RFC-反应流程图PPT课件

反应流程图ResponseFlowChecklist PCSElements CreateMeasurementPlan EstablishMonitor SPC ImplementResponseFlowChecklist RFC Element1 Element2 Element3 Contents IntroductionWhatisanRFC BenefitsofUsinganRFCWhenShouldanRFCbeUsed DevelopinganRFCDocumentationofRFCResultsRFCStorageandRetentionRFCContinuousImprovementGuidelinesRFCExpectations WhatisanRFC Adocumenttocontainsuspectproductandreturntheprocess equipmenttoaproductivestateasquicklyaspossible Composedofdefinedsetoftasks actionitems tobeperformedinspecificorderRequirescertaindecisionstobemadetofindsolutiontotheproblemandthereforemayleadtotwoormoredifferentsolutionsdependingonthescenario RFCStructure Diagnosis activitiesareusedfirsttodeterminethecauseoftheprocessinstability Foreachpossiblecause thereisasetof remedy activitiesthatareusedtofixtheproblemoncethecausehasbeendetermined Verification activityisthefinalstep Itisperformedtomakesurethattheprocessproblemhasbeenfixed ExampleofanRFC FlowchartType ExposedCopperMonitoringRFCSpecxx xxxx BenefitsofUsinganRFC IdentifiescauseofprocessorequipmentfailuresControlchartsandSPCtrendrulestellusonlywhentheprocessisout of control notwhyitisout of control Theycannottelluswhattodotofixtheproblem either Forthat weneedtheRFC LeadsMfgTechnician SpecialistthroughstepsinsolvingtheprobleminthequickestpossibletimeMinimalneedforEngineeringinvolvementDocumentsproblemcauseandresolutionhistory WhenShouldanRFCbeCreated StatisticalprocesscontrolWhenanout of control OOC conditionoccurredProductqualityandyieldcontrolWhenquestionableproductsaredetectedatanystationWhenlowyieldinglotsareseenatanystationProcess EquipmentfailureForrestoringamachinetoproductionafterithasbeenshutdownduetoaprocess equipmentrelatedfailure RFCModel WhoDevelopstheRFC Initiatedandledbytheprocessorequipmentowner e g ModuleEngineer inateamenvironmentRFCDevelopmentTeamshouldincludethefollowing Process EquipmentEngineersProductEngineersQ REngineersMaintenanceTechniciansManufacturingpersonnelShiftManagers MfgSupervisors MS MT OperatorStatisticiansContentexperts RFCDevelopmentFlow Step1 Brainstormpotentialcauses UsingaFishbonediagram brainstormallthepossiblecausesofout of controlsignalsfortheprocessstep Consider5M Efactors Useanyexistingdataorexperienceoncausesofout of controlincidents AugmentthelistwithallapplicablecausesfromotherexistingRFCsforsimilarparameters Don tforgettoincludesomeofthelessobviousones suchasgaugeinstability calculationerrors orplottingerrors UseFMEAwhenavailable Step1 Brainstormpotentialcauses cont Example Problem MissingunitsPotentialcauses IncompletelotidentifierImproperstagingoflotCountingSOPviolationEquipmentjammingWronginformationonticket Step2 Assesslikelihoodandease EstablishbasisforinitialorderingofpotentialcausesLikelihoodofbeingthecauseoftheproblemEaseofcheckingUseLikely EasematrixScoreeachpotentialcauseonascaleof1to5DonotconsiderdifficultyoffixingtheproblemForeachpotentialcause addLikelihoodandEasescorestogetanoverallscore Example MissingunitsLikely EaseMatrix Scale Likely1 Likelytobethecause5 UnlikelytobethecauseEase1 Easytocheck5 Difficulttocheck Step2 Assesslikelihoodandease cont Step3 CreateoverallRFCprocessflow Rankeachpotentialcauseaccordingtoitstotal Likely Ease score i e lowesttotalscorehashighestpriority Examinetheprioritizedlistforlogicalorderingandgrouping