法雷奥PDCA循环模板-简单翻译版本-20140210.pdf

QUICK RESPONSE PDCA Leader Valeo incident number Customer Incident number Group Date of customer notification Opened date SUPPLIER Contact nameVEHICLE REF CUSTOMERPRODUCT Ref Fam VALEO CHECK WarrantyMAIN FINDINGS 0 km Returnof sorting by Shift related Line ReturnSYshift Internal XN Period related SupplierLOCATION OF THE PROBLEM PROBLEM DESCRIPTION BY CUSTOMERADDITIONAL INFORMATION LogisticRY Operator related ProjectXN Isolated case PLAN Valeo viewSupplier view What happened What symptom do we see on our part 1 Define the problem Why is it a problem Was part reworked by Supplier by using 5W 2H When it happened When was it manufactured at Supplier ACT WHAT ARE THE IMMEDIATE COUNTERMEASURES IMMEDIATE COUNTERMEASURESWHODATEWHERE Who detected name of operator Who manufactured 1 IMMEDIATE COUNTERMEASURES IN SUPPLIER PERIMETER Where detected In which other applications product is used 5 Define Immediate How detected Action plan process How many Did a similar problem happen previously at Valeo or internally 2 Measure the PHOTO OR DRAWING of Bad good part problem 2 IMMEDIATE COUNTERMEASURES IN VALEO LINE WHODATEWHERE DO First contained shipment N Date activityNb NG PartsNb SortedPPMSorting date WHOIdentification OK parts Results of sorting in Valeo plant PPM Results of sorting in Transport PPM Results of sorting in Logistics platform PPMPLANT Mger APU Mger QUALITY MgerDATE Results of sorting in Supplier plant PPM LIMIT TIME 24 Hrs Period of Production From ToWHAT ARE THE VALEO COMMENTS ON IMMEDIATE COUNTERMEASURES Customers Oldest partMost recent part Period of NG parts Date of OK parts Who attended face to face meeting from Customer and Valeo CHECK RESULTS OF SORTING shifts by Manufacturing dates 4 Check results WHAT IS THE PROBLEM Use 5W 2H to know what is the Current Situation C S Are you capturing the defect when reinjecting product in normal QUICK ANSWER Make Sorting activity to protect customer 3 Make sorting 6 Get feed back from customers A CD P 0 2 4 6 8 10 12 NG PARTS Follow up ValeoSupplier Defective parts at customer 0 2 4 6 8 10 12 0 2 4 6 8 10 12 Sorting results Def Shift 1 Def Shift 2 Def Shift 3 Qty Shift 1 Qty Shift 2 Qty Shift 3 Defects PDCA快速反应表 领导团队 事件编号 消费者编号 消费者通知日期 开放日期 供应商 联系人 车辆信息 消费者 产品 问题发生地点 消费者问题描述额外信息 计划 5W 2H确定问题 问题衡量 不良品跟踪 厂家观点供应商观点 问题是什么 为什么是个问题 发生时间 谁发现的 哪发现的 如何检测到的 多少 症状 供应商是否返工 制造时间 谁制造的 产品是否用作其它场合 正常操作情况下是否发现这个问题 先前是否有类似问题发生 不良 好的补品的产品图纸 应对措施 部门 运输 供应商处 物流平台 生产日期 不良品周期 最早到 OK品周期 最早发运编号 数字 挑选时间 人员标注OK品 检查 检查结果 主要发现 相关班组 相关周期 相关操作者 独立事件 行动 直接对策 供应商层面直接对策 厂家层面直接对策 限制时间 24小时工厂经理 质量经理 消费者反馈 谁参加的面对面会议 评价 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 Valeo PDCA Analysis1 Analysis Plan Do 62584598 xls xls2010 07 04 ANALYSIS Plan Do Leader Valeo Incident nr Group Opened date Problem Last update PLAN PLAN PROBLEM RESOLUTION 1 Plan Problem ResolutionWHAT WHO WHEN Confirm actual situation Quick Response PDCA Make Factor Tree Analysis for Occurrence Make Factor Tree Analysis for non detection Confirm root cause with 5 Why s Implement action plan Confirm efficiency of Action plan Standardize and Generalize 2 Make the FTA for occurrenceFIND ROOT CAUSE WITH 5 WHY s FOR OCCURRENCE Potential root causeWhy Verif Why Verif Why Verif Why Verif Why Verif 3 Validate the root cause for occurrence 4 Make the FTA for Non detection 5 Validate the root cause for Non Detection 6 a Define action Verification is done based on tests measurements data to confirm root cause O Root cause X Not Root cause plan for root causesFIND ROOT CAUSE WITH 5 WHY s FOR NON DETECTION Potential root causeWhy Verif Why Verif Why Verif Why Verif Why Verif 6 b Justify why solution will work Verification is done based on tests measurements data to confirm root cause O Root cause X Not Root cause DO DEFINE VALIDATED ACTION PLAN FOR EACH ROOT CAUSE 6 Make the correctiveWHAT ACTIONS HOW WhoDate plan Date clos ACTIONS FOR OCCURRENCE This analysis must be validated by Valeo within 5 