PDCA质量改进培训手册全英文版

PDCAMANUALFORQUALITYPROGRESSTEAMSPDCAMANUAL-CONTENTWhyThisManual?PDCACycle4phasesPDCAStepByStep7stepswithtools’presentationPDCAProjectStatusSheetProjectBoard(VisualManagement)WHYTHISMANUAL?ContinuousimprovementisthekeytolongtermsuccessItrequiresinvolvementofall(fromoperatorstomanagement)Tosecureitsfuture,GlobalTubeOperationsinitiatethisambitiousprogramQualityProgressTeams(QPT)usingPDCAmethodologyinallplants6activeteamsineachplantbyDecember2000,muchmorein2001ThismanualaimsatsupportingQualityProgressTeamsinastepbystepworkapproachPDCACYCLEPDCAamethodin4phasesPDCAPLAN:fromproblemdefinitiontoactionplanDO:implementactionplanCHECK:evaluateresultsACT:standardizeandextendPLANPLANstep1. Identifyproblemandsetgoals

1.1Finalizeproblemstatement

1.2Collectandorganizedata

1.3Setobjectivesandmeasurementsstep2. AnalyzecausesSeekpossiblecausesandvalidatestep3. Generatesolution(s)

3.1Seekpossiblesolutions

3.2Test&selectstep4. PlanforimplementationDevelopactionplan&associatedresourcesDOStep5. ImplementactionplanImplementtheactionsasplanned(coordinateandfollow-up)CollectdataDOCHECKStep6. Evaluateresults(analyzedata)Aretheresultsinlinewithsetobjectives?Whatistheeffectivenessofeachaction?Wheredowehavegaps?Whathavewelearnt? Confirmactionstostandardize ConfirmnewoperatingstandardsCHECKACTStep7. StandardizeandextendCreatemeasurestoensurelong-termeffectivenessDocumentthenewrules:setproceduresandindicatorsSharetheprogresstosimilarareasRe-useSolutions(bestpracticesexchange)ACTPROJECTSELECTION–TEAMASSIGNMENTTOOLSManagementresponsibilitythroughPDCAsteeringcommitteeisto:SelectnewprojectsfocusingoncustomerrequirementsandinternalprioritiesSelectassociatedteamleaderandsponsorAssistteamleaderandsponsoratassemblingtherightteammembersImportanceforthecustomer(internal/external).Difficultyfortheteam9BOXMATRIXSelectingtherightproblemPDCA:STEPBYSTEPPLAN1.Identifyproblemandsetgoals1.1Finalizeproblemstatement1.2Collectandorganizedata1.3Setobjectivesandmeasurements2.Analyzecauses3.Generatesolution3.1Seekpossiblesolutions3.2Test&select4.Planforimplementation7stepsDO5.ImplementactionplanCHECK6.EvaluateresultsACT7.StandardizeandextendTOOLSProblemstatement5W+1HprocessmappingPLAN-STEP1.1

FINALIZEPROBLEMSTATEMENTINPUT:initialproblemasformulatedandhanded-overbythemanagementTIPSdonotformulateproblemasacauseavoidformulationasquestionorsolutiondefineproblemusingavailablefactsisitapriority/realisticproject?OBJECTIVEGiveoperationaldefinitionofproblemPROCESSReviewexistingdatadescribingproblemGetteamfeedback-additionalfactualdataGoandseetheproblemifpossible Completedescription-what/where/who/when/howmuchIdentifyhowthingswouldbeifproblemwassolvedOUTPUTWhat:problemdescription-whatarethesymptoms?Whereisitdetected?Whoisconcerned?When?Sincewhen?Recurrent?Forever?Whyisitimportant?Howmuch-quantifyintermsof%,n°,ppm,time...cleardefinitionofproblem(recordedonprojectsheet)firstdefinitionofobjectivetobereachedprocessmapPLAN:STEP1.2

COLLECTANDORGANIZEDATAOBJECTIVECollectdatatobetterunderstandtheproblemPROCESSBrainstormrequiredadditionaldataMapprocessPreparedatacollectionplan(who/what/when/how)ExecuteplanOrganizedatainmeaningfulform(chart,graphs,Pareto…)AnalyzestructuredinformationOUTPUT(inputforstep1.3)allchartsdescribingproblemcompletedescriptionofproblemTIPSunderstandwhyyoumakecharts

“Proliferationofchartswithoutpurposeistobeavoided”-DemingTOOLSDatacollectionplanChecksheetParetodiagramControlchartHistogramProcessmappingotherchartsUppercontrollimitAverageLowercontrollimitOutofcontrolTimeUnitControlChartTOOLSFORDATACOLLECTIONANDANALYSISDefectMOTUWETHFRTotalA3B1C5D15E18Total17866542Week/March2-6Resp.Supervisor:GlenDEFECTSINFINALASSEMBLYChecksheetRankingofproblems

