DELPHI 的FTQ-中英文.ppt

1、First Time Quality,2,First Time Quality Training Module,Training Objectives 培训目标: To Understand 理解 What First Time Quality Is 什么是一次下线合格率? Why It Is Important 一次下线合格率的重要性 Why We Need to Measure It 为什么需要对一次下线合格率进行测量? How to Calculate It 如何计算? What the FTQ Deployment Process is 怎样进行FTQ? What the Basic

2、Quality Tools Are 基本质量工具是什么? How to Apply the Quality Tools 怎样运用基本质量工具? What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 每个工厂应该监控和汇报什么?,3,First Time Quality Training Module,What is First Time Quality? 什么是一次下线合格率? First Time Quality is a measure of the number

3、 of pieces rejected in a manufacturing process versus the total number of pieces attempted 一次下线合格率是测量制造过程中不合格品数与总产品数的比值.,REJECTS,4,First Time Quality Training Module,Why is FTQ important? 一次下线合格率的重要性 Because if we dont make good parts the first time, we have to inspect in quality 因为如果我们第一次没有生产出好的产品,

4、我们就必须进行检验. We know inspection is at best 85% effective 我们知道检验最多只有85%的有效性. Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因而,如果任何时候一次下线合格率大于0,我们都需要依赖检验来保护客户. To reduce manufacturing costs 降低制造成本 To eliminate waste through the value stream and meet cus

5、tomer requirements (take time) 通过价值流和满足客户要求来消除浪费.,5,Catch Defects,Filter,Inspection misses some defects 检验会遗漏一些缺陷,Defects not caught 漏网缺陷,Voice of the Customer 客户的声音,Problem问题,D,D,The Role of Inspection,D,Inspection is like a filter 检验好比一个筛子,6,1,2,Catch & Count defects 抓住并计算缺陷,React to ALARM LIMITS

6、超过警戒线的反应,Follow Reaction Plan 执行反应计划,Voice of the Customer客户的声音,The Role of First Time Quality Process,Reaction Plan,ZERO Defects Forward,7,Analyze Data分析数据 Understand Defects and Decide the Order of Priority: 理解缺陷并决定优先次序 Assign problems to Cross-Functional Group: 向跨功能小组提出问题 Select and Plan the Impr

7、ovement: 1.Right Information 2.Right Cause 3.Right Timing 选择并计划改善问题 正确的信息 正确的原因 正确的时间选择 Fix the Biggest Problems First: 首先找到最大的问题所在,Responsible Team Works Problems 相关团队负责解决问题,DEFECT 1. - 2. - 3. -,Hour Glass,The Role of First Time Quality Process,4,3,2,3,2,2,1,1,1,1,8,Inspection Exercise,THE NECESSI

8、TY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD C

9、ARRY ON WITH THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT.,Count the Number of Fs contained in the paragraph below (60sec) 数一下下面总共出现了几个“F”（60秒）,9,Inspection Exercise

10、,THE NECESSITY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL T

11、HEY SHOULD CARRY ON WITH THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT.,Total of 36 Fs,10,First Time Quality Training Module,Why does FTQ need to be measured? 为什么需要测量

12、FTQ Main Reasons 主要原因: It is the first signal that a process is out of control 它是过程失控最先发出的信号 It allows us to respond to problems internally before they reach our customers 它使我们能够在问题到达客户之前先在内部作出反应. It measures improvement from corrective actions implemented 通过执行纠正措施后来衡量问题改善的情况. If we dont fix our qua

13、lity problems internally, we will never be able to fix our external customer issues 如果我们不能在内部找到质量问题,我们就不能确定外部客户的问题.,11,First Time Quality Training Module,How is First Time Quality calculated? 如何计算FTQ FTQ is reported in parts per million (PPM) defective FTQ反映每一百万个产品中的缺陷产品数. It can be measured at any

14、step in the manufacturing process where parts are rejected 可以在有拒收产生的制造过程的任何一步测量FTQ. It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 通过以不合格品数除以总数来计算. The total number of pieces attempted includes all good pieces produced plus all pieces rejected

15、总的产品数包括生产出来的所有合格品数和不合格品数之和. Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不合格品数包括所有报废和经过返工后合格的产品数. 公式: Number of Pcs. Rejected不合格品数 Total Number of Pcs. Attempted总产品数,X 1,000,000 = FTQ PPM,12,First Time Quality Trai

16、ning Module,How is First Time Quality calculated?如何计算FTQ? An example at the cell level: Cell “A” has six operations A单元有6个操作工序 Reject data is collected at operations 3 and 6 在第三和第六工序收集到不合格品数据 Cell “A” produced 1040 good pieces during the first hour of production. 第一个小时A单元共生产良品1040件 At OP.3, 28 pcs.