days after Incident Notification Update Quick Response containment actions results Click on this link TO UPDATE QUICK RESPONSE CONTAINMENT ACTION RESULTS Click on this link TO MAKE FACTORS TREE ANALYSIS FOR OCCURRENCE WITH 4M s FTA Occ A P C D 事故发生后5天内必须要确认 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 根本问题的有效行动计划 行动如何实施 事件发生 问题解决计划 是什么 什么时候 实际情况确认 事件因素树分析 根本原因验证 未觉察因素树分析 未察觉根本原因验证 解决根本问题的行动计划 证明为什么行动会有效 潜在原因 为什么 基于测试结果和测量数据来确定根本原因 事件因素树分析 未察觉因素树分析 5个原因确定根本原因 行动计划的实施 行动计划有效性的确认 标准和总结 Valeo PDCA Analysis2 Analysis Check Act 62584598 xls xls2010 07 04 ANALYSIS Check Act Leader Valeo Incident nr Group Opened date Problem Last update CHECK CONTROL THE EFFICIENCY OF THE ACTIONS 7 Measure the Results ACT1 Establish the new Standard WHODATE PlanDATE Act2 Generalization of countermeasures to similar lines pdts PRODUCT FMEANOYES 8 Save resultsPROCESS FMEALines StandardizeMEAN FMEAProducts generalizeCONTROL PLAN MAINTENANCE PLAN PROCEDURE3 Warn other sites Divisions Suppliers sites DESIGN STANDARDNOYES L L CSupp AUDIT Valeo Sites Plant ManagerQuality MgerDate 10 DAYS MAX 9 Verify PERFORM FOLLOW UP 1 MONTH AFTER THE IMPLEMENTATION OF PLANT MgerPROD MgerTECH MgerQUALITY MgerDATE permanency CORRECTIVE ACTION of Action 1 MONTH MAX Action if result not good planAFTER SUCCESSFULL CHECK This analysis must be validated by Valeo within 10 days after Incident Notification Click here to COMPLETE CHECK PART OF ASSIGNMENT SHEET Click here to COMPLETE EFFICIENCY CONTROL DATA Data AN M 2M 1C SW 5 daysW 10 daysW 1 monthTarget 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 EFFICIENCY CONTROL PPM A P C D 事故申报10日内本分析就要进行验证 集团 问题 负责人 启动日期 最新更新 效率控制 有效控制 结果测量 保留结果标准和总结 产品FMEA 过程 平均 控制计划 维护计划 过程 设计标准 谁 对策 生产线 产品 其他部门 供应商告知 行动计划的永久性验证 纠正措施的履行必须在一个月内进行 如果结果不理想 采取的行动 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 Rev 5af L CHECK QUALITY PROCESS DOCUMENTATION 2 1 PROCEDURES AND JOB INSTRUCTIONS 2 2 MAINTENANCE INSTRUCTIONS 2 3 RECORDS START UP CHECKLISTS REACTION SHEETS PREVENTIVE MAINTENANCE VISUAL AID3 VISUAL AIDS ARE POSTED TO HELP OPERATORS INTEGRATE CHANGE ABCWE OPERATOR 4 OPERATORS AND OTHER FUNCTIONS ARE TRAINED 4 1 PROOF OF TRAINING IS AVAILABLE RECORDS 5 MINUTES 4 2 OPERATORS CAN CORRECTLY DESCRIBE WHAT HAS CHANGED AT THEIR LEVEL 4 2 1 MANUFACTURING PROCESS STEPS 4 2 2 MAINTENANCE STEPS COMMENTS CHECK FORM 1 PROCESS HAS BEEN MODIFIED ACCORDING TO THE ACTION PLAN OF THIS PDCA CHECK THE FULL PERIMETER 2 ALL DOCUMENTATION HAS BEEN MODIFIED ACCORDING TO THE PROCESS CHANGE AND HAS BEEN VALIDATED BY OPERATORS VERIFICATION PER SHIFT O OK X Non OK 过程 文件 目视 直观教具 操作人员 评价 过程根据本表已经更改 完整的周边检查 过程已更改 且操作人员已验证 过程和工作指令 维护指令 记录 启动检查表 反应表格 预防性 定期检修 目视教具是为了帮助操作者做一体化的改变 操作人员及其他相关人员经过培训 培训证据保留 记录 5分钟 操作人员可以正确的描述他们层次内所做的变更 制造流程 维护保养流程 检验 班组 检查质量 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 Factor Tree Analysis for problem FACTORSCONTROL POINTSTANDARDOK PARTSBAD PARTSJUDGMENTCOMMENTS OCCURRENCE Focus of analysis and action plan must be on true causes A good way to analyze a true cause is to start a new FTA to identify which factors are involved at newt Why level Std OK Meet std Direct link 事件 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 Factor Tree Analysis for problem FACTORSCONTROL POINTSTANDARDOK PARTSBAD PARTSJUDGMENTCOMMENTS Focus of analysis and action plan must be on true causes A good way to analyze a true cause is to start a new FTA to identify which factors are involved at newt Why level NON DETECTION Std OK Meet std Direct link 因素树分析 因素 控制点 标准 OK品 评价不良品 未察觉 直接联系达标标准OK 分析及行动计划必须基于真正的原因 开始一个新的因素树分析方法来界定因素是否相关是寻找根本原因的行之有效的一个方式 本页已使用福昕阅读器进行编辑 福昕软件 C 2 0 0 5 2 0 0 9 版权所有 仅供试用 DATABASE 1 NG PARTS FOLLOW UP Valeo Supplier DATABASE 2 SHIFT BY MANUFACTURING DATE Def Shift 1 Def Shift 2 Def Shift 3 Qty Shift 1 Qty Shift 2 Qty Shift 3 Prod Shift 1 Prod Shift 2 Prod Shift 3 Escaped 1 Escaped 2 Escaped 3 Escaped total000000000 Do not hesitate to add columns to input more dates if needed Beware Include data fr