GP-12不良统计明细 The 10 weeks

1、 Prepared by统统计计人人 :SunnyPrepared on 统统计计日日期期:Date 日日期期Part No.零件号InternalPart No.Sorted挑挑选选的的内内部部零零件件号号NCR No.内内部部不不符符合合报报告告号号SSMR No.(for purch.material)供供应应商商问问题题物物料料报报告告号号（生生产产材材料料）检检验验项项目目Defect缺缺陷陷Qty Sorted已已挑挑选选数数量量Qty Def.缺缺陷陷数数量量03011612957647640108110215外观钢绳开裂5，毛头1，划痕216408030116700945105

2、100120010416外观连接处起皮9，连接处开裂2，管子压伤1，海绵破199013030116700945115110120020116外观连接处开裂29，小孔开裂2，钢绳弯18203203011671086779779012002016外观海绵破损4，管子紧2，C铌镨压坏112107030116FE50370373111020116外观钢绳紧4，钢绳开裂9108013030116FE50370373111020116外观管堵31，钢绳开叉9，C铌镨压线不良3,06孔偏2，管子压伤2，注塑气泡缺料8280055030116700943893890120020216外观钢绳紧21002030

3、116700943893890120020216外观6000030116700943893890120020216外观管子气泡11501030116700943903900120020216外观开裂1，钢绳没出头2，管子气泡215005030116700943903900120020216外观钢绳紧20，缺料1，钢绳头短175022030216700945105100120010416外观连接处开裂3，连接处透明2081023030216710867797790120020216外观海绵破损8，管子压伤1，压接头短1，管子紧4121014030216710861221220120020216外

4、观管子压伤12201030216700945115110120020116外观连接处开裂71，钢绳开叉1，小孔开裂1，夹子透明199074030216700943903900120020216外观钢绳紧27，钢绳头短3140030030216700943903900120020216外观钢绳开叉5，圆球没出头17240022030216561911910120010116外观压伤1，管子紧5，钢绳开叉50420056030216FE50370373111020216外观管堵3，钢绳开叉4，锚头缺料6，锚头气泡2282015030316700945115110120020116外观连接处起皮69

5、，钢绳开叉3，连接处透明272074030316700943903900120020216外观钢绳紧17，压接头短39002003031612957647640108110215外观缺料1，划痕1470203031613936986980120120115外观10000030316700943893890120020216外观油多管子紧25，缺料5，拱出头3，压扁1，断裂116503503031690388-103870120020116外观管子紧14，钢绳开裂2，印字方向错1，钢绳没出头5150022030316710861221220120020216外观44000303167108612

6、21220120020216外观海绵破损4，弯钩开裂1，管子紧6，炮弹缺料1100012030316FE50370373111020216外观管堵12,06孔偏5，管划伤1，C铌镨不良1，锚头缺料528002403031690388-083880120020116外观管子紧6，钢绳开裂3，印字方向错2，钢绳没出头720001803031690389-093910120010116外观10000030316710867797790120020216外观海绵破损4，钢绳开叉12205030316710867797790120020216外观海绵破损3770303041690389-09391012

7、0010116/020116外观头太短230302523003041690388-083880120020116外观管子紧12，钢绳开裂2，圆球头歪8，印字不良1，钢绳不出头535002803041690388-083880120020116外观锚头缺料15，压接头短1，管子紧1，钢绳开叉15001803041690388-103870120020116外观压接头太短8，管子紧727501503041690388-103870120020116外观管子紧2，印字方向反1，钢绳没出头210005030416710867797790120020216外观海绵破损3，装配扎错133040304167

8、00943903900120020216外观管子油太多1215012030416700943893890120020216外观管子油太多1230012030416700943893890120020216外观钢绳紧83508030416700943893890120020216外观油多管子紧1230012030416710861221220120020216外观海绵破27702030416710861221220120020216外观海绵破损4，管子紧2，马蹄缺料111007030416FE50370373111020216外观气泡2，管划伤2，管堵5,06孔偏2280011030416700