(numberofevents)Frequency(defects/week)ParetoDiagramTOOLSFORDATACOLLECTIONANDANALYSIS-Cont'dHistogramProcessMappingDEBCGFAOtherChartsTHECHECKSHEET

GatheringandorganizingdataVALUEWhatfactsordatapatternswillhelpustobetterunderstandtheproblemanditscause(s)?Howdowetranslateour«

opinions

»abouttheprobleminto«

facts

»?Checksheetsareusedtocapturefactualdatafromthebeginning.Theyarefilledbyoperatorstodescribethesituationfollowingthedatacollectionplan.DefectMOTUWETHFRTotalA3B1C5D15E18Total17866542WEEK/March2-6Resp.Supervisor:GlenDEFECTSINFINALASSEMBLYTOOLSTHEPARETODIAGRAM

ShowingtherelativeimportanceofproblemsRankingofproblems(numberofevents)Frequency(defects/week)DefectRankingofproblems(cost)Reworkcost/week,dollarsDefectVALUEWhatistherelativeimportanceofeachpartoftheproblems?Whatshouldbethestartingpointforproblemsolving?Whereshouldwefocusourattention?TOOLSTHECONTROLCHART

UnderstandingvariabilityinaprocessVALUEInthevariationweobserveinaproblemcharacteristicorparameter,whatpartisnaturalvariation(withintheprocesscontrollimits)andwhatpartisduetospecificspecialcauses?Howoftendoestheprocessgooutofcontrol?Arethereanydiscernabletrendsthatshouldconcernus?Cananypreventiveactionsbetakenbasedonthesetrends?UppercontrollimitAverageLowercontrollimitOutofcontrolTimeUnitTOOLSControlchartrandomvariationVs.specialeventsTHEHISTOGRAM

ShowingthedistributionofdataVALUEHowfrequentlydoesacertaineffectoccur?Whatdoesthefrequencydistributionlooklike-anormalcurveorsomeotherstatisticalform?Howfrequentlyistheprocessoutsideofspecifications?Whatisthenatureofthedeviationoutsideofspecifications,e.g.,syntheticallyornot,...ShaftdiameterFrequencyTOOLSCHARTSANDGRAPHS

AnalyzingandpresentingdifferenttypesofdataRunchartBarchartABCDEFGPiechartDEBCGFAVALUEWhatarethetrendsorpatternsinthedataovertime?Istheaveragechangingovertime?Dotheresultsvaryovertime?Istherecyclically(e.g.,dayofweekorseason)Doparticulartimes,shifts,oroperatingpracticesshowmoreproblemsthanothers?RadarchartTOOLSPLAN-STEP1.3

SETOBJECTIVESANDMEASUREMENTSPROCESSFromdataanalysisconfirmproblemstatementandassociatedobjectives(time/cost/quality)andmeasuresValidaterestatedobjectiveswithmanagementOBJECTIVEclearlydefineandvalidateobjectivesOUTPUT(=inputforstep2)measurableobjectivesagreedbymanagementEXAMPLEWhat:screenscratchesdefectreportedby2customersforA59productsWhere:scratchesaredetectedatcustomerXandYfinalinspectionstationandareexistingatunpacking.NoscratchattubeplantinspectionWho:customerX&Y,warehousing?transport?packing?When:permanentdefectatX,newsinceSeptemberatYhowmuch:defectwas500ppmatX,jumpat3800ppminSeptember,defectwasnotreportedatY,jumpat2900ppminSeptemberGOAL:Solvetobringto0thisdefectwithin3monthsTIPSdonotjumptosolutionatthisstagePLAN-STEP2

ANALYZECAUSESOUTPUT(=inputofstep3)problemcausesidentifiedandmeasuredOBJECTIVESseekpossiblecausesandvalidaterootcausesPROCESSBrainstormallpossiblecausesOrganizedata(Ishikawadiagram)Select(throughteamconsensus)2or3maincausesfromtheIshikawadiagramAnalyzedeeper,themaincauses,5why’sConfirmbytestsandmeasurementsthatthecausesselectedaretherealones(rootcauses)TIPSdon’teliminatecausestooquickly!TOOLSBrainstormingParetodiagramIshikawaScatterDiagram5why’sTOOLSUSEDATTHISSTAGEPROBLEMMETHODMATERIALMACHINEMANENVIRONMENTISHIKAWARankingofproblems

(numberofevents)Frequency(defects/week)ParetoDiagramVariable1Variable2ScatterDiagramIdentifythemainrootcausesoftheproblemwhywhywhy why why

rootcause5Why’sBrainstormingTogetherBRAINSTORMING

SynergyoftheteamandreviewofallideasAllTeamMembersHavetoBeInvolvedUnderstandtheexactissue,topicGeneratethoughts,ideaswithoutcriticismBebriefwhendevelopinganideaAftertheSessionIsCompletedOrganize,categorizeandevaluateTOOLSTHECAUSE-AND-EFFECTORISHIKAWADIAGRAM

