WCM-QC支柱资料.ppt

1、1,6. Quality control质量控制,1,1,Step 2 步骤 2,Step 3 步骤 3,Step 4 步骤 4,Step 5 步骤 5,Step 6 步骤 6,Step 7 步骤 7,Step 1 步骤 1,Identification and analysis of current conditions 确认和分析当前条件,Restoration of basics conditions恢复基本条件,Analysis of the causes of chronic problems分析长期损失的原因,Reduction and elimination of causes

2、of chronic losses 减少和消除导致长期损失的原因,Establishent of conditions for zero defects建立零缺陷条件,Improvement of methods of conditions for zero defects改善零缺陷条件的方法,Maintenance of conditions for zero defects 维护零缺陷条件,STEP7 步骤 7,Select topic选择主题,STEP1 步骤1,Understand situation and set targets了解形势并设定目标,STEP2 步骤2,Plan ac

3、tivities计划活动,STEP3 步骤3,Analyze causes分析原因,STEP4 步骤4,Consider and implement countermeasures考虑并实施对策,STEP5 步骤5,Check results检查结果,STEP6 步骤6,Standardize and establish control建立标准化的控制,STEP7 步骤7,STEP6 步骤 6,Investigation of current conditions调查当前条件,STEP1 步骤 1,Restoration of the abnormal conditions恢复异常条件,STE

4、P2 步骤 2,Factor analysis of chronic losses分析导致长期损失的因素,STEP3 步骤 3,Reduce and eliminate all causes of chronic losses减少和消除导致长期损失的所有原因,STEP4 步骤 4,Establishment of proper conditions for zero defects 建立零缺陷的合适条件,STEP5 步骤 5,Maintenance of proper conditions for zero defects维护零缺陷的合适条件,Improvement of maintenanc

5、e methods of conditions for zero defects改善零缺陷条件的方法,Machine 机器,Man人员,Material材料,Method方法,Quality maintenance 7 steps维护质量的七个步骤,Problem solving 7 steps解决问题的七个步骤,2,Step 1 步骤 1,Step 2 步骤 2,Step 3 步骤 3,Step 4 步骤 4,Step 5 步骤 5,Step 6 步骤 6,Step 7 步骤 7,Definition of current conditions 确定当前条件,First restoring

6、of the abnormal conditions首次恢复异常条件,Cause-and-effect analysis of chronic defects长期缺陷的因果分析,Attack against the main causes of chronic defects克服长期缺陷的主要原因,Definition of zero scrap condition确定零报废的条件,Check conditions for zero scraps检查零报废条件,Improvement of zero scrap conditions改善零报废条件,Quality maintenance质量维护

7、,Proactive 前瞻性,Reactive反应性,Preventive 预防性,3,Level 1 等级 1,Level 2 等级 2,Level 3 等级 3,Level 4 等级 4,Level 5 等级 5,Level 6 等级 6,Level 7 等级 7,The seven levels of quality maintenance 质量维护的七个等级,1. Defect identification and classification 缺陷识别和分类,2. Complete QA matrix 完成QA矩阵,3. The process of Q components det

8、ermination have been completed.已完成质量零部件确定过程,4. More than 50$ of quality problems have been solved. 已解决50%以上的质量问题,5. More than 80% of quality problems have been solved. 已解决80%以上的质量问题,6. Quality control parameters are set for the entire process to guarantee quality 100% at the process. 设定整个过程的质量控制参数，以

9、确保工序上100%的质量。,7. Well established quality control 建立良好的质量控制,1,2,3,4,5,Expansion and development 延伸和发展呢,4,1. Defect identification and classification 缺陷识别和分类 * 1st QA matrix * 第一个QA矩阵 * Measurement of Cp, Cpk * Cp，Cpk测量 2. Complete QA matrix 完成QA矩阵 * QA matrix with 4M analysis * 含4M分析的QA矩阵 3. The pro

10、cess of Q component determination has been completed for model areas /machines. 已完成示范区/样机的质量零部件确定过程 * Sufficient zero defect conditions have been established for the model processes. * 已为示范过程建立了足够的零缺陷条件。 4. More than 50% of quality problems have been solved. 已解决50%以上的质量问题 5. More than 80% of quality

