《质量控制介绍》PPT课件

FirstTimeQuality一次下线合格率,2,FirstTimeQuality,WhatFirstTimeQualityIs一次下线合格率是什么?WhyItIsImportant它的重要性在于?WhyWeNeedtoMeasureIt我们为什么要去测量它?HowtoCalculateIt如何进行计算?FTQDeployment,EvaluationandImprovementProcessFTQ调度,评估及改进程序Responsibilities职责TheStructuredApproachSteps结构化改进步骤TheBasicQualityTools基本质量工具HowtoApplytheQualityTools工具使用方法MonitoringandReporting检测及报告ClassExercise,3,WhatisFirstTimeQuality?一次下线合格率是什么?FirstTimeQualityisameasureofthenumberofpiecesrejectedinamanufacturingprocessversusthetotalnumberofpiecesattempted.一次下线合格率是指在一次生产过程中所产生的不合格品与总产量的比值,FirstTimeQuality,4,DefineALARMLIMITS确定警戒线CatchandCountDefects捕捉并计算不良品ReacttoALARMLIMITS对警戒作出反应,FollowReactionPlan根据应对计划,VoiceoftheCustomer客户反馈,FirstTimeQuality,InitiateStructuredProblemSolving开始结构化问题的解决,ZERODefectsForward,Astructuredapproach,5,FTQcanbeviewedasatwophaseapproach:FTQ可以分为两个步骤Immediateactionandcontainment快速反应及解决Wheneveralarmlimitsareexceeded一旦超过警戒线,及时做出反应Helpsensurecustomerprotection提供帮助来保护客户ContinualImprovement持续的改进Managementobjectivetoreducequantityofrejectsandoperationalcost管理目标是不断的减少不良品,降低生产成本LeadershipMUSTensure,supportandfollow-upwithimplementationofFTQintheirfacilitytobesuccessful领导者必须保证,支持并遵循FTQ,以使其在工厂成功运用.,FirstTimeQuality,6,WhyisFTQimportant?FTQ为什么重要?Becauseifwedontmakegoodpartsthefirsttime,wehaveto“inspectin”quality因为如果我们不能一次产出合格品,我们就必须对产品质量进行多次检验Weknowinspectionisatbest85%effective检验至多在85%的情况下是有效的Therefore,anytimeFTQisgreaterthan0,wearedependentoninspectiontoprotectthecustomer因此,当FTQ不为0时,我们只有依靠检验来保护客户的利益Toreducemanufacturingcostsanddefectsthroughcontinualimprovement(FTQTrackerorStepDownChartaretoolstoutilize)通过使用FTQ追综表或SDC表,持续的改进可以降低生产成本,减少不良品.Tomonitorprocessstabilityandreactquicklytopotentialissues(Alarmlimitsandprocessmonitoringsheets)通过警戒线表及过程监控表,我们可以监控过程的稳定性并对潜在问题快速应对,FirstTimeQuality,7,FTQshouldbeviewedasatooltofacilitateoperationalimprovementin:FTQ应被视为用来促进生产改进的工具Quality质量Cost成本,FirstTimeQuality,8,intothis!,toturnthis,FTQisKeytoourSuccessFTQ是我们成功实现财富增值的秘诀,FirstTimeQuality,9,WhydoesFTQneedtobemeasured?为什么FTQ需要被测量MainReasons:主要原因:Itistheearlysignalthataprocessisoutofcontrol它对异常过程作出早期反映信号.Itallowsustorespondtoproblemsinternallybeforetheyreachourcustomers它让我们在顾客发现问题前在内部做出反应.Itmeasuresimprovementfromcorrectiveactionsimplemented它可以对矫正措施的效果进行评估监测Ifwedontfixourqualityproblemsinternally,wewillneverbeabletofixourexternalcustomerissues如果我们不能在内部解决质量问题的话,我们也不会有能力去解决外部的客户问题.,FirstTimeQuality,10,Filter过滤器,Inspectionmissessomedefects检查漏掉了一些不良品,Defectsnotcaught漏掉的不良品,Problem问题,D,Inspectionislikeafilter.检查就像过滤器,Thefatalflawofinspection检查的致命缺陷,FirstTimeQuality,11,HowisFirstTimeQualitycalculated?FTQ如何计算FTQisreportedinpartspermillion(PPM)defectiveFTQ以每百万产品不良率来报告Itcanbemeasuredatanystepinthemanufacturingprocesswherepartsarerejectedespeciallywherethedefectisoriginated.它可以在生产过程中产生不合格品的任何一个步骤进行测量,尤其是不良品的起源Itiscalculatedbycountingthenumberofpiecesrejectedversusthetotalnumberofpiecesattempted它的计算方式是不良品总数与总产量的比Thetotalnumberofpiecesattemptedincludesallgoodpiecesproducedplusallpiecesrejected总产量包括所有合格品与所有不良品.Piecesrejectedareallpartsscrappedorreworkedpriortousagebysubsequentprocesses.Theactualcalculationlookslikethis:不良品包括所有还未流入下一工序的废料和重工品.