福特8D报告ppt课件

1、1FORD 8D Methodology / DMAIC Approach & PDCA.2PDCA introduction8D introduction DMAIC brief introductionCIT introduction.3PDCAPDCA Cycle: Plan 方案 Do 执行 Check 检查 Action 纠正活动.4PDCA 改良方式C-Check检查A-Action纠正活动D-Do执行P-Plan方案Continuous ImprovementPDCA是一个继续的质量改善的螺旋上升循环.5优质企业客戶称心PDCAPDCAPDCAPDCA 继续改良PDCA不是一个平

2、面环，它是阶梯式上升的，这个循环走完一遍应该就曾经处理一部分问题，获得一部分成果，到了循环的下一个周期，在范围上就应该产生了变化，所以说它不是一个平面环。.6Ford-8D PracticeFollow this template!.7运用 Ford 8D 的时机 Consequences identified因果关系的鉴别 Cause unknown缘由不明时用8D来找缘由 Resources for problem solution & recurrence prevention management-approved 处理问题的资源和防止再发生措施的同意 Single-person ca

3、pacity for problem-solving exceeded不是一个人能处理的，需求经过脑力激荡和团队协作来处理 Symptoms defined异常情况曾经出现，并很明显 Symptom quantified with measurement异常情况可量化.8Ford-8D WorkflowDescribe the ProblemD1: 主题选定及小组成立D2: 问题描画及缘由确认D3: 展开暂时防堵措施D4: 定义及验证真因D5: 列出, 选定及验证永久对策D6: 执行永久对策及效果确认D7: 预防再发及规范化D8: 恭贺团队及未来方向Prevent RecurrenceImpl

4、ement Permanent Corrective ActionRecognize Team & Individual ContributionsYNEstablish a TeamDevelop Interim Containment ActionDefine & Verify Root CauseChoose & Verify Permanent Corrective Actions.9D1: Team BuildingEstablish a team with people:与此project 或任务相关的人有cross function的人一同参与有相关的knowledge expe

5、rience定期每周/每月review进度.10D2: Problem Description What is wrong with what? How can the problem be quantified? What? When? Where? How much? Cause & Effect? Something changed / never been successful?.11D3: Development of ICAICA = Interim Containment Action (暂时防堵措施) Quick fixes Temporary detective action

6、s Isolation from harmful effects. Short-term action before PCA are taken.PCA = Permanent Corrective Action.12D4: Definition & Verification of Root Cause Identify “real problem- 5 why Test each possible cause. Systematic use of resources. Ideality (What it is in best way)NO?YES?.13 Root Cause Identif

7、ication - SamplingProblem: Bipolar transistor gain in BiCMOS process out-of-spec high at e-test (WAT). 在WAT测试中发现BiCMOS工艺中的双极晶体管增益高出规 范的要求 Why#1 Why was the bipolar transistor gain too high? 为什么这个双极晶体管的增益太高？Answer#1: Emitter junction was too deep. 发谢极太深How do you know when you have found the true roo

8、t cause? there must be some element of human decision. .14Why#2: Why was the emitter junction too deep? 为什么发谢极太深？Answer#2: Actual furnace temperature was slightly high. (confirmed by manual profiling) 炉管的实践温度偏高了一点Why#3: Why was the actual furnace temperature slightly high? 为什么实践的温度会偏高一点？Answer#3: Fu

9、rnace controller spike thermocouples (T/Cs) did not extend far enough into the heat zone. 炉管的热电偶控制器不可以控制到炉管加热的整个区域 Root Cause Identification - Sampling.15 Root Cause Identification - SamplingWhy#4: Why didnt the spike thermocouples not extend far enough into the heat zone? 为什么炉管的热电偶控制器不可以控制到炉管加热的整个区

10、 域？Answer#4a: Thermocouples were slightly shorter than previous ones. 这个热电偶比之前的一个短Answer#4b: T/C position was not checked after installation. 安装后热电偶的位置没有检查热电偶的位置偏移了 .16D4: Definition & Verification of Root CauseWhy#5a: Why were the spike T/Cs slightly shorter than previous ones? 为什么这个热电偶比之前的一个短？Answ