11、 problems have been solved. 已解决80%以上的质量问题 6. Quality control parameters are set for the entire process to guarantee quality 100% at the process. Every quality issues are under control. 设定整个过程的质量控制参数，以确保工序上100%的质量。所有质量问题均在可控范围内。 7. Well established quality control 建立良好的质量控制 Feed back system to EPM an

12、d EEM 早期产品管理和早期设备管理反馈系统,The seven levels of Quality maintenance 质量维护的七个等级,5,Approaches方法,6,6.Results of the controls控制结果,1.Chosing the problem to solve选择要解决的问题,Collecting data. Choosing the characteristic to attack. Setting targets (value and expiration)收集数据。选择需要克服的特征。设定目标（价值和终结）,Deciding what to do

13、. Defining the schedule and assign the responsibility决定要执行的内容。确定安排表并分配责任。,Verifying the current value of the characteristics. Ranking the possible causes. Deciding about arguments to face up.验证特性的当前值。将可能的原因分级。决定争论的结果。,2.Understanding the situation and the targets了解形势和目标,3.Activity Plan活动计划,5.Conside

14、ring and implanting the solution考虑和贯彻解决方案,4.Cause Analysis原因分析,Considering the solutions: suggesting ideas for the solutions, arguing about how to implant them. Implanting the solutions: planning how to implant the points. Implanting the solutions.考虑解决方案：提出解决方案的想法，讨论如何贯彻。贯彻解决方案：计划如何贯彻解决方案。贯彻解决方案。,Ve

15、rifying the results of the means. Comparing the results with the target. Identifying the tangible and non-tangible benefits验证方式结果，将结果与目标进行对比。识别有形和无形效益。,7.Standardizing and establishing the control.,Standardizing: establishing new standards and revising the old ones. Deciding the control methods, est

16、ablishing the control. Making responsible people familiar with new methods. Training responsible people and making sure that benefits are kept.标准化：建立新标准，修改旧标准。决定控制方法，建立控制系统。使负责人员熟悉新方法。对负责人员进行培训，确保维持效益。,Step 1 步骤 1,Step 2 步骤 2,Step 3 步骤 3,Step 4 步骤 4,Step 5 步骤 5,Step 6 步骤 6,Step 7 步骤 7,AA A B C quali

17、ty problems 质量问题,7,Level 1 等级 1,Level 2 等级 2,Level 3 等级 3,Level 4 等级 4,Level 5 等级 5,Level 6 等级 6,Level 7 等级 7,The seven levels of quality control 质量控制的七个等级,1. Creation of basic knowledge创建基本知识,2. Extensive use of these methods and tools广泛应用这些方法和工具,3. Application of intermediate methods and tools应用中级

18、方法和工具,4. Challenge to use more advanced and sophisticated methods and tools挑战性的使用更为高级和复杂的方法和工具,5. From inductive (analytical) approaches to deductive (design) approaches从归纳（分析）方法到演绎（设计）方法,6. Continuous searching for opportunities to improve quality using more and more sophisticated methods and tools

19、从归纳（分析）方法到演绎（设计）方法,7. Continuous challenge toward IPS持续挑战理想生产系统,1,2,3,4,5,Expansion and development延伸和发展,8,The seven levels of QC质量控制的七个等级 1. Creation of basic knowledge to attack easily attackable but profitable quality problems by using the basic QC methods and tools使用基本质量控制方法和工具创建基本知识，该基本知识易于克服可克

20、服的但可营利的质量问题 2. Extensive use of these methods and tools for the entire plant quality problems (more than 50% of the people)将这些方法和工具广泛用于整个工厂的质量问题（50%以上的人）。 3. Applications of intermediate methods and tools to attack more difficult, chronicle but still attackable quality problems使用中级方法和工具克服更为困难、更为久远、但

21、仍然可克服的质量问题。 4. Challenge to use more advanced and sophisticated methods and tools to attack most difficult and complicated QC problems (involvement of more than 80% of the people)使用更为高级、更为复杂的方法和工具克服更为困难、更为复杂的质量控制问题（包含80%以上的人）。 5. From inductive (analytical) approaches to deductive (design) approache