具体计算方式如下:NumberofPcs.Rejected不良品总数TotalNumberofPcs.Attempted总产量,X1,000,000=FTQPPM,FirstTimeQuality,12,HowisFirstTimeQualitycalculated?一次下线合格率如何进行计算?Anexampleatthecelllevel:举个电池的例子Cell“A”hassixoperationsA类电池需要六个工序Rejectdataiscollectedatoperations3and6.在工序3和6中采集到了不良品数据Cell“A”produced1040goodpiecesduringthefirsthour.在第一个小时内生产了1040个合格品AtOP.3,28pcs.wererejected.在工序3,28件不合格品AtOP.6,16pcs.wererejected.在工序6,16件不合格品WhatistheFTQinPPMforCellA?A类电池的百万一次下线合格率是多少?28+16441040+28+161084,1,2,3,4,5,6,=X1,000,000=40,590PPMFTQ,28,16,TallySheet计数图,FirstTimeQuality一次下线合格率,13,FirstTimeQuality,WhatFirstTimeQualityIsFTQ是什么WhyItIsImportant它为什么重要WhyWeNeedtoMeasureIt我们为什么要去测量它HowtoCalculateIt如何进行计算FTQDeployment,EvaluationandImprovementProcessFTQ的调度,评估及改进程序Responsibilities责任TheStructuredApproach结构性方法TheBasicQualityTools基本质量工具HowtoApplytheQualityTools如何使用质量工具MonitoringandReporting检测与报告ClassExercise,14,FTQImprovementProcessFTQ改进程序,Stakeholderinvolvement投资者参与模式,15,LEAD,SUPPORT,TypicalResponsibilitiesFlowchart典型的职责流程图,FTQImprovementProcessFTQ改进程序,16,SQorSDEResponsibilities质量工程师职责Ensuresupplierunderstands,andifnecessary,obtainsappropriatetrainingontheFTQImprovementprocess确保供应商明了FTQ，如有必要，要接受关于FTQ改进程序的适当培训MonitorimplementationprogressduringFTQactivities在FTQ活动中进行进程的监控Conduct5stepsiteevaluationforFTQimplementation对FTQ的执行，进行步评估Setstageforimprovementactivities为改进行动奠定基础Outlineplanofattack批评的大致计划Documentimprovementplan(i.e.throughanA3)文件改进计划（如：通过A3）,FTQImplementationFTQ执行,17,SELECT选择,CONTAIN抑制,CORRECT矫正,PREVENT预防,FTQImprovementProcessOverall全面的FTQ改进程序,18,DefineALARMLIMITS确定警戒限CatchandCountDefects捕捉并清点不良ReacttoALARMLIMITS反应,FollowReactionPlan,VoiceoftheCustomer客户反馈,FirstTimeQuality,InitiateStructuredProblemSolving开始程式化问题解决,ZERODefectsForward,Astructuredapproach,19,FTQImprovementProcessFTQ改进程序,Definealarmlimitsandreactionplan确定警戒限及反应计划AlarmlimitsmustbebasedoncurrentprocessrejectdataoravailabledatafromMachinequalificationruns,RunatRate,historicaldata,etc.警戒必须基于现工序的不良数据或是从机器在一定功率下运行产生的历史数据，等Needtocollectdatalongenoughtoensureyouunderstandthetypesandquantitiesofdefectsthatfalloutfromyourcurrentprocess.Limitsforcommoncause(chronic)rejectsmaybestatisticallycalculated必须经过足够长时间的数据收集，我们才能确定从现运行程序中漏掉的不良品的种类和数量一些共同原因产生的不良也可通过这些统计被找出Understandprocessandexpecteddefects(whattypesandquantitiesofdefects)了解程序和预估不良（不良品的种类和数量）Determinetheprocessnormalrangeofvariationbychartingtherejectdataovertime通过对不良数据制表认知，确定程序的正常变化幅度,20,FTQImprovementProcessFTQ改进程序,Definealarmlimitsandreactionplan确定警戒限及反应计划Limitsforspecialcause(nonchronic)rejectsmustbesetatonepiece突发原因产生的不良显示必须在一产生时就做出调整Limitsmustbecommunicatedtooperatorssotheycanreact限定还必须与操作员交流清楚以便他们能及时反应Ifalarmlimitsareexceeded,theremustbeadocumentedreactionplanwhichincludescontainmentofproductandprocesscorrections.如果警戒限被超，要有书面的反应计划包括生产抑制以及程序更正Employeesmayfindcleverwaystoidentifyabnormalprocessstateastheprocessmatures随着程序的成熟，职工也会发现识别异常的巧妙方法Theimmediateactiontakenisthemostimportantstepincontainingtheproblemuntilithasbeeneliminatedandverified遏制问题的最重要的步骤是快速采取行动直到问题被消除并核实,21,QualityAlarmLimit:品质警戒限,Example:RejectedPartsCounter例：不合格品的计数,Thecounterisflippedforeachdefect.Thecolorwillchangefromgreentoyellowtored.