质量问题分析法(DIVE).ppt

1、,DIVE Process Training August 14, 2013,Getting Started,What is DIVE/什么是DIVE? DIVE is a process for problem solving. DIVE是解决问题的一种流程 DIVE includes 4 steps: (1) Define, (2) Investigate, (3) Verify & (4) Ensure. DIVE有4个步骤(1)定义,(2)调查,(3)验证,(4)保证 DIVE can be applied to any problem from RMAs to production

2、failures to business problems. DIVE适用于RMA到生产过程中的所有问题以及商务问题,Slide no. 2,Source Photonics Confidential and Proprietary,Terminology,Escape: a defect that leaves its originating process and is found by an internal or external customer. Escape：失效品已离开自身的生产流程，而被外边或内部客户发现。以下包含了公司各类可能的“Escape” RMA OQA Failur

3、e ORT Failure DVT Failure SMT/OSA Failure Found in TRX (SMT/OSA失效流到了模块线） RRCA: Relentless Root Cause Analysis RRCA：深入根本原因分析,Slide no. 2,Source Photonics Confidential and Proprietary,Escape,Quality Clinic质量诊断,Slide no. 2,Source Photonics Confidential and Proprietary,Quality Clinic: a physical locatio

4、n containing all necessary test equipment for RRCA where DIVE teams rapidly investigate, diagnose & correct product and process defects. 质量诊所：具备DIVE小组实行快速调查，诊断，纠错所需测试设备的场所 Level 1 Clinic: focused on Escapes, SPs most serious quality problems. (also known as “the Hospital”) 一级诊断：重点诊断Escape问题（即跨流程间的流出

5、）和最严重的质量问题（也称 “质量医院”）。 Line Level Clinic: focused on In-Process Turnbacks. 产线级诊断：关注产品生产流程内的失效,DIVE Report,Slide no. 2,Source Photonics Confidential and Proprietary,DIVE Report replaces FAR, but now covers all Escape types. DIVE 报告替代FAR，但包含了 所有Escape类型,Case Owner can be from any department, not just

6、FA. 案件负责人将来自任何部门，而不限限于FA,DIVE Board,Slide no. 2,Source Photonics Confidential and Proprietary,Inputs to Level 1 Clinic,Slide no. 2,Source Photonics Confidential and Proprietary,RMA,Admit to Level 1 Clinic,Customer Compliant,ORT Failure,OQA Failure,SMT / OSA to TRX Line Escape,DVT Failure,REL Failure

7、,Step 1: Define第一步：定义,Slide no. 2,Source Photonics Confidential and Proprietary,Add to DIVE Board,New Case in Clinic,Initiate DIVE Report,Assign Case Owner,Define Problem,Assemble DIVE Team,Update DIVE Report (“D”),Initial Screening,New Issue?,Check Existing CAs,Initiate CAR,No,Yes,CA Status?,Comple

8、ted, but Not Effective,In Process,Exit Clinic Process,Scope & Containment Evaluation,Move to Investigate Phase,Upload to CAR System,Define DIVE Report定义 DIVE 报告,Slide no. 2,Source Photonics Confidential and Proprietary,Limit 1 Failure Mode (or Case) per DIVE Report. 每份DIVE报告包括且仅包括一种失效模式（或一个案例） Case

9、Defects = defect units all with same failure mode. 案例缺陷数：有着相同失效模式的所有缺陷,Describe the facts of the case here, but dont start RRCA until the “Investigate” section.此处只须描述故障 现象，到“调查”阶段时再填写RRCA,Is this a repeat failure? Have we seen similar problems before? 是否为重复出现的故障？以前是否出现 过相似的问题？,Step 2: Investigate第二步

10、： 调查,Slide no. 2,Source Photonics Confidential and Proprietary,Root Cause?,Update DIVE Board Status,Update DIVE Report (“I”),Create Fishbone Diagram,Inspect Defective Units,Generate Potential Root Causes,Test Root Cause,Perform 5-Whys Analysis,No,Yes,RRCA Process,Start Investigate Phase,Rank Potenti

11、al Root Causes,Identify Likely Root Cause,Move to Verify Phase,Upload to CAR System,Investigate DIVE Report调查 DIVE 报告,Slide no. 2,Source Photonics Confidential and Proprietary,Summarize Root Cause findings. Use “RRCA Ongoing” if Root Cause not yet found.总结根本原因， 如果还没找出根因，请注明 “RRCA 进行中”,Describe RRCA

12、process to date. Summarize test results and use Appendix A for additional data. 描述截止至今的RRCA 分析流程， 总结测试结果，如有其他的测试数据， 以附录A的格式一并附上,Investigate DIVE Report (Appendix A)调查 DIVE 报告(附录A),Slide no. 2,Source Photonics Confidential and Proprietary,Investigate Fishbone Diagram调查 鱼骨图,Slide no. 2,Source Photonic

13、s Confidential and Proprietary,Escape Symptoms,ENVIRONMENT,METHODS,PEOPLE,MEASUREMENTS,SYSTEM & EQUIPMENT,MATERIALS,Wrong SPEC,Missed Test Station,Untrained Operator,Wrong PCB,Out of Calibration,Rework Process,ESD Damage,Missing QC Station,Contamination,Inadequate Training,Solder Station,Poor Temp C

14、ontrol,Investigate 5 Whys Analysis调查 5个为什么分析法,Slide no. 2,Source Photonics Confidential and Proprietary,Failure Symptoms/问题现象: .,Step 3: Verify第3步：验证,Slide no. 2,Source Photonics Confidential and Proprietary,Start Verify Phase,Update DIVE Report (“V”),Update DIVE Board Status,Generate Corrective Act

15、ions,Apply Corrective Actions,Release for Rework,Verify Corrective Actions,CA Works?,Upload to CAR System,Move to Ensure,Yes,No,Verify DIVE Report验证- DIVE 报告,Slide no. 2,Source Photonics Confidential and Proprietary,Once implemented, verify that the Corrective Action creates the expected results./验证

16、改正 措施是否达到预期效果,Review full scope of the defect and Corrective Action. Could the same issue happen on other products / parts / processes?/对问题和改正措施进行 全面检查。其他产品/零部件/流程是否存在同样的 问题,Verify Defect Proofing验证 防失误,Slide no. 2,Source Photonics Confidential and Proprietary,Defect Proofing: Process design that el

17、iminates the possibility of defect every time. 防失误: 防止失误的必要流程,Good,Better,Best,Warning of potential defects. 潜在问题警告,Alert when defect is occurring. 发生失误时发出警告,Physically prevent defect from occurring. 从根本上防止失误发生,Verify Defect Proofing验证 防失误,Slide no. 2,Source Photonics Confidential and Proprietary,Le

18、vel 3,Level 2,Level 1,Step 4: Ensure第4步： 保证,Slide no. 2,Source Photonics Confidential and Proprietary,Start Ensure Phase,Update DIVE Board Status,Create 6-month Audit Plan,Exit Clinic Process,Update DIVE Report (“E”),Upload to CAR System,Remove Case from DIVE Board,Conduct Monthly Audits,Ensure DIVE Report保