22、s从归纳（分析）方法到演绎（设计）方法 6. Continuous searching for opportunities to improve quality using more and more sophisticated methods and tools. Fully engaged in quality control at all levels. The best quality among competitors. 100% quality assurance.使用越来越复杂的方法和工具持续寻找提高质量的机会。在所有等级上均全身心投入质量控制中。在竞争者中保持最佳质量。100%

23、质量保证。 7. Continuous challenge toward IPS.持续挑战理想生产系统,9,Classification of AA, A, B and C quality issues AA、A、B和C级质量问题的分类,10,QC (Reactive) 质量控制（反应性）,1. 5G,2. 5W + 1H, 5Why,7WCM tools 七种世界级制造工具,4. 10 QC Viewpoints 十种质量控制观点,5. Reactive QA matrix 反应性QA矩阵,6. Management of clams 索赔管理,7. 4M analysis 4M分析,8.

24、7 QC tools 七种质量控制工具,9. 7 steps of QC problem solving 解决质量控制问题的七个步骤,10. SQC 标准质量控制,11,QC (Reactive)质量控制（反应性） 1. 5G 2. 5W + 1H, 5Why 3. 7 WCM tools 七种世界级制造工具 4. The 10 QC viewpoints 十种质量控制观点 5. Reactive QA matrix 反应性QA矩阵 6. Management of claims coming from manufacturing 生产制造索赔管理 7. 4M analysis and cou

25、ntermeasures 4M分析和对策 * HERCA * SOP * 标准操作程序 * QC of the in-coming materials * 来料质量控制 * Process capability Cp, Cpk * 工序能力Cp，Cpk,12,QC of incoming materials (8 stages) 来料质量控制（8个阶段）,13,8. 7 QC tools cause-and-effect diagrams, pareto diagrams, graphs, check sheets, histograms, scatter diagrams, control

26、charts七种质量控制工具因果关系图、排列图、曲线图、检查表、柱状图、散点图、控制图表 9. 7 steps of QC problem solving Select topic, understand situation and set targets, plan activities, analyze causes, consider and implement countermeasures, check results, standardize and establish control)解决质量控制问题的七个步骤选择主题、认清形势和设定目标、计划活动、分析原因、考虑和执行对策、检查

27、结果、建立控制并将其标准化 10. SQC for product characteristics (result oriented SQC)产品特性的标准质量控制（结果导向标准质量控制） Step 1 4 of 7 steps of quality maintenance 质量问题七个步骤中的步骤1-4,14,QC (Preventive) 质量控制（预防性）,Preventive QA matrix 预防性QA矩阵,2. SQC 标准质量控制,3. Step 5, 6 of 7 steps of quality Maintenance 质量维护七个步骤中的步骤5和6,Visualizati

28、on 可视化,5. HERCA,6. Error proofing, Fool proofing 防错、防误,Visual SOP 可视化标准操作程序,8. QC of in- coming materials 来料质量控制,9. QA network QA网络,10. Claims trend analysi 索赔趋势分析,15,QC (Preventive) 质量控制（预防性） 1. Preventive QA matrix 预防性QA矩阵 2. SQC for causes (Process control) 原因标准质量控制（过程控制） 3. Step 5, 6 of 7 steps

29、of quality maintenance 质量维护七个步骤中的步骤5和6 - X matrix, QM matrix, P PAX矩阵，QM矩阵，PPA - Five questions for zero defects 零缺陷的五个问题 - Minimal checking time for zero defects conditions 零缺陷条件的最少检查时间 4. Visualization of processing point 处理点的可视化 5. HERCA TWTTP HERCA教育员工的方法 6. Error proofing, fool proofing 防误、防错 7

30、. Visual SOP combined with Q gate 可视化标准操作程序与质量门相结合 8. QC of in-coming materials 来料质量控制 9. QA network QA网络 10. Claims trend analysis 索赔趋势分析,16,ERROR ANALYSIS 错误分析,MATERIAL材料,MACHINE机器,METHOD方法,MAN 人员,TWTTP 教育员工的方法,ACTION 行动,HUMAN ERRORS ROOT CAUSE 人为失误根本原因,CERTIFICATION TWTTP 证明TWTTP,MONITORING 监督,EX