Similarproblemcausescanbeinvestigatedsimultaneouslyorincombinedactions Avoidredundancy Actionsshouldbegroupedbyusers MS MT Operator Technician Engineer ExaminetheorderingfromotherexistingsimilarorrelatedRFCs Onesuggestionistostartwithcalculationandplottingerrorchecking Nextshouldbemeasurementprocedure equipmentchecking Itisbesttoruleoutpossibledata plotting measurementerrorsfirst beforewetamperwiththemachineorprocessitself IftheFMEAhasbeenusedasabasisinStep1 theFMEAoccurrencenumbershouldalsobeusedasareferenceinassigninglikelihoodandeasescores Step3 CreateoverallRFCprocessflow cont Example MissingunitsInitialflowbasedonLikely Easeoverallscore 1 Incompletelotidentifiers highestpriority2 CountingSOPviolation3 Improperstagingoflots4 Equipmentjamming5 Wronginformationontickets lowestpriority EXERCISE1 Ingroupsof4to5people IdentifyaproblemcommontothegroupCreateaninitialRFCusingSteps1to3ChooseareporterPresenttotheclassafter20minutes DefinitionofTerms ACTION specificinstructionstellingtheRFCUserwhattaskstoperformnextAvoidredundantactions bespecificClarifyownershipoftheactionClusterownershipofactions avoidbouncingbetweenownersDATA informationcollectedbytheRFCUserIncludesobservationsandmeasurements DefinitionofTerms QUESTION requirestheRFCUsertoevaluatethedataagainstspecificcriteriaUsequestionsthatrequireyes noresponseAvoidsubjectivequestionsRESPONSE whatactionshouldtheRFCUsertakebasedontheevaluationofthedataEnsureallresponsesleadtoanaction Step4 CreatedetailedRFCprocessflow Listallstepsrequiredforthefollowing DetermineifpotentialcauseexistsFixpotentialcauseTestandverifyfixUseflowdiagramtocommunicatethelogicalflowoftheRFC Whencreatingflowforfixingtheproblem UtilizesynergyfromotherRFCsinwordinganddescriptions Actionsmustbeabsolutelyclear Avoidambiguity ThedecisionflowmaystopwhenallOperator verifiablecauseshavebeenexhausted ManychecklistsmaycontinuethroughTechnician verifiable orevenEngineer verifiable causesaswell Examinetheoveralldecisionflowforcompletenessandlogic Checkforinfiniteloopsanddeadends Modifyifneeded Example Missingunits Step4 CreatedetailedRFCprocessflow cont Step5 ComposetheRFC TranslatethedetailedflowcreatedinStep4intoanRFCdraft Anactionforverifyingifprocess equipmentisupforproductionwhenafinalsolutionisachievedshouldalwaysbeincludedintheRFC Includeinstructionsforre startingtheprocess Iftheacceptcriteriaspecifiedintheverificationprocedurehavebeensatisfied itissafetoassumethattheproblemhasbeensolved Otherwise itmustbeassumedthattheproblemhasnotyetbeenfixed Ifout of specprocessingcouldhaveoccurred theRFCmayreferencetheapplicablespecordispositionprocedures However thedispositionprocedureshouldnotappearintheRFC Verificationofprocess equipmentstatuscanbedoneintwoways RunacertainnumberofunitsUse2 sigmalimitrule Step5 ComposetheRFC cont RunningacertainnumberofunitsQuantitytobeprocessedforverificationisdeterminedbytheRFCDevelopmentTeamandshouldbespecifiedintheRFCVerification monitoringshouldberequiredafterrunningtheunitstodeterminewhethertoresumeproductionornot Step5 ComposetheRFC cont 2 SigmaLimitRuleIfnextcontrolchartpointiswithin2 sigmalimits itissafetoassumethattheproblemhasbeensolvedAllsucceedingcontrolchartpointswillfollowthestandard3 sigmalimitruleOtherwise itmustbeassumedthattheproblemhasnotbeenfixedandcontinueusingtheRFCtodiagnoseandfixtheproblem Step5 ComposetheRFC cont