ShowingpossiblecausesofaspecificproblemValueusedtoidentifyexplore,anddisplaythepossiblecausesofaspecificproblemWhataretherootcause(s)oftheproblem?Whichfactorsareimportantinsize?Whichfactorsarepotentiallyopentochangebytheteam?Whatspecific«cause»ordriveroftheproblemdowewanttotackleinourperformancegoal?PROBLEMMETHODMATERIALMACHINEMANENVIRONMENTTOOLSTHESCATTERDIAGRAM

TestingatheoryaboutarelationshipbetweenvariablesVALUEConfirmthat2variablesarecorrelatedWhatisthenatureoftherelationshipbetweenthevariables?Variable1Variable2TOOLSOBJECTIVEIdentifyallpotentialsolutionsandthepossibilityoftestingthemeasilyandquicklyPLAN-STEP3.1

SEEKPOSSIBLESOLUTIONSPROCESSBrainstormpotentialsolutionsVerifysuggestedsolutionsversusrootcausesSelectbestcandidatesolutionsClearlydescribesolutionsDeterminewhethersimpletestispossibleTIPSlimitsolutionstonomorethan10OUTPUT(=inputforstep3.2)shortlistofsolutionsTOOLSbrainstormingandvotingVOTING

Techniquestoselectthesolution1Voteeachteammemberchoosesoneoftheproposedsolutionsthesolutionsreceivingthemostvoteswillbeaccepted3Voteseachteammemberhas3voteswithvaluesof1,2and3eachteammemberusesthese6pointstoratethesuggestedsolutions.thesolutionswiththehighestscorewillberetainedTOOLSPLAN-STEP3.2

TESTANDSELECTOBJECTIVEselectfinalsolutionstobeimplementedPROCESSDetermineandimplementtestplanforeasytotestsolutionsValidatetestresultsBuildselectionmatrixMakefinalselectionValidate(asnecessary)withmanagementOUTPUT(=inputofstep4)rankedselectedsolutions(tobeimplemented)TIPSformulatecriteriasothatrankingaddsupTOOLSDatacollectionScatterDecisionmatrixDECISIONMATRIX–Cont'dDeterminetheEvaluationCriteriaTOOLSPLAN-STEP4

PLANIMPLEMENTATIONPROCESS:foreachsolution,define:WhattodoWhoisinchargeForwhenWhataretherequiredresourcesWhataretheexpectedresultsTIPS ensurecoordinationtoavoidredundanciesamongtasksinvolveactionownerifnotpartoftheteamOBJECTIVEbuildeffectiveandoperationalactionplanOUTPUTcompleteactionplanTOOLSactionplanGanttchartACTIONPLAN

Define/what/where/who/resources/when/resultsTOOLSGANTTCHART

PlanningforimplementationActivityWho1Developimplementationplan2Holdkick-offmeeting3Startmachinemodification4Runtrail5Confirmparts6Reportstatus7Modifyifnecessary8StandardizedTimeKick-offmeetingDevelopplanModifyequipmentRuntrialConfirmpartsReviewresultsModifyStandardizeGanttchartshowsstepstobeimplementedandtimingforthebeginningandendingofeachactivityalongwithlinksbetweencriticalpathitemsFlowchartsareutilizedtoshowlogicalstepsinvolvedinimplementingplanTOOLSDO-STEP5

IMPLEMENTACTIONPLANOBJECTIVEGetthejobdonePROCESSExecutetrainingandinformationplanImplementthesolutiononanexperimentalbasisEvaluatetheresultsFull-scaleapplicationofsolutionCheckofallactionscompletionOUTPUTallactionscompletedassociatedmeasurementanddatacollectedTIPSdrive/followonshopfloormakeactions/resultsvisibleTOOLSactionplanGanttchartACTIONPLANTOOLSStatusasofMarch25CHECK-STEP6

EVALUATERESULTSPROCESSCollectdataandauditthearea/process...OrganizedatainmeaningfulformAnalyzeinformation:Aretheresultsshowingimprovement?howdoresultscomparetotarget?,Analyzegaps?(5why

’s),…CompletesolutionsifpossibleConfirmeachsolutioneffectivenessIfresultsokoracceptable--gotostep7Ifresultsnotokatall--returntostep2DecideonnextstepsOBJECTIVESconfirmwhethersolutionsdeliverexpectedresultscheckwhetherprojectobjectivesaremetOUTPUTagreementonsolutionstobestandardizedFormalizationofwhathasbeenlearnedTOOLSallcharts(see1.2)5why

’sACT-STEP7

STANDARDIZEANDEXTENDOBJECTIVEkeeptheimprovement,spreadthelearningsandsolutionstosimil