17、were rejected. 第三工序发现28件不合格品 At OP.6, 16 pcs. were rejected. 第六工序发现16件不合格品 What is the FTQ in PPM for Cell A? A单元FTQ的PPM是多少? 28 + 16 1040 + 28 + 16,1,2,3,4,5,6,X 1,000,000 = 40590 PPM FTQ,28,16,Tally Sheet,13,First Time Quality Training Module,What is the First Time Quality Improvement Process? 什么是F

18、TQ改善过程? FTQ process defines a common process to be used by all Delphi manufacturing plants to meet the business plan requirements and drive defect-free manufacturing FTQ是Delphi 工厂常用的以达到商业计划要求和无缺陷生产要求的一个方法. The FTQ process defines FTQ定义: Process Steps 流程步骤 Stakeholders 有关系的人 Deployment Chart (functio

19、nal flow chart) for identifying lead functions 用于识别重要功能的布置图表(功能流程图) Control Plan for Tracking Implementation 控制计划和跟踪执行,14,IDENTIFY &,COUNT,DISCREPANT,PARTS,IMPLEMENT IMPROVEMENT执行改善,EVALUATE评估,INSTITUTION- ALIZE LESSONS LEARNED 系统化经验教训,TOOLS FOR,IDENTIFICATION用于识别的工具:,- PROCESS CONTROL,PLAN过程控制计划,-

20、BOUNDARY SAMPLES边界样品,TOOLS FOR COUNTING用于计数的工具:,- PARTS COUNTERS产品计数器,- TALLY SHEETS计数表,- SIZED CONTAINERS有尺寸大小的容器,TOOLS工具:,- PARETO直方图,- CAUSE & EFFECT,(FISHBONE) 原因和结果(鱼骨图),- CONCENTRATION,DIAGRAM集合表,- FLOW CHART流程图,- HISTOGRAM柱状图,- SCATTER,DIAGRAM散布图,- CHECK SHEET检查表,- 5 WHYS 5个为什么,EXAMPLES例子:,-

21、CROSS-FUNCTIONAL,TEAMS跨功能小组,- CHANGE BOARDS变化看板,- RPN REDUCTION降低RPN,- STATISTICAL ENGINEERING,PROJECTS统计工程方案,ACTION PLAN行动计划:,- WHAT, WHEN, WHO事件,时间,人物,TOOL工具:,- ACTION PLAN 行动计划,TOOLS工具:,- PFMEA过程流程图,- PROCESS CONTROL PLAN 过程控制计划,- LOOK-ACROSS-CHART 浏览表,- 5 WHYS 5个为什么,SELECT & PLAN IMPROVEMENT 选择和

22、计划改善,NEW LEVEL OF QUALITY? 新的质量水平,DEFINE,REACTION,PLAN &,ALARM,LIMITS 定义反应计划和警戒线,RECORD DATA 记录数据,TOOLS工具:,- CONTROL CHART控制图,ANALYZE,DATA 分析数据,TOOL工具:,- RUN CHART 运行图,- GATE CHART 门图,ALARM EXCEEDED 是否超过警戒?,IMPLEMENT ALARM REACTION PLAN 执行报警反应计划,YES,NO,NO,YES,IDENTIFY确认,ANALYZE分析,PLAN计划,EVALUATE评估,I

23、MPLEMENT执行,FTQ Improvement Process,识别和清点有差异的产品,15,FTQ Improvement Process Stakeholder Footprint,Plant A Plt B Plt C,CELL 1,2,3,4,5,7,8,N,6,OPERATOR 操作人员,OPERATOR 操作人员,OPERATOR 操作人员,OPERATOR 操作人员,OPERATOR 操作人员,TEAM,LEADER 小组领导,CROSS-,FUNCTIONAL,TEAM 跨功能小组,PRODUCT ENGINEERING MANAGER 产品工程经理,QUALITY,MA

24、NAGER 质量经理,MAINTENANCE,MANAGER 设备维护经理,OPERATIONS,MANAGER 制造经理,PROCESS ENGINEERING MANAGER 工艺工程经理,PLANT MANAGER 工厂经理,PC&L,MANAGER 物流经理,CELL 工作站,16,First Time Quality Improvement Process Deployment Flow Chart,LEAD 负责,SUPPORT 支持,17,First Time Quality Training Module,Process Step 1 第一步 Define reaction p

25、lan and alarm limits 定义反应计划和警戒线 You have to start someplace Alarm limits must be based on current process reject data or available data from Run at Rate, historical data, etc. 警戒线必须基于在当前工艺下生产的不合格品数据, 或源于按节拍生产,历史数据,等. Alarm limits must be statistically calculated 警戒线必须按当前情况进行统计计算或根据历史数据（历史质量水平）进行划定。

26、Alarm limits must be communicated to operators so they can react 警戒线必须与操作人员进行交流沟通. If alarm limits are exceeded, there must be a reaction plan to implement 如果超过警戒线,必须有一个可执行的反应计划. The reaction plan must clearly define what actions are to be taken 反应计划必须明确定义所需采取的行动.,DEFINE REACTION PLANS & ALARM LIMIT