ThelastRFCactionshouldstatewhethertheRFCwassuccessfulinfindingtheproblemcause ItdescribesfinalengineeringactionstakenwhentheRFCisnotsuccessfulDesignatesthattheactionowneristheEngineerIfapplicable itinstructstheEngineertoreturntheRFCtotheMS MT OperatorUsethehexagontoolExample Step5 ComposetheRFC cont TheRFCDevelopmentTeamisresponsiblefordeterminingiftheRFCactionstakenneedtobedocumentedforpassdownandtraceabilitypurposes ForRFCactionstakenthatneedtobedocumented Createacoversheetonlyifrequirementispaper baseddocumentation ThefollowinginformationarerequiredtobesuppliedbytheprimaryRFCUserifapplicable equipmentnumber lotnumbersaffected leadcount date shift timeproblemwasencountered EmployeeIDofMS MT Operatorand orTechnician ThecoversheetshouldcontainrequiredRFCinstructionsaswellasincludeRFCtriggerpoint i e whentousetheRFC Ifelectronicdocumentation e g automatedRFCtool EDC isrequired itshouldcapturethesameinformationaslistedabove ExampleofanRFCCoverSheet ExampleofaFlowchartRFC ColumnType ExampleofaFlowchartRFC ConventionalType EXERCISE2 UsingthesamegroupingasinExerciseA CompletetheRFCflowfollowingSteps4to5ChooseareporterPresenttotheclassafter20minutes Step6 DevelopmentTeamReview ReviewtheRFCtoensurecorrectnessReviewforlogic typographicalandothererrors clearandconsistentwording ease of use correctformatting infiniteloops anddeadends Step7 PublishtheRFC IncorporateRFCintoaspecandpublishTheentireRFCshouldbedocumentedwithinthemoduleoperatingspecorasanattachment ConductRFCtrainingtoallusersandstakeholders DocumentationofRFCResults Ifrequirementispaper baseddocumentation Foreveryactionitemcompleted RFCUsertoSignoutsideofthetooldiagramforaflowcharttypeRFCSignoutsideofthe Initial columnforatabulartypeRFCWhetherrequirementispaper basedorelectronicdocumentation RFCUsershoulddocumentthelastRFCactioncompletedandcorrespondingcorrectiveactions Example Inpapercontrolcharts documentationiswrittenonthebackofthecharttogetherwithcommentsfortheOOCpoints InEDC documentationisdoneintheAnnotationportionoftheEDCscreen RFCStorageandRetention Manufacturing orwhichevergrouptheprimaryRFCUserbelongsto isresponsibleforcreatingastorageandretentionsystemfordocumentedRFCactions RetentionperiodfordocumentedRFCactionsmustbedefined RFCContinuousImprovement RFChastobereviewedperiodicallyforimprovementondocumentedperiodicbasisorwheneverthereisanychangeintheprocess equipment CheckeffectivenessofdefinedRFCactionitemsEvaluateperformanceofmachineaffectedReviewoverallRFCusageAssesssuccessofRFCinfindingtheproblemRFCOwnerisresponsibleforreviewingtheRFC RFCmustberevised updatedwhenfoundtobeineffectiveorinsufficientduringthereview ContinuousImprovementGuidelines CheckeffectivenessofdefinedRFCActionItemsMakeafrequencycharttoshowhowmanytimestheRFCstoppedateachactionitem DoesahighfrequencyLastActionCompletedindicateaprocessing procedural orequipmentchangeisinordertopreventtheproblem ShouldaspecificActionbemovedclosertothefrontoftheRFC DoestheproblemdescriptionandsolutionlistedundertheLastActionCompletedaccuratelyreflecttheactualproblemandwhatwasdonetoresolveit ContinuousImprovementGuidelines cont EvaluateperformanceofmachineaffectedDoesthesamemachine haveallormostoftheproblems Aretheproblemsspreadequallyamongallthemachines Lookiftherearetimepatterns Whatdotheseindicate Example DomostoftheRFCsinMarchstoppedatActionC DomostoftheRFCsfromShift1stoppedatActionE Contin