9、945115110120020216外观连接处起皮1628016030416561911910120010116外观管子压扁2，管子紧2，钢绳开叉5048005403051612957647640108110215外观锚头缺料2，钢绳开裂1，注芯233005030516L04336636630120010216外观毛头挤出1，小孔开裂3，小孔打偏3，注芯缺料1，小炸弹紧570013030516710867797790120020216外观海绵破2，压接头短1275303051690388-103870120020116外观缺料6，管子紧5，印字方向错2，圆球头歪25，钢绳没出头15225053

10、030516FE50370373111020216外观管堵4，锚头气泡2,06孔偏2，钢绳开叉128509030516700945115110120010416外观小孔开裂52705030516700945115110120010416/020116外观注塑方向错1，小孔开裂1，钢绳开叉55407030516700943903900120020316外观缺料 1，管子压坏1，钢绳紧25204030516700943903900120020216/020316外观管子紧1，炮弹缺料17502030516700943903900120020316外观压扁1，油多钢绳紧230030305167009

11、43893890120020216外观管子油太多73007030516700943893890120020316外观钢绳紧37783030516700943893890120020316外观油多管子紧18，压扁1105019030516700943893890120020316外观管子紧1，管子压伤1，炮弹缺料29004030516710861221220120020216外观海绵破227520771731181TALLY SHEET SUMMARY 不不良良品品统统计计汇汇总总Summary for 汇汇总总: % of Def.缺缺陷陷比比例例Qty Scrap报报废废数数量量QtyRew

12、ork返返工工数数量量Time (h)Spent onSorting挑挑选选工工时时Time (h)Spent onRework返返工工工工时时Qty Sorted/ All PartsTotalSorted挑挑选选数数量量/所所有有挑挑选选零零件件总总数数0.49%80406295、62981.3190%320906322、63110.58%701106277、62731.20%130706147、61931.96%55011061472.00%201.5062850.00%002062850.00%001062900.33%501006248、62852.93%2

13、206.506248、62852.84%230906322、63111.16%1401106277、62730.45%102062777.47%7401106322、63112.14%3001106285、62480.92%220406295、62981.33%560706278、63200.53%1501106147、619310.28%740806313、63222.22%200806285、62480.43%20106298、62950.00%00206285、62622.12%3501106248、62851.47%2204063040.00%004062731.20%12090627

14、30.86%2401106147、61930.90%1805062940.00%00306298、62942.27%502062730.39%307062777.60%23007.506298、63090.80%2808.506294、63043.60%1801063040.55%150506294、63040.50%502.5063041.21%403062778.00%1201062854.00%1202062482.29%803.506248、62854.00%1202062480.26%207062730.64%7010062730.39%1101106147、61935.71%160

15、3063131.13%540806278、63230.15%506.5062981.86%1305062291.09%302.5062732.36%5304.506304、62940.32%901106147、61930.00%503063221.30%706063220.77%40406248、62850.00%20506285、62481.00%302062482.33%702062850.39%30606285、62481.81%190706248、62980.44%40606248、62850.73%202.50627711800363002016.3.1-16日质质量量分分析析拉拉脱

16、脱力力改改善善（The quality analysis of the pull-out force to improve）Date日期Part No.零件号InternalPart No.Sorted挑挑选选的的内内部部零零件件号号NCR No.内内部部不不符符合合报报告告号号生生产产材材料料批批号号ProductioProduction nmaterialmaterialbatchbatchnumbernumber检检验验 项项目目inspectioinspection n itemitem Defect缺缺陷陷Qty Def.缺缺陷陷数数量量03011690388-09391012002

17、0116拉脱力钢绳开叉1030216710861221220110020216拉脱力C铌镨漏压（拉脱力203031690389-093910120010116/020116 拉脱力圆球拉断6030716710861221220110020216/020316 拉脱力C铌镨压坏（6277）1031116710861221220110020316/030116拉脱力6277 C铌镨压坏1斯斯达达史史密密特特（上上海海）汽汽车车零零部部件件有有限限公公司司Stahlschmidt (shanghai)Automtive Co.,Ltd.03121670094511511011020160312-00

18、1020216拉脱力拉断1pcs1% of Def.缺缺陷陷比比例例Qty Scrap报报废废数数量量Time (h)Spent onSorting挑挑选选工工时时Qty Sorted/ All PartsTotalSorted挑挑选选数数量量/所所有有挑挑选选零零件件总总数数操作工根根本本原原因因分分析析Rootcauseanalysis遏制措施shortcontainmentaction实施纠正措施ImplementCorrectiveAction負負責責人人Responsibleperson0.04%17.528506295、6298生产问题组装时绳开叉没有压接好，controinGp1

