《FTQ中英文》PPT课件

FirstTimeQuality,2,FirstTimeQualityTrainingModule,TrainingObjectives培训目标:ToUnderstand理解WhatFirstTimeQualityIs什么是一次下线合格率?WhyItIsImportant一次下线合格率的重要性WhyWeNeedtoMeasureIt为什么需要对一次下线合格率进行测量?HowtoCalculateIt如何计算?WhattheFTQDeploymentProcessis怎样进行FTQ?WhattheBasicQualityToolsAre基本质量工具是什么?HowtoApplytheQualityTools怎样运用基本质量工具?WhattheDeliverablesarethateachPlantWillbeResponsibleforMonitoringandReporting每个工厂应该监控和汇报什么?,3,FirstTimeQualityTrainingModule,WhatisFirstTimeQuality?什么是一次下线合格率?FirstTimeQualityisameasureofthenumberofpiecesrejectedinamanufacturingprocessversusthetotalnumberofpiecesattempted一次下线合格率是测量制造过程中不合格品数与总产品数的比值.,REJECTS,4,FirstTimeQualityTrainingModule,WhyisFTQimportant?一次下线合格率的重要性Becauseifwedontmakegoodpartsthefirsttime,wehavetoinspectinquality因为如果我们第一次没有生产出好的产品,我们就必须进行检验.Weknowinspectionisatbest85%effective我们知道检验最多只有85%的有效性.Therefore,anytimeFTQisgreaterthan0,wearedependentoninspectiontoprotectthecustomer因而,如果任何时候一次下线合格率大于0,我们都需要依赖检验来保护客户.Toreducemanufacturingcosts降低制造成本Toeliminatewastethroughthevaluestreamandmeetcustomerrequirements(taketime)通过价值流和满足客户要求来消除浪费.,5,CatchDefects,Filter,Inspectionmissessomedefects检验会遗漏一些缺陷,Defectsnotcaught漏网缺陷,VoiceoftheCustomer客户的声音,Problem问题,D,D,TheRoleofInspection,D,Inspectionislikeafilter检验好比一个筛子,6,1,2,Catch&Countdefects抓住并计算缺陷,ReacttoALARMLIMITS超过警戒线的反应,FollowReactionPlan执行反应计划,VoiceoftheCustomer客户的声音,TheRoleofFirstTimeQualityProcess,ReactionPlan,ZERODefectsForward,7,AnalyzeData分析数据UnderstandDefectsandDecidetheOrderofPriority:理解缺陷并决定优先次序AssignproblemstoCross-FunctionalGroup:向跨功能小组提出问题SelectandPlantheImprovement:1.RightInformation2.RightCause3.RightTiming选择并计划改善问题正确的信息正确的原因正确的时间选择FixtheBiggestProblemsFirst:首先找到最大的问题所在,ResponsibleTeamWorksProblems相关团队负责解决问题,DEFECT1.-2.-3.-,HourGlass,TheRoleofFirstTimeQualityProcess,4,3,2,3,2,2,1,1,1,1,8,InspectionExercise,THENECESSITYOFTRAININGFARMHANDSFORFIRSTCLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCKISFOREMOSTINTHEMINDSOFFARMOWNERS.SINCETHEFOREFATHERSOFTHEFARMOWNERSTRAINEDTHEFARMHANDSFORTHEFIRST-CLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCK.THEFARMSOWNERSFEELTHEYSHOULDCARRYONWITHTHEFAMILYTRADITIONOFTRAININGFARMHANDSOFFIRST-CLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCKBECAUSETHEYBELIEVEITISTHEBASISOFGOODFUNDAMENTALFARMMANAGEMENT.,CounttheNumberofFscontainedintheparagraphbelow(60sec)数一下下面总共出现了几个“F”（60秒）,9,InspectionExercise,THENECESSITYOFTRAININGFARMHANDSFORFIRSTCLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCKISFOREMOSTINTHEMINDSOFFARMOWNERS.SINCETHEFOREFATHERSOFTHEFARMOWNERSTRAINEDTHEFARMHANDSFORTHEFIRST-CLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCK.THEFARMSOWNERSFEELTHEYSHOULDCARRYONWITHTHEFAMILYTRADITIONOFTRAININGFARMHANDSOFFIRST-CLASSFARMSINTHEFATHERLYHANDLINGOFFARMLIVESTOCKBECAUSETHEYBELIEVEITISTHEBASISOFGOODFUNDAMENTALFARMMANAGEMENT.,Totalof36Fs,10,FirstTimeQualityTrainingModule,WhydoesFTQneedtobemeasured?