27、S 定义反应计划 和警戒线,18,First Time Quality Training Module,Process Step 2 第二步 Identify and count discrepant parts 识别和计算有差异的产品数 Operators must have sufficient tools and skills in order to identify product discrepancies 操作人员必须有足够的途径和技能来确认产品的差异. Tools to enhance the operators ability to identify product discr

28、epancies include 用于加强操作人员确认产品差异的途径有: Boundary Samples 极限样品 Illustrations 图表 Photographs 照片 Gages 量具 Tools for counting discrepant parts include 用于清点差异产品的工具有: Parts Counters 产品计数器 Tally Sheets 计数表 Sized Containers 容量固定的容器,IDENTIFY & COUNT DISCREPANT PARTS 识别和清点 有差异的产品,19,First Time Quality Training M

29、odule,Process Step 3 第三步 Implement Alarm Reaction Plan if Limit Exceeded 超过警戒线时反应计划的执行 Reaction Plan 反应计划:,IMPLEMENT ALARM REACTION PLAN 执行警戒反应计划,Alarm Limit Exceeded 是否超过警戒线? Contain 遏制 Investigate 调查 Implement Containment Plan Until Problem Fixed 执行遏制计划直到找到问题,Yes,Containment Plan遏制计划,20,First Time

30、 Quality Training Module,Process Step 4 第四步 Record Data 记录数据 Data must be recorded and plotted over time 必须按时间记录数据: What chart should be used 应使用什么图表? Since the area of opportunity varies from sample to sample, the reject count must be converted into a rate prior to charting 如果单位时间内生产的样品数不同，在制表时，需将拒

31、收数转换为比率. 如果单位时间内生产的样品数相同，图表上反映的即拒收数。 We do this by measuring FTQ in PPM/percent 用PPM或百分比来计算FTQ,RECORD DATA 记录数据,21,n = avg sample size (18) np = number nonconforming k = subgroups (25) _ np = np1+np2+.npk k,avg= 9.8,Alarm Limit Calculation using np Chart,22,First Time Quality Training Module,Process

32、 Step 5 第五步 Analyze Data 分析数据 The basic quality tools are 基本质量工具: Flow Charting 流程图 Check Sheets 检查表 Pareto 柏拉图 Cause and Effect 原因和结果 Run Chart 运行图表 Histogram 柱图 Scatter Diagram 散点图 Control Chart 控制图,ANALYZE DATA 分析数据,23,First Time Quality Training Module,Process Step 5 第五步 Analyze Data 分析数据,Proble

33、m Identification 确认问题,Problem Analysis 分析问题,Charts can be used for different purposes in various stages of the problem-solving process 在解决问题的各个阶段都可使用图表用于不同的目的。 The tools included in the intersecting portion of this diagram can be used in both the problem identification and problem analysis phase of

34、problem solving 交叉部分的工具可同时用于确认问题和分析问题.,Flowchart Checksheet Brainstorming Nominal Group Technique,Pareto Chart Cause & Effect Run Chart Stratification,Histogram Scatter Diagram Control Chart Process Capability Force Field Analysis,ANALYZE DATA 分析数据,24,FTQ Tools- 柱状图,25,FTQ Tools-柏拉图,26,FTQ Tools-散布图

35、,27,FTQ Tools-控制图,28,FTQ Tools-流程图,29,FTQ Tools-检查表,30,Example Cause & Effect Diagram (Fishbone),FTQ Tools-因果图,31,FTQ Tools-走势图,32,First Time Quality Manager Audit Checklist Example-FTQ管理者审核检查表,Example,33,First Time Quality Training Module,Process Step 6 第六步 Select and Plan Improvement 选择和计划问题的改善 Af

36、ter FTQ problems have been identified through data analysis, improvement plans must be developed 通过数据分析找到FTQ的问题后,必须进行改善计划. A recommended template has been provided to track implementation status of corrective actions 推荐一种用于追踪纠正措施执行情况的模板.,SELECT & PLAN IMPROVEMENT 选择和计划改善,34,FTQ Tools,35,First Time Q

37、uality Training Module,Action Plan Template 行动计划模板,36,First Time Quality Training Module,Process Step 7 第七步 Implement Improvement 执行改善 Work the Action Plan 制订行动计划 Update Plan as Required 更新计划 Document Improvements on Chart 在图表上记录改善情况,IMPLEMENT IMPROVEMENT 执行改善,37,First Time Quality Training Module,P

38、rocess Step 8 第八步 Evaluate 评价 Once the Corrective Action has been implemented, the data must be evaluated for trends or shifts 一旦执行纠正措施,必须对数据的趋势进行评估. Did the problem stay “killed?” If so, change alarm limits 如果问题已被消灭,须更改警戒线. This is one of the reasons it is so important to collect data over time 这就是按时间收集数据是如此重要的原因. Without data there is no way to evaluate the impact of the corrective action on the process 如果没有数据就无法评估纠正措施对过程的影响. If no significant reduction in FTQ PPM is observed, then it is possible the cause was misidentified to begin with 如果没有显著降低FTQ的PPM值,很可能在最初没有找到产生问题的真正原因.,EVALU