19、2 fullinspection1教育培训（educationandtraining)江飞 Crane 0.13%2615006273、62771.操作工粗心大意，放在工作台上的产品误判混在压接在一起产品中。产品分类区分放置盒子内，标识隔离（Theproductclassification isplacedinside thebox. ）1.教育培训educationandtraining江飞 Crane 0.22%6826756309、6298压接时钢绳未插入圆球的另一端，拉力小拉断。区分、标识隔离，(Identificationisolation压接工加强教育培训。Compressionj

20、ointeducationandtraining江飞 Crane 0.08%1512506277、6273压接时C铌镨放置在工装里面位置时没到位，产生压坏1.区分标识，隔离2.检查作业方法。1.用不良品警示卡（Badproductwarningcard，）2.教育培训educationandtraining江飞 Crane 0.04%11025006273、6277压接时C铌镨放置在工装里面位置时没到位，产生压坏1.区分标识，隔离2.检查作业方法。1.用不良品警示卡，教育培训1.用不良品警示卡（Badproductwarningcard，）2.教育培训educationandtraining江

21、飞 Crane 2016.3.1-16日质质量量分分析析拉拉脱脱力力改改善善（The quality analysis of the pull-out force to improve）斯斯达达史史密密特特（上上海海）汽汽车车零零部部件件有有限限公公司司Stahlschmidt (shanghai)Automtive Co.,Ltd.0.06%1717506303、6278供应商材料钢丝熔接头问题（Suppliermaterialsteel wirefusionjointproblem ）1.在Gp12全检质量控制(,TotalqualitycontroinGp12 fullinspectio

22、n，2.区分标识隔离(Identificationisolation，3.追溯采购批次(Traceabilitypurchasingbatch可追溯性采购批次)。1.对供应商开不合格报告F-QA-8-20，ReportnumberSSMR,8D改善报告（F-QA-8-13）。谢旭华Sheraton xie记录日期： 2016.3.15检验总工时398总选数量119567总不良数量12不良率0.01%第10周（3.01-3.05）GP12/199-3缺陷统计表Date/日期Part No/零件号InternalPart No.Sorted/挑选的内部零件号SSMR No.(for purch.m

23、aterial)供应商问题物料报告号（生产材料）QtySorted已挑选数量QtyDef.缺陷数量% ofDef.缺陷比例QtyScrap报废数量QtyRework返工数量Time (h)Spent onSorting挑选工时Time(h)SpentonRework返工工时03011612957647640108110215164080.49%8040030116700945105100120010416990131.31%130110030116700945115110120020116820323.90%3209003011671086779779012002016121070.58%70

24、110030116FE503703731110201161080131.20E503703731110201162800551.96%55011003011670094389389012002021610022.00%201.5003011670094389389012002021660000.00%002003011670094389389012002021615010.00%1010030116700943903900120020216150050.33%50100030116700943903900120020216750222.93%2206.50030216

25、700945105100120010416810232.84%230900302167108677977901200202161210141.16%14011003021671086122122012002021622010.45%1020030216700945115110120020116990747.47%7401100302167009439039001200202161400302.14%3001100302167009439039001200202162400220.92%220400302165619119101200101164200561.33%56070030216FE50

26、3703731110202162820150.53%1501100303167009451151101200201167207410.28%74080030316700943903900120020216900202.22%200800303161295764764010811021547020.43%201003031613936986980120120115100000.00%00200303167009438938901200202161650352.12%35011003031690388-1038701200201161500221.47%2204003031671086122122

27、012002021644000.00%00400303167108612212201200202161000121.20%12090030316FE503703731110202162800240.86%24011003031690388-0838801200201162000180.90%1805003031690389-093910120010116100000.00%003003031671086779779012002021622052.27%502003031671086779779012002021677030.39%307003041690389-093910120010116/