为什么需要测量FTQMainReasons主要原因:Itisthefirstsignalthataprocessisoutofcontrol它是过程失控最先发出的信号Itallowsustorespondtoproblemsinternallybeforetheyreachourcustomers它使我们能够在问题到达客户之前先在内部作出反应.Itmeasuresimprovementfromcorrectiveactionsimplemented通过执行纠正措施后来衡量问题改善的情况.Ifwedontfixourqualityproblemsinternally,wewillneverbeabletofixourexternalcustomerissues如果我们不能在内部找到质量问题,我们就不能确定外部客户的问题.,11,FirstTimeQualityTrainingModule,HowisFirstTimeQualitycalculated?如何计算FTQFTQisreportedinpartspermillion(PPM)defectiveFTQ反映每一百万个产品中的缺陷产品数.Itcanbemeasuredatanystepinthemanufacturingprocesswherepartsarerejected可以在有拒收产生的制造过程的任何一步测量FTQ.Itiscalculatedbycountingthenumberofpiecesrejectedversusthetotalnumberofpiecesattempted通过以不合格品数除以总数来计算.Thetotalnumberofpiecesattemptedincludesallgoodpiecesproducedplusallpiecesrejected总的产品数包括生产出来的所有合格品数和不合格品数之和.Piecesrejectedareallpartsscrappedorreworkedpriortousagebysubsequentprocesses.Theactualcalculationlookslikethis:不合格品数包括所有报废和经过返工后合格的产品数.公式:NumberofPcs.Rejected不合格品数TotalNumberofPcs.Attempted总产品数,X1,000,000=FTQPPM,12,FirstTimeQualityTrainingModule,HowisFirstTimeQualitycalculated?如何计算FTQ?Anexampleatthecelllevel:Cell“A”hassixoperationsA单元有6个操作工序Rejectdataiscollectedatoperations3and6在第三和第六工序收集到不合格品数据Cell“A”produced1040goodpiecesduringthefirsthourofproduction.第一个小时A单元共生产良品1040件AtOP.3,28pcs.wererejected.第三工序发现28件不合格品AtOP.6,16pcs.wererejected.第六工序发现16件不合格品WhatistheFTQinPPMforCellA?A单元FTQ的PPM是多少?28+161040+28+16,1,2,3,4,5,6,X1,000,000=40590PPMFTQ,28,16,TallySheet,13,FirstTimeQualityTrainingModule,WhatistheFirstTimeQualityImprovementProcess?什么是FTQ改善过程?FTQprocessdefinesacommonprocesstobeusedbyallDelphimanufacturingplantstomeetthebusinessplanrequirementsanddrivedefect-freemanufacturingFTQ是Delphi工厂常用的以达到商业计划要求和无缺陷生产要求的一个方法.TheFTQprocessdefinesFTQ定义:ProcessSteps流程步骤Stakeholders有关系的人DeploymentChart(functionalflowchart)foridentifyingleadfunctions用于识别重要功能的布置图表(功能流程图)ControlPlanforTrackingImplementation控制计划和跟踪执行,14,IDENTIFY&,COUNT,DISCREPANT,PARTS,IMPLEMENTIMPROVEMENT执行改善,EVALUATE评估,INSTITUTION-ALIZELESSONSLEARNED系统化经验教训,TOOLSFOR,IDENTIFICATION用于识别的工具:,-PROCESSCONTROL,PLAN过程控制计划,-BOUNDARYSAMPLES边界样品,TOOLSFORCOUNTING用于计数的工具:,-PARTSCOUNTERS产品计数器,-TALLYSHEETS计数表,-SIZEDCONTAINERS有尺寸大小的容器,TOOLS工具:,-PARETO直方