8D培训教材精编版

1、Training Module 8D Problem Solving 培训教程培训教程 8D 问题解决问题解决 PRIVATE Why are we here? 为什么我们在这里？为什么我们在这里？ We want you to teach this module in the future to your key people under you. 我们希望在不久的将来您能把这一我们希望在不久的将来您能把这一教程教授给您的下属。教程教授给您的下属。 Problem Solving (SQ and Supplier Support - Private Method, Process How w

2、e do work? 方法方法,过程过程-我们如何工作？我们如何工作？ Input + Method = Output 输入输入 + 方法方法 = 输出输出 ? You own your “method”! 你拥有属于自己的“ 方法”! ? “Method” differentiates the output. “方法” 区分了输出 Problem Solving (SQ and Supplier Support - Private Method, Process How we do work? 方法方法,过程过程-我们如何工作？我们如何工作？ Method of doing work is

3、a Competitive Advantage 工作的方法是强有力的竞争优势工作的方法是强有力的竞争优势 Input + Method = Output 输入输入 + 方法方法 = 输出输出 Problem Solving (SQ and Supplier Support - Private 盈利能力盈利能力 Profitability 竞争能力竞争能力 Competitiveness 满意度满意度 Satisfaction 及时化及时化 Just in time 平准化平准化 &能力能力 Leveling & Capacity 连续流连续流 Continuous flow 拉动系统拉动系统

4、Pull system 节拍时间节拍时间 Takt time 员工参与员工参与 Employee involvement 安全安全 &人机工程学人机工程学 Safety & Ergonomy 柔性柔性&激励激励 Flexibility & Motivation 训练到标准化训练到标准化 Discipline to standards 持续改进持续改进 Continuous improvement 质量第一质量第一 Quality first 质量保证质量保证 Quality assurance 质量方法质量方法 Quality methods 高频次交货高频次交货 Frequent deliv

5、eries 生产线概念生产线概念 Line concepts 过程过程&结果结果 Process & Result 不要批评，不要指责不要批评，不要指责 Dont judge, dont blame ! 六西格玛六西格玛 Six Sigma 团队合作团队合作 Team work 5S 5S 标准化标准化 Standards 全员生产性维护全员生产性维护 消除浪费消除浪费 Muda elimination TPM Problem Solving (SQ and Supplier Support - Private What are Problems? 什么是问题什么是问题? Problems a

6、re gaps between the actual condition and the desired condition. 问题是现实与期望的差距问题是现实与期望的差距 Gap = Problem 实际情况 差距=问题 期望情况 Problem Solving (SQ and Supplier Support - Private Problem Solving问题解决问题解决 Gap = Problem = = 实际情况 8D Problem Solving Method 8D问题解决方法 期望情况 Gap = Problem 实际情况 Problem Solving (SQ and Su

7、pplier Support - Private 期望情况 Method of Problem Solving 问题解决的方法问题解决的方法 8D Problem Solving, Corporate Standard AS63 Form a team 1 组建团队组建团队 5 2 Describe the Problem 描述问题描述问题 Implement Containment Actions 实行实行“围堵围堵”行动行动 Identify Root Causes 定义根本原因定义根本原因 Choose and implement Corrective Actions 选择并实行纠正措施

8、选择并实行纠正措施 Evaluate Result 评估结果评估结果 6 3 7 Prevent Reoccurence 预防再次发生预防再次发生 4 8 Congratulate the team 团队庆祝团队庆祝 Problem Solving (SQ and Supplier Support - Private 1 Form a team 8D Problem Solving, Autoliv Standard AS63 组建团队组建团队 Get the right people! 去找正确的人! Problem Solving (SQ and Supplier Support - Pr

9、ivate 2 Describe the Problem 描述问题描述问题 8D Problem Solving, Autoliv Standard AS63 ? Use Data 使用数据 ? Pictures/sketches of Desired and Actual conditions实际与期望情况下的照片和草图 ? “Go and See” approach 去现场观察 ? Compare OK and NOT OK conditions比较 “OK” 和 “NOT OK” 的情况 ? “A well defined problem is 50% solved.”当一个问题有了很好