28、02011630252307.60%23007.5003041690388-0838801200201163500280.80%2808.5003041690388-083880120020116500183.60%1801003041690388-1038701200201162750150.55%1505003041690388-103870120020116100050.50%502.5003041671086779779012002021633041.21%4030030416700943903900120020216150128.00%120100304167009438938901

29、20020216300124.00%1202003041670094389389012002021635082.29%803.50030416700943893890120020216300124.00%1202003041671086122122012002021677020.26%2070030416710861221220120020216110070.64%70100030416FE503703731110202162800110.39%110110030416700945115110120020216280165.71%16030030416561911910120010116480

30、0541.13%5408003051612957647640108110215330050.15%506.50030516L04336636630120010216700131.86%1305003051671086779779012002021627531.09%302.5003051690388-1038701200201162250532.36%5304.50030516FE50370373111020216285090.32%9011003051670094511511012001041627050.00%5030030516700945115110120010416/02011654

31、071.30%706003051670094390390012002031652040.77%4040030516700943903900120020216/02031675020.00%205003051670094390390012002031630031.00%302003051670094389389012002021630072.33%702003051670094389389012002031677830.39%30600305167009438938901200203161050191.81%1907003051670094389389012002031690040.44%406

32、003051671086122122012002021627520.73%202.50合计：7717311811181363第10周（3.01-3.05）GP12/199-3检验汇总表Project No/项目名称Part No/零件号InternalPart No.Sorted/挑选的内部零件号InternalPart No.Sorted/挑选的内部零件号QtySorted已挑选数量QtyDef.缺陷数量% ofDef.缺陷比例QtyScrap报废数量Time(h)SpentonSorting挑选工时Productivity perhour每小时完成量rankingEfficiency/效率

33、排行榜RU03041690389-09391012040252305.71%23010.5383603041690388-0838801206000641.07%6414.5414503051690388-1038701207500951.27%9516469403051670094389389012064781031.59%10344147903011670094390390012086701201.38%12051.516880305167108612212201203805240.63%2434.5110110302167108677977901204015360.90%3636.511

34、0120302167009451051001201800362.00%3620901403051670094511511012036202085.75%208409113FE5037030516FE50370373111151501270.84%1276224475619103041656191191012090001101.22%110156001JC-49030516129576476401085410150.28%1511.5470303031613936986980120100000.00%025002Lear030516L04336636630120700131.86%1351401

35、0合计：77173 11811181363缺陷分类Defect缺陷外购件切割铸锌注塑z形钩缺料生锈管子变形管子破裂套管长度不良钢绳长度不良印字不良印白点不良打毛不良漏打毛蘑菇头不良钢绳开叉钢绳压伤飞边变形缺料管子压伤注塑缺料注塑飞边尺寸不良钢绳开裂5，毛头1，划痕21 1连接处起皮9，连接处开裂2，管子压伤1，海绵破11 1连接处开裂29，小孔开裂2，钢绳弯1海绵破损4，管子紧2，C铌镨压坏1钢绳紧4，钢绳开裂9管堵31，钢绳开叉9，C铌镨压线不良3,06孔偏2，管子压伤2，注塑气泡缺料82 28 8钢绳紧2管子气泡1开裂1，钢绳没出头2，管子气泡2钢绳紧20，缺料1，钢绳头短11 1连接处开

36、裂3，连接处透明20海绵破损8，管子压伤1，压接头短1，管子紧41 1管子压伤11 1连接处开裂71，钢绳开叉1，小孔开裂1，夹子透明1钢绳紧27，钢绳头短3钢绳开叉5，圆球没出头17压伤1，管子紧5，钢绳开叉501 1管堵3，钢绳开叉4，锚头缺料6，锚头气泡26 6连接处起皮69，钢绳开叉3，连接处透明2钢绳紧17，压接头短3缺料1，划痕11 1油多管子紧25，缺料5，拱出头3，压扁1，断裂11 15 53 3管子紧14，钢绳开裂2，印字方向错1，钢绳没出头51 1海绵破损4，弯钩开裂1，管子紧6，炮弹缺料11 1管堵12,06孔偏5，管划伤1，C铌镨不良1，锚头缺料55 5管子紧6，钢绳开