在每个不良品上要附上这种卡片颜色有绿黄红三种Yellowindicatesactionrequiredandredwillstoptheprocess.黄色表示要采取行动，而红色表示停止工序Smallwhitetagsareplacedwitheachdefectiveparttoidentifythespecificdefect.每个不良品上会有一个白色小标签注明不良原因,22,Identifyandcountrejectedparts识别及清点不良品Operatorsmusthavesufficienttoolsandskillsinordertoidentifyproductdiscrepancies操作员必须有足够的工具及技能来识别产品缺陷Itisrecommendedthatrejectedpartsberemovedfromthecellstationatadefinedfrequencysotheymaybecountedandcategorizedbydefectorreworkcode不良品应定期从工作区移开，以便进行计数并不良品号码登记Toolstoenhancetheoperatorsabilitytoidentifyproductdiscrepanciesinclude:用来增强操作员识别产品差异的工具包括：BoundarySamples对比样品Illustrations图表Photographs照片Gages计量器Toolsforcountingrejectedpartsinclude:清点不良品的工具有：PartsCounters计数器TallySheets计数表SizedContainers定容器,FTQImprovementProcessFTQ改进程序,23,ImplementAlarmReactionPlanifLimitExceeded如果超过警戒限，执行反应计划ReactionPlan:反应计划,FTQImprovementProcessFTQ改进程序,24,RecordData记录数据Datamustberecordedandplottedovertime:要按时记录数据并绘制数据图Atthecelllevel,thenumberofpiecesrejectedshallberecordedbydefectcategoryatadefinedfrequency.Thisdatamustbeusedtoreacttoabnormalprocessconditions(processmonitoring)每个作业区都必须用不良记录表以一定频次来记录不良品数目数据必须用来对异常程序作出反应（程序监测）Sincetheareaofopportunityvariesfromsampletosample,therejectcountmustbeconvertedintoarate(FTQPPM)priortocharting因为样品与样品的EachareashouldhaveaperformancetrackingboardthatwouldreflectthemanufacturingFTQinformationbyshift,FTQImprovementProcessFTQ改进程序,25,AnalyzeData分析数据Thebasicqualitytoolsare:基本的品质工具FlowCharting流程图CheckSheets报帐单Pareto柏拉图CauseandEffect因果图RunChartHistogram柱状图ScatterDiagram散布图ControlChart控制图,FTQImprovementProcessFTQ改进程序,26,InitiateStructuredProblemSolving开始程式化问题解决UnderstandDefectsandDecidetheOrderofPriority:了解不良并确定优先顺序AssignproblemstoCross-FunctionalGroup:向独立功能性小组提交问题SelectandPlantheImprovement:1RightInformation2RightCause3RightTiming选择并计划改进:1正确的信息2正确的原因3正确的时间FixtheBiggestProblemsFirst:先解决最大的问题,Problems,1,2,1,2,ResponsibleTeamWorksProblems负责小组指出问题,DEFECT1.-2.-3.-,4,3,2,3,2,2,1,1,1,1,FirstTimeQualityProcess一次下线合格率程序,27,AnalyzeData分析数据,ProblemIdentification问题识别,ProblemAnalysis分析问题,Flowchart流程图Brainstorming头脑风暴,ParetoChart柏拉图Cause&Effect因果图ControlChart控制图CheckSheet报帐图RunChart趋向图Stratification分层图,Histogram柱状图ScatterDiagram散布图ProcessCapability加工能力,Chartscanbeusedfordifferentpurposesinvariousstagesoftheproblem-solvingprocess在问题解决程序中许多阶段,图表都可以用于不同的目的.Thetoolsincludedintheintersectingportionofthisdiagramcanbeusedinboththeproblemidentificationandproblemanalysisphaseofproblemsolving位于上图交叉部位的工具既可以用于问题的识别也可用于问题的分析.,FTQImprovementProcessFTQ改进程序,28,SelectandPlanImprovement选择和计划改进AfterFTQproblemshavebeenidentifiedthroughdataanalysis,improvementplansmustbedeveloped通过数据分析FTQ问题被界定后，改进计划必须被制定Arecommendedtemplatehasbeenprovidedtotrackimplementationstatusofcorrectiveactions(FTQTrackerorStepDownChart)跟踪纠正行动执行状况推荐模板被提供（FTQ跟踪或趋势图）Tobemakeproblemsolvingtrulyeffective,standardworkmustbeutilized.Standardworkislikearecipe:varyingmethodandcontentwillnotyieldsameresults!对于被有效解决的制造问题，必须形成工作标准。工作标准就象一个处方：不同的工作方法和内容将得出不同的结果,FTQImprovementProcess,29,ImplementandEvaluate执行和评价OncetheCorrecti