRCI Containmentactionmustbetakeninthesameday shiftascustomerdefecthappened PlantQRCI Customer Supplierissues Top3scrap 80 covered internalescalatedissues UAP Quality ProductionQuality Passonlygoodpartstothenextstage Qualitystartswithcleanlinessandorder 5S Zoning Onething oneplaceOneplace oneowner 5Sindetail JobInstruction Workinstruction Precisedescriptionofalloperationsandinspections Howtodothejobwell atfirstapproach 1 OK1stpart FAU S PSG 0630 Scope Identifypotentialrisksafteratthebeginningoftheshiftoractivitiesinvolvingthestopoftheline maintenance changeover alerts Assurethecorrectrestartoftheprocess OK1stpart DailyChecksheetOK 1stpartOK Checkbeforehandthatallrequiredconditionsaremettoproducegoodparts inasafelyway I amresponsibleofmyworkstationandthesurroundings soIwillmakesureeverythingisOKtostartproduction IfanysinglecheckitemisNOK theproductionshallnotbestarted OK1stpart DailyCheck sheetOK 1stpartOK GO Doneateverystartofshift processchange over breakdownBack upmodeclearlyidentified availableatworkstationKeepanddisplay1stpartOKuntilnextchange shiftIfnextstart upNOKorcustomerconcern identifyscopeofsuspectpartsforcontainment 7qualitybasic VisualManagementofOK1stPart 7qualitybasic VisualManagementofOK1stPart ReactionrulesforNOKstatus OKprocesschecksheet OKproductchecksheet OK NOK Checkpoint Whattocheck Howtocheck WhattodoifNOK ValidatedbyGL OK1stPart MandatoryRules 1 OK1stpartinstructionsandOK1stpartcheck sheetsarecreatedoutofcontrolplan Theycover HSE 5S training pokayoke s processparameters productcharacteristics TheydescribewhenOK1stpartchecksaretobeperformed Alocationisreadyforthe1stOKpart 2 Foreachcheckitem checkingmethod OKcriteriaandreactionrulesaredefined 3 TheGAPLeadervalidatesOK1stpartcheck 1stOKpartandcheck sheets 4 IfoneitemormoreisnotOK productionisnotstarteduntiladulyvalidatedback upmodeisapplied Suspectpartsaremanaged Cultureofself managementandthederogationincaseofNOK 2 Pokayoke FAU S PSG 0650 Scope Systematicallydetect catchandblockanerrorbeforeitturnsintoadefect Freethemindtofocusonvalue addedoperations PokaYoke Productpokayoke Processpokayoke FullyconsistentwithFMEA ControlplanUse redrabbit masterparts tocheckpokayokeIfnotOK stopproduction thenapplythereactionrules Simpleerror proofingdevicestopreventhumanerrors EachPoka yokemustcontain 1 Clearinstructionwithreferencenumber3 Checkingmethodandfrequency2 Workingprinciple4 Backupmodeincaseoffailure Poka Yoke followup TypeofPoka Yoke PokaYoke VisualManagement AllPYpadlockmustbeturntoredtoensurethePYwillbecheckedagainbeforetherestartingoftheproduction POKAYOKE PokaYokeMR MANDATORYRULES ChecksinserialproductionAllPY sarechecked validated atthefrequencyrequiredinthecontrolplan ForS Rcharacteristics atthestartofeveryshift breakdown change overorqualityissuewhencharacteristicisimpacted Padlocktagsareturnedtogreenorredaccordingresult Actionsareinitiatedaccordingreactionrules Backupmode ifapplicableandonlyifassafeasthenormaloperationi e forS Rfasteningcharacteristics 100 manualinspection e g torquewrench 100 visualmarkingoncheckedcharacteristicRecordingofpartsproducedinbackupmode date shift operator quantity marking 3 Selfinspection Stopatdefect FAU S PSG 0620 Scope Preventanydefectivepartstobepassedonthenextstage internal Customer Operatormusthavetheabilitytojudgewhethertheoperationthatisbeingperformediscorrect Selfinspection TheoperatorknowshowtojudgeiftheoperationisOKorNOK i e Boundarysamples defectsamples TheoperatorcheckshisworkrightawayTheoperatorknowswhattodoifpartisnotOK scraporrepair Theoperatorisempoweredtostoptheline machineatdefect accordingtoreactionrules Thedefecthastobeanalyzedwiththeteamtotakeimmediateactions OpenalineQRCIaccordingtothereactionrules Stopatdefect Mainobjectives EliminateproblemsReducereworksReduceScrapImproveproductivityGetGAPautonomousImproveproductandprocessknowledge It samanagementdecisiontodoit Targetmanualoperations 1stdefectContinuousprocesses setyourownlimitsfortotalvaluesandconsecutiveparts Ultimatetarget Stopat1stdefect Video SelfInspection MandatoryRules ItemsCreateandupdatejobinstructionstipulatinghowtocorrectlyperformthejob inlinewithControlPlanrequirements TrainoperatorsforStandardizeWorkValidateacquisitionofskillslevelStrictlyfollowself inspection Donottopassanydefectiveparttothenextworkstation EnsurestrictrespectofSelf InspectionwithinStandardizedWork Stopthelinewhenaproblemoccurs atfirstdefectformanualprocesses atthresholdforcontinuousprocesses TakeimmediateactiontosolvetheproblembyusingQRCIline Incaseofdefectcreatedupstream immediatefeedbacktooccurrenceprocessandimmediateactiontocontainandimprovedetection Monitoreffectivenessofself inspectionbytrackingmisseddefects operatorbyoperator ResponsibleSupervisor GAPleaderGAPleaderSupervisorOperatorGAPleaderOperatorGAPTeamSupervisors FinalInspectionandTQW FAU S PSG 0610 Scope