31、TENSION/STANDARDIZATION 延伸/标准化,PROCESS WEAKNESS工艺缺陷,17,QC (Proactive) 质量控制（前瞻性）,1. Step 7步骤7,2. New 7 QC tools 七种质量控制新工具,3. Use of various tools 使用各种工具,4. Proactive QA Matrix 前瞻性QA矩阵,5. QFD 质量功能部署,6. DR system DR系统,7. Reliability engineering FTA, FMEA 可靠性工程，FTA，FMEA,8. DOE+ANOVA,9.DF(X),10. Robust D

32、esign 稳健设计,18,QC (Proactive)质量控制（前瞻性） 1. Step 7 of 7 steps of quality maintenance : Easy checking for maintenance and zero defects conditions,质量维护七个步骤中的步骤7：简单检查维护和零缺陷条件 HERCA TWTTP Identification at one of three phases (perception, judgment and action) and its proper countermeasure HERCATWTTP在三个阶段（感

33、知、判断和行动）中的一个阶段进行识别及其合适的对策 2. The new 7 QC tools relations diagrams, systematic diagrams, matrix diagrams, affinity diagrams, arrow diagrams, process decision program charts, matrix data analysis七种质量控制新工具（关系图、系统图、矩阵图、分类图、矢量图、过程决定计划流程图、矩阵数据分析） 3. Use of various tools of statistical analyses such as re

34、gression analysis, multi-variant analysis, etc.使用各种系统分析工具，如：回归分析、多元分析等。 4. Proactive QA matrix前瞻性QA矩阵 5. QFD, process QFD质量功能部署、过程质量功能部署 6. DR system, DRBFD (DR based on failure modes) DR系统，DRBFD（基于故障模式的DR） 7. Reliability engineering, FTA, FMEA, process FMEA, FMECA可靠性工程、FTA、故障模式和影响分析、过程故障模式和影响分析、FME

35、CA 8. DOE + ANOVA, Factorial design, Orthogonal array, Parameter design, Tolerance design 因子设计、正交阵列、参数设计、公差设计 9. DF(X) 10. Robust design, Taguchi methods 稳健设计，田口法,19,QC (Proactive) 质量控制（前瞻性）,1. Step 7 步骤7,2. New 7 QC tools 七种质量控制新工具,3. Use of various tools 使用各种工具,4. Proactive QA Matrix 前瞻性QA矩阵,5. QF

36、D 质量功能部署,6. DR system DR系统,7. Reliability engineering FTA, FMEA 可靠性工程，FTA，FMEA,8. DOE+ANOVA,9.DF(X),10. Robust Design 稳健设计,20,QC (Proactive) 质量控制（前瞻性） 1. Step 7 of 7 steps of quality maintenance : Easy checking for maintenance and zero defects conditions,质量维护七个步骤中的步骤7：简单检查维护和零缺陷条件, 2. The new 7 QC t

37、ools relations diagrams, systematic diagrams, matrix diagrams, affinity diagrams, arrow diagrams, process decision program charts, matrix data analysis七种质量控制新工具（关系图、系统图、矩阵图、分类图、矢量图、过程决定计划流程图、矩阵数据分析） 3. Use of various tools of statistical analyses such as regression analysis, multi-variant analysis,

38、etc.使用各种系统分析工具，如：回归分析、多元分析等。 4. Proactive QA matrix前瞻性QA矩阵 5. QFD, process QFD质量功能部署、过程质量功能部署 6. DR system, DRBFD (DR based on failure modes) DR系统，DRBFD（基于故障模式的DR） 7. Reliability engineering, FTA, FMEA, process FMEA, FMECA可靠性工程、FTA、故障模式和影响分析、过程故障模式和影响分析、FMECA 8. DOE + ANOVA, Factorial design 因子设计 Or

39、thogonal array 正交阵列 Parameter design 参数设计 Tolerance design 公差设计 9. DF(X) 10. Robust design, Taguchi methods 稳健设计，田口法,21,Criteria to Evaluate Achievement Level Quality Control 评估实现等级的标准质量控制,(6) Quality Control Evaluation Levels 质量控制评估等级 0. No action No proper Quality Control is practiced. Based on in

40、spection the good and rejects are sorted out. No measurement of Cp, Cpk. 无行动 未实行合适的质量控制。通过检验，将合格与不合格的产品分开。未测量Cp，Cpk。 1. Overall view, 4M analysis, measurement of Cp, Cpk QA matrix developed analyzing external (customer) quality issues and internally identified defects. Quantity and cost impact of qu