37、裂3，印字方向错2，钢绳没出头72 2第10周（3.01-3.05）GP12/199-3缺陷统计表海绵破损4，钢绳开叉1海绵破损3头太短230管子紧12，钢绳开裂2，圆球头歪8，印字不良1，钢绳不出头51 1锚头缺料15，压接头短1，管子紧1，钢绳开叉11515压接头太短8，管子紧7管子紧2，印字方向反1，钢绳没出头21 1海绵破损3，装配扎错1管子油太多12管子油太多12钢绳紧8油多管子紧12海绵破2海绵破损4，管子紧2，马蹄缺料11 1气泡2，管划伤2，管堵5,06孔偏2连接处起皮16管子压扁2，管子紧2，钢绳开叉502 2锚头缺料2，钢绳开裂1，注芯22 22 2毛头挤出1，小孔开裂3，

38、小孔打偏3，注芯缺料1，小炸弹紧51 11 1海绵破2，压接头短1缺料6，管子紧5，印字方向错2，圆球头歪25，钢绳没出头152 26 6管堵4，锚头气泡2,06孔偏2，钢绳开叉1小孔开裂5注塑方向错1，小孔开裂1，钢绳开叉5缺料 1，管子压坏1，钢绳紧21 11 1管子紧1，炮弹缺料11 1压扁1，油多钢绳紧21 1管子油太多7钢绳紧3油多管子紧18，压扁11 1管子紧1，管子压伤1，炮弹缺料21 12 2海绵破2000000700000020113 55500000007000000201135550902240012415335304140130001252031037缺缺陷陷曲曲线线图

39、图z形钩缺料生锈管子变形管子破裂套管长度不良钢绳长度不良印字不良印白点不良打毛不良漏打毛蘑菇头不良钢绳开叉钢绳压伤飞边变形缺料管子压伤 注塑缺料注塑飞边尺寸不良多胶，气泡碰伤，划伤开裂变形色差注塑方向错油污,油点钢绳开叉铌镨形状压接不完全钢绳压接尺寸不良孔偏压接孔形状不良连接处开裂压接空深度不良配件用量错误配件装配顺序错误装配方向错钢丝绳套管装配紧钢丝绳弯管子划伤海绵未粘牢固海绵破损050100150200250300350缺陷曲线图10.514.5164451.534.536.52040621511.52570605040302010090389-0990388-0890388-107009

40、43897009439071086122710867797009451070094511FE50375619112957641393698L0433663挑挑选选工工时时柱柱形形图图Series1230649510312024363620812711015013383 414 469 147 168 110 110 90 91 244 600 470 500 140 5.71%1.07%1.27%1.59%1.38%0.63%0.90%2.00%5.75%0.84%1.22%0.28%0.00%1.86%90389-0990388-0890388-10700943897009439071086

41、122710867797009451070094511FE50375619112957641393698L043366301002003004005006007000.00%1.00%2.00%3.00%4.00%5.00%6.00%7.00%8.00%Qty Scrap报废数量Productivity per hour每小时完成量% of Def.缺陷比例0000007000000201135550902240012415335304140130001252031037缺缺陷陷曲曲线线图图z形钩缺料生锈管子变形管子破裂套管长度不良钢绳长度不良印字不良印白点不良打毛不良漏打毛蘑菇头不良钢绳开叉

42、钢绳压伤飞边变形缺料管子压伤 注塑缺料注塑飞边尺寸不良多胶，气泡碰伤，划伤开裂变形色差注塑方向错油污,油点钢绳开叉铌镨形状压接不完全钢绳压接尺寸不良孔偏压接孔形状不良连接处开裂压接空深度不良配件用量错误配件装配顺序错误装配方向错钢丝绳套管装配紧钢丝绳弯管子划伤海绵未粘牢固海绵破损050100150200250300350缺陷曲线图230649510312024363620812711015013383 414 469 147 168 110 110 90 91 244 600 470 500 140 5.71%1.07%1.27%1.59%1.38%0.63%0.90%2.00%5.75%0.