Performedafinalinspectionintheproductionline ofthefinalproduct scharacteristics functional dimensional tosystematicallydetect catchadefectbeforetheproductreachesthefinalcustomer Finalinspection Individualmonitoringofmisseddefects FIisthelastworkstationbeforethecustomerTheoperatormustknowthecheckitems number inspectionpaths whichareregularlyupdated TheoperatorshouldremovedoublechecksTheFIworkstationandoperatorareclosetothelinetoinformtheGAPleaderifadefectisfoundtosendimmediatefeedbacktotheoperators WorkInstructionsdedicatedtoFI ManagementofFinalInspection Video ListofCheckingpoints VisualmanagementofFI FinalInspection Mandatoryrules TemporaryQualityWall Beforelaunchofnewproduction productiontransferorbyManagementdecision TheoperatorreportstotheproductionsupervisorTheoperatorshoulddoublechecksomeofthefinalinspectionpoints underthesameconditionsasthefinalinspector Theoperatorisclosetothelineforimmediatefeedbacktothefinalinspectionincaseofdefectdetection AconvergenceplanissetupforquickremovaloftheTQW followedbysupervisor UAPmanager TemporaryQualityWall ValidatedFinalInspectionValidationform TrainedInspectors Individualtrackingofmisseddefects InspectionInstructions StandardizedWork Noadditionalordifferentcheckitemcomparedtoline DefectTallySheet Dailydefecttracking convergenceChartAnddefecttallysheet 2 3 OnePieceFlowwithlittletonobuffer 5 6 7 Stationislocatedveryclosetothelineforquickfeedbackatdefect 4 1 TQW MandatoryRules Redbins FAU S PSG 0660 Scope Separateandisolatenon conformingorsuspectproductsfromtheflowProvidesamplesfordefectanalysis leadingtotheireradication Redbins keypoints TheBinsarecontainers box hanger trolley rack etc toputnon conformingmaterialofanypartoftheprocess boughtoutparts semi finishedgoodorfinishedgoods Scrap Red andrepair Yellow binsfitthepartsizeandshape Preferably thecontentofthebinsshouldbevisible Redandyellowbinsshallneverbeusedasgarbagebins Theoperatoridentifiesthedefectonthenon conformingpart usingredsticker arrow tape cloth etc toeasefurtheranalysis Insiderepairbins repairpartsandsuspectpartsarelabeleddifferently SelfInspectionisfundamental RedBins Binsarezonedproperly i e Stop Defect3Pieces SCRAP Sortingrules Flow markingofbins racksofnon conformingpartsandthereturnintotheline RED Partisscrap forbiddenorimpossibletoreworkYELLOW REWORK 1 Redbinsarevisible inzonedareas easilyaccessiblebyoperators 2 Eachnon conformingpartisidentifiedwithitsdefect s marked 3 Repairsandscrapsarephysicallyseparated Gapleaderauditsthecontentofscrapbins 4 Redbinsareemptyattheendofshift byGAPleader Redbins Mandatoryrules Sorting Labeling Recording AnalysisofNOKitems Pareto QRCIonmaincontributors Validateimprovement ManagementoftheBinsandQuickReaction ReworkunderControl FAU S PSG 0640 Scope Performethenecessaryactivitiestomakeanonconformingproductmeetthequalityrequirements Reworkundercontrol Goodzoning sortingarethemostimportantelement Reworkisanonsystematic non value addingoperationperformedonaproduct Reworkisawaste weneedtoeliminateitbyattackingtherootcauses MandatoryRuleMostofS RandQualityalertsarecausebybadcomplianceofbasicmanagementrules CarefulwithS Rparts Rework repair non standardoperations GoalisZEROREPAIRSRepairsmustbespecifiedintheControlPlanandWorkinstructions withacceptancecriteria NonstandardoperationsRepairedpartsareidentified Partflowisorganized On linerepairSimplerepair missingcomponent badriveting Immediate byoperatororGAPLeader Off linerepairTechnicallyimpossibleonthelineortakestoomuchtime Quickly byGAPLeaderordesignatedoperator ondedicatedrepairstation includedinthepolyvalencematrix accordingtorepairinstructions Repairsarerecorded IndicatorismanagedRepairstationsaresimple inexpensive Reworkundercontrol SpecificValidationfromGapLeaderorFinalInspector QRCI FAU S LSG 5420 44 WhatisQRCI AMANAGEMENTattitudetoimmediatelyrespondtonon performance1stpriority SecuretheCustomer2ndpriority AvoidReoccurrence uick esponse ontinuous mprovement Forcustomersatisfaction Q I C R S R QRCIManagement QRCIispacedbydailymanagementroutines calledQRCIreviews ateachofthethreelevelsofPlantorganization Managerassignstasksfortopissuesescalatedfromthelines Ensurecontainmentofeachcustomerdefectwithinsamedayorsameshift Operatorstakeaconcreteactiontosolveproblemsimmediately 45 46 6keypointsofQRCI 1 REALPLACE2 REALPARTS3 REALDATA4 QUICKRESPONSE5 LOGICALTHINKING6 ON JOB COACHING LOGICALTHINKINGLogicalthinkingreferstotheabilitytoexplainsimplythelogicalsequenceofanalysesandactions Theproblemis Therootcauseis Therefore thecorrective preventiveactionsare Andthewaywewillpreventrecurrence LLS is CapitalizationandTransversalization 5W 2Hextractedfrom8Dreport AddPictures Sketchestoclearlyshowdefect adaptsizeifneeded ONERootcauseextractedfrom8Dreport Linktotheupdatedtemplatewithcompletefillinginstructionsandexamples 47 Check whichisimportantfact