图,-CAUSE&EFFECT,(FISHBONE)原因和结果(鱼骨图),-CONCENTRATION,DIAGRAM集合表,-FLOWCHART流程图,-HISTOGRAM柱状图,-SCATTER,DIAGRAM散布图,-CHECKSHEET检查表,-5WHYS5个为什么,EXAMPLES例子:,-CROSS-FUNCTIONAL,TEAMS跨功能小组,-CHANGEBOARDS变化看板,-RPNREDUCTION降低RPN,-STATISTICALENGINEERING,PROJECTS统计工程方案,ACTIONPLAN行动计划:,-WHAT,WHEN,WHO事件,时间,人物,TOOL工具:,-ACTIONPLAN行动计划,TOOLS工具:,-PFMEA过程流程图,-PROCESSCONTROLPLAN过程控制计划,-LOOK-ACROSS-CHART浏览表,-5WHYS5个为什么,SELECT&PLANIMPROVEMENT选择和计划改善,NEWLEVELOFQUALITY?新的质量水平,DEFINE,REACTION,PLAN&,ALARM,LIMITS定义反应计划和警戒线,RECORDDATA记录数据,TOOLS工具:,-CONTROLCHART控制图,ANALYZE,DATA分析数据,TOOL工具:,-RUNCHART运行图,-GATECHART门图,ALARMEXCEEDED是否超过警戒?,IMPLEMENTALARMREACTIONPLAN执行报警反应计划,YES,NO,NO,YES,IDENTIFY确认,ANALYZE分析,PLAN计划,EVALUATE评估,IMPLEMENT执行,FTQImprovementProcess,识别和清点有差异的产品,15,FTQImprovementProcessStakeholderFootprint,PlantAPltBPltC,CELL1,2,3,4,5,7,8,N,6,OPERATOR操作人员,OPERATOR操作人员,OPERATOR操作人员,OPERATOR操作人员,OPERATOR操作人员,TEAM,LEADER小组领导,CROSS-,FUNCTIONAL,TEAM跨功能小组,PRODUCTENGINEERINGMANAGER产品工程经理,QUALITY,MANAGER质量经理,MAINTENANCE,MANAGER设备维护经理,OPERATIONS,MANAGER制造经理,PROCESSENGINEERINGMANAGER工艺工程经理,PLANTMANAGER工厂经理,PC&L,MANAGER物流经理,CELL工作站,16,FirstTimeQualityImprovementProcessDeploymentFlowChart,LEAD负责,SUPPORT支持,17,FirstTimeQualityTrainingModule,ProcessStep1第一步Definereactionplanandalarmlimits定义反应计划和警戒线YouhavetostartsomeplaceAlarmlimitsmustbebasedoncurrentprocessrejectdataoravailabledatafromRunatRate,historicaldata,etc.警戒线必须基于在当前工艺下生产的不合格品数据,或源于按节拍生产,历史数据,等.Alarmlimitsmustbestatisticallycalculated警戒线必须进行统计计算.Alarmlimitsmustbecommunicatedtooperatorssotheycanreact警戒线必须与操作人员进行交流沟通.Ifalarmlimitsareexceeded,theremustbeareactionplantoimplement如果超过警戒线,必须有一个可执行的反应计划.Thereactionplanmustclearlydefinewhatactionsaretobetaken反应计划必须明确定义所需采取的行动.,DEFINEREACTIONPLANS&ALARMLIMITS定义反应计划和警戒线,18,FirstTimeQualityTrainingModule,ProcessStep2第二步Identifyandcountdiscrepantparts识别和计算有差异的产品数Operatorsmusthavesufficienttoolsandskillsinordertoidentifyproductdiscrepancies操作人员必须有足够的途径和技能来确认产品的差异.Toolstoenhancetheoperatorsabilitytoidentifyproductdiscrepanciesinclude用于加强操作人员确认产品差异的途径有:BoundarySamples极限样品Illustrations图表Photographs照片Gages量具Toolsforcountingdiscrepantpartsinclude用于清点差异产品的工具有:PartsCounters产品计数器TallySheets计数表SizedContainers容量固定的容器,IDENTIFY&COUNTDISCREPANTPARTS识别和清点有差异的产品,19,FirstTimeQualityTrainingModule,ProcessStep3第三步ImplementAlarmReactionPlanifLimitExceeded超过警戒线时反应计划的执行ReactionPlan反应计划:,IMPLEMENTALARMREACTIONPLAN执行警戒反应计划,AlarmLimitExceeded是否超过警戒线?Contain遏制Investigate调查ImplementContainmentPlanUntilProblemFixed执行遏制计划直到找到问题,Yes,ContainmentPlan遏制计划,20,FirstTimeQualityTrainingModule,ProcessStep4第四步RecordData记录数据Datamustberecordedandplottedovertime必须按时间记录数据:Whatchartshouldbeused应使用什么图表?Sincetheareaofopportunityvariesfromsampletosample,therejectcountmustbeconvertedintoaratepriortocharting如果单位时间内生产的样品数有很大不同，在制表时，需将拒收数转换为比率.WedothisbymeasuringFTQinPPM用PPM计算FTQPPMisaratePPM是一个比率.,RECORDDATA记录数据,21,n=avgsamplesize(18)np=numbernonconformingk=subgroups(25)_np=np1+np2+.npkk,avg=9.8,AlarmLimitCalculationusingnpChart,22,FirstTimeQualityTrainingModule,ProcessStep5第五步AnalyzeData分析数据Thebasicqualitytoolsare基本质量工具:FlowCharting流程图CheckSheets检查表Pareto柏拉图CauseandEffect原因和结果RunChart运行图表Histogram柱图ScatterDiagram散点图ControlChart控制图,ANALYZEDATA分析数据,23,FirstTimeQualityTrainingModule,ProcessStep5第五步AnalyzeData分析数据,ProblemIdentification确认问题,ProblemAnalysis分析问题,Chartscanbeusedfordifferentpurposesinvariousstagesoftheproblem-solvingprocess在解决问题的各个阶段都可使用图表用于不同的目的。Thetoolsincludedintheintersectingportionofthisdiagramcanbeusedinboththeproblemidentificationandproblemanalysisphaseofproblemsolving交叉部分的工具可同时用于确认问题和分析问题.,FlowchartChecksheetBrainstormingNominalGroupTechnique,ParetoChartCause&EffectRunChartStratification,HistogramScatterDiagramControlChartProcessCapabilityForceFieldAnalysis,ANALYZEDATA分析数据,24,FTQTools-柱状图,25,FTQTools-柏拉图,26,FTQTools-散布图,27,FTQTools-控制图,28,FTQTools-流程图,29,FTQTools-检查表,30,ExampleCause&EffectDiagram(Fishbone),FTQTools-因果图,31,FTQTools-走势图,32,FirstTimeQualityManagerAuditChecklistExample-FTQ管理者审核检查表,Example,33,FirstTimeQualityTrainingModule,ProcessStep6第六步SelectandPlanImprovement选择和计划问题的改善AfterFTQproblemshavebeenidentifiedthroughdataanalysis,improvementplansmustbedeveloped通过数据分析找到FTQ的问题后,必须进行改善计划.Arecommendedtemplatehasbeenprovidedtotrackimplementationstatusofcorrectiveactions推荐一种用于追踪纠正措施执行情况的模板.,SELECT&PLANIMPROVEMENT选择和计划改善,34,FTQTools,35,FirstTimeQualityTrainingModule,ActionPlanTemplate行动计划模板,36,FirstTimeQualityTrainingModule,ProcessStep7第七步ImplementImprovement执行改善WorktheActionPlan制订行动计划UpdatePlanasRequired更新计划DocumentImprovementsonChart在图表上记录改善情况,IMPLEMENTIMPROVEMENT执行改善,37,FirstTimeQualityTrainingModule,ProcessStep8第八步Evaluate评价OncetheCorrectiveActionhasbeenimplemented,thedatamustbeevaluatedfortrendsorshifts一旦执行纠正措施,必须对数据的趋势进行评估.Didtheproblemstay“killed?”Ifso,changealarmlimits如果问题已被消灭,须更改警戒线.Thisisoneofthereasonsitissoimportanttocollectdataovertime这就是按时间收集数据是如此重要的原因.Withoutdatathereisnowaytoevaluatetheimpactofthecorrectiveactionontheprocess如果没有数据就无法评估纠正措施对过程的影响.IfnosignificantreductioninFTQPPMisobserved,thenitispossiblethecausewasmisidentifiedtobeginwith如果没有显著降低FTQ的PPM值,很可能在最初没有找到产生问题的真正原因.,EVALUATE