10、的定义，那该问题就已经解决了一半 Who, What, Where, When and How Many 谁,什么,哪里,何时,多少 Problem Solving (SQ and Supplier Support - Private 3 Implement Containment Actions 实行实行“围堵围堵”行动行动 ? Quickly contain non-conformances from ? Problem Start Point ? Problem Stop Point 8D Problem Solving, Autoliv Standard AS63 迅速控制从问题开始点

11、至问题结束点之间的不合格品 ? Appropriate instructions 恰当的指导 ? Validated to ensure effective确保有效 ? Verified by management 管理层审核 No bad parts to the customer! 不向客户递送不合格品! Problem Solving (SQ and Supplier Support - Private 4 Identify Root Causes 定义根本原因定义根本原因 8D Problem Solving, Autoliv Standard AS63 ? Why the probl

12、em occurred?问题为什么发生? ? Why was the problem not detected?为什么问题没有被察觉到? Tools工具工具: ? Observation - Watch the process 观察观察-关注流程关注流程 ? 5 Why 5个为什么个为什么 ? 现场再现现场再现 ? Fish鱼骨图鱼骨图 ? Go and See 去现场去现场 ? More其他其他 Find the true cause! 找到真正的原因！ Problem Solving (SQ and Supplier Support - Private 5 Why Tool 5个为什么个为

13、什么 5 Why ? Ask “why” to understand problems 通过问” 为什么来理解问题 ?Ask “why” at least 5 times. 至少问5次” 为什么” ? Ask as many “whys” as you can, then go 1 more 尽量多问几次” 为什么” ? Verify that the “whys” are true 验证这些” 为什么” 是正确的 ?Gather data, go and see.收集现场收集数据 ?Try to turn the problem on and off 试着还原并解决问题 Why? Why?

14、Why? . 为什么?为什么?为什么 . Problem Solving (SQ and Supplier Support - Private Example: 例子例子 5 Why Problem: 问题： Printer always displays “Failure”. Why ? 打印机总显示“失败”，为什么？ ? Jam in feeder. Why ? 进纸处卡纸，为什么？ ? Multiple sheets were drawn-in at the same time. Why ? 同时进多张纸，为什么？ ? Sheets were inserted incorrectly (

15、“Dog -ears”). Why ? 纸张放入错误（褶角） ，为什么？ ? The feeder is difficult to reach. Why ? 进纸口很难碰到，为什么？ ? The printer is too close to the wall. 打印机离墙太近 Conclusion: Move printer away from the wall. 结论 : 把打印机搬离墙壁 . Problem Solving (SQ and Supplier Support - Private 5 Corrective Actions 选择并实行纠正措施选择并实行纠正措施 8D Probl

16、em Solving, Choose and Implement Autoliv Standard AS63 ? How was the occurrence fixed?怎样处理这一事件怎样处理这一事件? ? How was the non-detection fixed?怎样解决检查中的疏漏怎样解决检查中的疏漏 Install permanent fixes! 实现永久性的解决! Problem Solving (SQ and Supplier Support - Private 6 Evaluate Result 8D Problem Solving, Autoliv Standard

17、AS63 评估结果评估结果 ? Is the problem solved?问题解决了吗 ? Show me the data!给我看数据 ? Time or sample size.时间或样品尺寸 Confirm the problem is eliminated! 确定问题已经排除! Problem Solving (SQ and Supplier Support - Private 7 Prevent Reoccurence 预防再次发生预防再次发生 8D Problem Solving, Autoliv Standard AS63 ? Look at similar products

18、and processes纵观相似的产品，设备和工艺。 ? Keep your lessons for the long-term为将来积累经验 ? Find and fix the system cause that prevents the problem 通过发现和解决系统导致的问题来预防问题的产生 ? Assure the fixes are effective today ! 确定措施有效 Tomorrow !明年! One year from now !从现在起的一年! Never repeat a problem. 不让问题重现 Problem Solving (SQ and Supplier Support - Private 8 Congratulate the team 团队庆祝团队庆祝 8 D Problem Solving, Autoliv Standard AS63 ? Rein