41、ality defects are clearly identified. Managing defects and emergency defect prevention work order system. Based on QA matrix, model processes for Quality Control have been chosen, and 4M analysis at critical process areas is applied properly. For machine related quality problems, Step 1 Step 4 of QM

42、 have been implemented. Step 1 7 of QC 7 steps applied to the followings : 全貌图、4M分析、Cp和Cpk测量 发展QA矩阵分析外部（客户）质量问题并识别内部缺陷。明确定义质量缺陷的数量和成本影响。管理缺陷和紧急缺陷预防工作指令系统。根据QA 矩阵选择了质量控制示范过程。将4M分析合理运用于关键过程区域。对于有质量问题的机器，执行了质量管理步骤1-4。将质量控制步骤1-7应用于以下方面： materials : input control 材料：输入控制 method : SOP 方法：标准操作程序 Man : Erro

43、r proofing, fool proofing, training 人员：防误、防错、培训 The results improve Quality Control giving benefits. Cp, Cpk are measured.结果为提高了质量控制，产生了效益。测量Cp和Cpk。,22,2. Establishment of conditions for zero defects for model areas Step 5 of QM to the model processes. Five questions for zero defects are raised at t

44、he critical processing point to identify root causes of quality problems. Conditions for zero defects are known for more than 40 percent of the quality problems and operating standards are well established for them. 建立示范区零缺陷条件 质量管理步骤5用于示范过程。在关键处理点提出零缺陷的五个问题，以识别质量问题的根本原因。将零缺陷条件应用于40%以上的质量问题，并为其建立良好的操

45、作步骤。 For equipment related quality problems, Step 1 4 of QM to AA machines have been implemented. Cp, Cpk are measured.对于有质量问题的设备，已对AA级的机器执行了质量管理的步骤1-4。测量Cp和Cpk。 For non equipment related quality problems, Step 1 7 of QC have been implemented :对于无质量问题的设备，执行了质量控制的步骤1-7： For Materials, material input

46、control is well established.关于材料，建立了良好的材料输入控制系统 For Methods, SOP is well established to guarantee quality at the processes.关于方法，建立良好的标准操作程序，以确保工序质量。 For Man (human errors), TWTTP is extensively applied, fool proof or error proofing devices are well installed. For the lack of knowledge and skills, pr

47、oper education and training are done.对于人员（人为失误），广泛应用了TWTTP，且安装了防误或防错装置。对于缺乏知识和技能的员工，进行了合适的教育和培训。,Criteria to Evaluate Achievement Level Quality Control 评估实现等级的标准质量控制,23,3. Establishment of conditions for zero defects, application of PPA for difficult and chronic problems For equipment related qualit

48、y problems, Step 1 5 of QM have been implemented. PPA is applied at the critical processing points to determine unknown causes of quality problems. For equipment related quality problems, X-matrix and QM-matrix are made to establish operating standards. The approach is moving from preventive to proa

49、ctive. 建立零缺陷条件，将PPA应用于困难且长期的问题对于有质量问题的设备，执行了质量管理步骤1-5。在关键处理点使用PPA，以确定质量问题的未知原因。对于有质量问题的设备，创建QM矩阵，以便建立操作标准。方法从预防性转移到了前瞻性上。 For non equipment related quality problems, Step 1 Step 7 of QC has been implemented : 对于无质量问题的设备，执行了质量控制的步骤1-7： For Materials, material input control is well established. 关于材料，建

50、立良好的材料输入控制系统。 For Methods, SOP is well established to guarantee quality at the processes. 关于方法，建立良好的标准操作程序，以确保工序质量。 For Man (human errors), fool proofing, error proofing devices are well installed. Fool proof devices are extensively used in case of absent-mindedness, forgetfulness, carelessness, inattention, etc. 对于人员（人为失误），安装了防误或防错装置。防误装置广泛应用于心不在焉、健忘、粗心、疏忽等情况中。 Conditions for zero defects are known for more than 70 percent of the quality problems and operating standards are well established for them.将零缺陷条件应用于70%以上的质量问题，并为其建立良好的操作步骤。,Criteria to Evaluate A