43、84%1.22%0.28%0.00%1.86%90389-0990388-0890388-10700943897009439071086122710867797009451070094511FE50375619112957641393698L043366301002003004005006007000.00%1.00%2.00%3.00%4.00%5.00%6.00%7.00%8.00%Qty Scrap报废数量Productivity per hour每小时完成量% of Def.缺陷比例铆接压接装配多胶，气泡碰伤，划伤开裂变形色差注塑方向错油污,油点钢绳开叉铌镨形状压接不完全钢绳压接尺寸不

44、良孔偏压接孔形状不良连接处开裂压接空深度不良配件用量错误配件装配顺序错误装配方向错钢丝绳套管装配紧钢丝绳弯管子划伤海绵未粘牢固海绵破损5 52 211111 129291 12 21 12 24 49 94 49 93 32 231312 21 12 21 12 21 1202023231 14 48 872721 11 13 327275 5171750505 52 24 43 371713 33 317171 11 125252 25 514141 16 64 41 15 512121 13 37 76 6缺陷分类注塑1 14 43 32302302 28 85 512121 11 11

45、18 87 72 22 21 13 3121212128 812122 22 24 42 22 25 52 2161650502 21 13 33 35 51 12 2252515155 52 21 12 24 45 51 15 51 12 21 12 27 73 318181 12 29022400124 153 35 304 1401300012520310370000007000000201135550902240012415335304140130001252031037缺缺陷陷曲曲线线图图z形钩缺料生锈管子变形管子破裂套管长度不良钢绳长度不良印字不良印白点不良打毛不良漏打毛蘑菇头不良

46、钢绳开叉钢绳压伤飞边变形缺料管子压伤 注塑缺料注塑飞边尺寸不良多胶，气泡碰伤，划伤开裂变形色差注塑方向错油污,油点钢绳开叉铌镨形状压接不完全钢绳压接尺寸不良孔偏压接孔形状不良连接处开裂压接空深度不良配件用量错误配件装配顺序错误装配方向错钢丝绳套管装配紧钢丝绳弯管子划伤海绵未粘牢固海绵破损050100150200250300350缺陷曲线图每周对缺陷较高的3种缺陷做出整改措施：1.钢丝绳压接尺寸不良2.钢丝绳与套管装配紧3.注塑开裂详细见报告0000007000000201135550902240012415335304140130001252031037缺缺陷陷曲曲线线图图z形钩缺料生锈管子变

47、形管子破裂套管长度不良钢绳长度不良印字不良印白点不良打毛不良漏打毛蘑菇头不良钢绳开叉钢绳压伤飞边变形缺料管子压伤 注塑缺料注塑飞边尺寸不良多胶，气泡碰伤，划伤开裂变形色差注塑方向错油污,油点钢绳开叉铌镨形状压接不完全钢绳压接尺寸不良孔偏压接孔形状不良连接处开裂压接空深度不良配件用量错误配件装配顺序错误装配方向错钢丝绳套管装配紧钢丝绳弯管子划伤海绵未粘牢固海绵破损050100150200250300350缺陷曲线图10.514.5164451.534.536.52040621511.52570605040302010090389-0990388-0890388-10700943897009439

48、071086122710867797009451070094511FE50375619112957641393698L0433663挑挑选选工工时时柱柱形形图图Series1230649510312024363620812711015013383 414 469 147 168 110 110 90 91 244 600 470 500 140 5.71%1.07%1.27%1.59%1.38%0.63%0.90%2.00%5.75%0.84%1.22%0.28%0.00%1.86%90389-0990388-0890388-1070094389700943907108612271086779

49、7009451070094511FE50375619112957641393698L043366301002003004005006007000.00%1.00%2.00%3.00%4.00%5.00%6.00%7.00%8.00%Qty Scrap报废数量Productivity per hour每小时完成量% of Def.缺陷比例230649510312024363620812711015013383 414 469 147 168 110 110 90 91 244 600 470 500 140 5.71%1.07%1.27%1.59%1.38%0.63%0.90%2.00%5.75

50、%0.84%1.22%0.28%0.00%1.86%90389-0990388-0890388-10700943897009439071086122710867797009451070094511FE50375619112957641393698L043366301002003004005006007000.00%1.00%2.00%3.00%4.00%5.00%6.00%7.00%8.00%Qty Scrap报废数量Productivity per hour每小时完成量% of Def.缺陷比例每周对缺陷较高的3种缺陷做出整改措施：1.钢丝绳压接尺寸不良2.钢丝绳与套管装配紧3.注塑开裂详细见报告NONCO