奥特利夫精益生产之-PDCA

1、1APS Training ModuleQF PDCAAutoliv1 June 2006QF-TM-024-C1.0AutolivQuality assurance Quality methods Six Sigma StandardsPull system Safety & Ergonomy Dont judge, dont blame !Flexibility & MotivationDiscipline to standards Continuous improvementProcess & ResultCustomersCompanyEmployeesSocietyQuality f

2、irstProfitabilityCompetitivenessSatisfaction Employee involvement Team work5SMuda eliminationTPMJust in time Leveling & CapacityLine conceptsContinuous flowTakt timeFrequent deliveriesProcess & ResultsTeam WorkContinuous ImprovementQuality MethodsWhy this trainingDuring this training you will learn:

3、What is PDCA ?When do I practice PDCA?Is PDCA a versatile toolWhen is the PDCA process completePDCA DefinedAPlanCDPDoCheckActPDCA isA simple but effective problem solving methodPDCAA continuous improvement methodPDCAAndPDCAMethod in which we do workshopsAndPDCA is a tool forProblem Solving Continuou

4、s ImprovementWorkshopsPDCA SuccessMust be used consistentlyEmphasis on DOINGPDCAPractice PDCA, and see the effectivenessBasic Philosophy of PDCAPlan: Set objectivesand build an logical planCheck: Study, analyze the results Do: Execute plan Test the planAct: Control, Lessons Learned, standardize, pre

5、vent recurrencePLANPlanGrasp current conditionSet a SMART GoalGo to the gemba and observe!Identify problemsSet expectationsWhy This WorkshopQuestions for PlanWhat do we want to accomplish?How will we know its an improvement? key indicatorsbefore - afterWhat changes will give us the result we are loo

6、king for?What resources are needed?PlanTake the time up front to plan, and you will be successful.If you fail to plan, you plan to fail.Beware ofAnalysis ParalysisMay have some setbacks, but improvement will always be greater over timePDCA CyclePlanning For Perfection (PFP)ImprovementTimePDCA Cycle

7、vs. PFPDO!DoExecute PlanThis Is An ExperimentTestMeasureAction registerBe Careful To Collect Necessary DataCHECKCheckFollow upStudy resultsHow did we doKey indicatorsDeep reflection“Are we better?Results may require you to go back to “PlanACTActControl process / operationMake decisionPrevent reoccur

8、renceWhere else can this apply lessons learnedBefore / After analysisCreate /update standardWhat is next!Keep in MindWe can revise “PlanPDCA is simple and flexiblePDCA is a cycleActCheckDoPlanPDCA Example The Problem: Plastic press-in has become very difficult for the operators to push in. Recently

9、the supplier changed material for a cost reduction.PDCA Example Check: -New part are just as hard to push in. -We lost our cost saving.-Incurred a change cost from supplier. -Deep reflection reveals we were going through motion of PDCA and not the real intentPlan: Have customer switch back to origin

10、al formula DO: Give the new parts (old formula) to cell to try.Act: Do PDCA with real intent PDCA Cycle 2 Plan: -Determine physical difference from the two formulas.-Investigate other possible causes (hole diameter, etc).-Investigate environmental causes.DO: -Test physical properties of the two part

11、s- Check hole diameter-Observe at gemba-talk to operatorsPDCA Cycle 2 Act: Determine if temperature affects push-in force Check: -Physical properties very similar-Hole diameter OK-Operator reveals that problem occurred after line was moved-Noticed parts located by cooling ventPDCA Cycle 3 Check: -Ha

12、ve operator run parts ambient temperature.-Operator has happy finger.Plan: Test push force at different temperature DO: Measure at ambient and vent temperatureAct: Move parts away from vent, and create block so parts cannot be placed back by vent. PDCA Example #2The Medical School Student opportunit

13、ies Another PDCA Example Improvement: Isabel thinks that she has spent too little time studying. She feels that the best way to improve her study skills is by putting in more hours. Key indicator: Taking old exams.The Problem: Isabel is a first-year medical student who has just taken her first set o

14、f examinations and is very unhappy with the results.PDCA Example Cycle 1Check: No improvement on exam Tired Low concentration - No friendsPlan: Study 30 more hours a week, get up earlier, go to bed later, take old exam at end of week DO: Studied only 15 /%7Eogehome/CQI/PDCA.htmlAct

15、: Find method that will allow exercise and social lifePDCA Example Cycle 2Check: Better results on exam, still needs more study but not interfere with exercise & socialPlan: Consult friends, attend all classes, rewrite notes, study text based on professor emphasisDO: Old study schedule, rewrites not

16、es, goes to text book when notes not /%7Eogehome/CQI/PDCA.htmlAct: Continue study method, find more timePDCA Example Cycle 3Check: Did even better on exam, and enjoyed it morePlan: Studying rewritten notes exercising, spend time studying with friendsDO: Exercises longer while studying notes, enjoys studying with friends and they help ou