玻璃改善案例

1、QDP ProjectLedsjo Glass Process Control ImprovementEdited by：Quality control departmentupdate：April,2013(wk1318)GoalReduce the defect rate from 21% to 8%.DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating裂纹刮花口部不平黑点Wk1338(13.9）Wk1352(13.12) 12% 8%2teamDefineMeas

2、ure Analyze Improve Control小组成员职位姓名职位职责项目组长刘再清质量经理负责统筹、协调整个质量改善项目;成员林雪梅CQI负责项目指导、项目实施 跟进.成员麦艳池QA主管负责拉线质量标准的制定与考核.成员陈观信SQE负责供应商改善项目的确认与技术支持,供应商的考核.成员刘鑫桂采购员负责对供应商质量要求的传达与跟踪,供应商的考核.成员李威总装车间主任负责来料质量状况的收集、退货与跟踪.成员陆杨QA主管协助拉线缺陷分类的分析,来料质量状况的反馈.成员张艳佳文员负责拉线退货状况的分析与跟踪.成员亿立思供应商玻璃不良品问题的改善.Extra Light Ledsjo Glas

3、s Quality Development plating3Time planfinishplanDefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating4Start up Meeting雅耀内部雅耀与供应商DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating5Main defect type of glass with Plato analysis

4、:DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating6物机人环法刮花Fishbone diagram analysisDefineMeasure Analyze Improve Control来料碰花包装设计不当,保护不良烘炉线碰花切边时玻璃碎片刮花烘炉线速度过快运输过程中碰花包装方法设计不当,虚位大碰撞制程碰花员工操作不当员工未培训,无作业指引缺乏包装风险评估制程刮花工序安排不合理吹制机速过快，相互碰撞Extra Light Ledsjo Glass Quality

5、 Development plating7物机人环法颈部短Fishbone diagram analysisDefineMeasure Analyze Improve Control要求不明确员工对标准不清晰作业指导书要求不清晰样板管理不当磨具是按照正常壁厚吹制要求开，壁厚加厚以后模具未做相应调整对客户更改管理不完善Extra Light Ledsjo Glass Quality Development plating8物机人环法变形Fishbone diagram analysisDefineMeasure Analyze Improve Control气压不稳定模温不够(未完全预热)要求不

6、明确员工对标准不清晰作业指导书要求不清晰样板管理不当Extra Light Ledsjo Glass Quality Development plating9物机人环法破碎 裂纹 Fishbone diagram analysisDefineMeasure Analyze Improve Control烘炉线碰撞烘炉线速度过快运输过程中碰撞包装方法设计不当,虚位大碰撞制程碰撞员工操作不当员工未培训,无作业指引缺乏包装风险评估新旧模混用模具管理不当模具管理无规范Extra Light Ledsjo Glass Quality Development plating10DefineMeasure

7、Analyze Improve Control序号改善行动责任人完成日期完成情况 1供应商验厂、考核品控、采购13.3close2对员工进行系统性的培训与考核,合格后才可上岗.亿立思13.4close3制定工序操作指导书,对CTQ工位重点控制并打印挂于拉线指导员工操作.亿立思13.5close4重新评估各工序与出货的包装方法,更改包装.亿立思13.5close5制定玻璃物料检验标准卡,注明 零缺陷要求并传达给供应商.陈观信、刘鑫桂13.5close7建立质量数据库,对玻璃质量情况进行统计、分析.亿立思、雅耀13.6close8制定玻璃CP(控制计划),、FMEA对各工序的质量进行控制,特别是相

8、关设备参数.亿立思13.6On-going9制定客户更改管理指引与模具管理规范(特别是客户更改时模具的管理).亿立思13.7On-going10制定设备维修保养计划与记录,定期对设备进行保养.亿立思13.7On-going改善行动:Extra Light Ledsjo Glass Quality Development plating11DefineMeasure Analyze Improve Control改善行动:Extra Light Ledsjo Glass Quality Development plating12DefineMeasure Analyze Improve Cont

9、rolExtra Light Ledsjo Glass Quality Development plating1. MSA:13DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating1. MSA:14DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating1. MSA:15DefineMeasure Analyze Improve ControlExt

10、ra Light Ledsjo Glass Quality Development plating2.标准化(拉线检验指导书):16DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating2.标准化(物料检验标准卡):17DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating3.包装改良:18DefineMeasure Analyze Improve

11、ControlExtra Light Ledsjo Glass Quality Development plating4.工艺改良:19DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating20DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating21DefineMeasure Analyze Improve ControlExtra Light Ledsjo Glass Quality Development plating缺陷描述原因分析改善措施负责人计划完成日期完成情况透光涂料粘度未达到要求提高涂料的粘度,增加粘度测试使用粘度以达到要求张建伟13.5.20Y破碎运输过程中碰撞改变包装方式，四周加衬板保护缓冲徐秀萍13.5.20Y黑点过烘箱时产生(退火炉