11、er#5a: Spike T/Cs were being purchased from a new vendor. 这个热电偶是从一个新的供应商那里采购的 Why#6a: Why was a new spike T/C vendor being used. 为什么要从这个新的供应商处采购？Answer#6a: Reduced costs. 降低本钱 Why#7a: Why wasnt this problem anticipated? 为什么没有预料到这个问题？Answer #7a: No guidelines or procedures for such changes (no physic

12、al comparison done and no “What-could-go-wrong? analysis). 对这样的变卦没有程序规定没有做对比实验，也没有“能够 会引起什么样的错误的分析“没有程序文件或检查表是一个经常导致问题发生的根本缘由。.17D4: Definition & Verification of Root CauseWhy#5b: Why was the T/C position not checked after installation? 为什么安装后热电偶的位置没有检查Answer#5b: Equipment tech did not expect any pr

13、oblem. 设备侦探没有预期有任何问题。 Why#6b: Why did the Equip Tech not expect any problem. 为什么设备侦探没有预期有任何问题？Answer#6b: He was not informed that a new spike T/C vendor was being used. 没有通知他运用了新厂商的热电偶 Why#7b: Why was Equip Tech not informed that a new spike T/C vendor was being used? 为什么没有通知他运用了新厂商的热电偶Answer #7b: N

14、o procedure to do so for such material changes. 对于这个资料的变卦，没有程序规定要这样做。“没有程序文件或检查表是一个经常导致问题发生的根本缘由。.18下面列举了一些在FAB反复发生的典型的根本缘由 没有程序、或程序不完善、或 程序没有文件化或没有检查表 文件化的程序不清楚、不明确、不完善或让人糊涂。 腾跃式的程序以节省时间.D4: Definition & Verification of Root Cause.19D5: Choice & Verification of PCAPCA = Permanent Corrective Action

15、Elimination of root cause? Costs? Production stop? Overtime work necessary for implementation? Overtime work necessary for maintenance? .20D5: Choice & Verification of PCA针对每一“为什么的答案都应至少有一个措施这也就意味着一个充分的预防处理方案至少有57个措施一种常犯的错误是把侦测措施作为预防措施。如检验、丈量、检查、监控、做先行批等。侦测措施是必需的，但不是充分的它们只是遏制了这个问题。侦测措施与消费没有直接的关系它们不能

16、对产品增值只是添加了本钱。它们就象买“保险，保险是有本钱的保险费.21D6: Implementation & Validation of PCA ICA removed Long-term result monitored.22D7: Prevention of Recurrence System modification according to PCA Improvement standardizationFollow me!文件化的程序并进展适当的培训才是真正的预防措施 .23预防措施可采取以下的格式进展：建立或修正程序针对没有程序或不完善程序程序的文件化(建立/修正文件)培训文件的执

17、行消除环境要素 D7: Prevention of Recurrence.24D8: Recognition of Team & Individual ContributionsAppreciation for every members effort !.25DEFINE the customer, their CTQ (Critical to Quality) issues, and the core process involved.MEASURE the performance of the core process involved.Stage 1: 定义改善时机Stage 2: 丈

18、量运作程度Stage 3: 分析改善时机Stage 4: 改善运作程度Stage 5: 控制运作程度CONTROL the Improvements to keep the process on the new course.IMPROVE the target process by designing creative solutions to fix and prevent problems.Changeoperations?Re-define the operationsNoYesANALYZE the data collected to determine root cause of

19、defects and opportunities for improvement.DMAIC Workflow.26Stage 1: Define Define who customers are, what their requirements are for products and services, and what their expectations are Define project boundaries? The stop and start of the process Define the process to be improved by mapping the process flow.27Stage 2: Measure Develop a data collection plan for the process Collect data from many sources to determine types of defects and m