七颗钻石流程

17DiamondProcess

七颗钻石流程2Whatisthe7DiamondProcess?

七颗钻石的流程是什么？The7DiamondProcessisoneofmanytoolsthatcanbeusedintheproblemsolvingprocess.七颗钻石流程是可以用来解决质量问题的工具之一。Thistoolisusedtoinvestigatediscrepanciesdiscoveredbythefollowing:它可以用来调查以下方面发现的差异

GlobalCustomerAuditSystem(GCAS)全球顾客评审

YardWalkAudits生产线上巡检

VerificationStations检验工位3

Purposeofthe7DiamondProcess

7颗钻石流程的目的

The7DiamondProcess

isastructuredwayofassessingourmanufacturingprocesstodeterminewhetherofnotithasfailedtomeetthequalitystandarddemandedbyourcustomers.7颗钻石流程是一个构建好的评价我们的制造流程是否满足了顾客所要求的质量标准的一个方法

47Diamond

Process流程Responsibility责任Production第一步

¨1Production第二步¨2Production第三步¨3Rel.Engineer/SQA/Supplier负责的SQDE工程师/供应商

¨4CorrectProcess?正确的工艺CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量Responsibility责任ProcessControlManagers工艺控制负责人¨5aIsEngineeringsupportrequired?是否需要工程方面的支持ProblemIdentifiedBeginInterrogation问题定义(开始调查)Responsibility责任QETPST(Lead)¨5bSMTRGM(Lead)¨6StatisticalEngineering(RedXStrategies)统计工程(红-X方法)¨7WillProcessChangeResolve?工艺更改能解决问题吗ProductChangeRequired?产品更改需要吗？HardyPerennialorExtremelyComplexProblem非常复杂的问题SQA -SupplierQualityAssuranceQET -QualityEngineeringTeamPST -PlantSupportTeamSMT -SystemsManagementTeamRGM-ReliabilityGrowthManagement5ReviewofResponsibility

职责回顾

Diamonds1-4 Production&Reliability钻石1-4生产&可靠性

Filter5a ProcessControlManager(PCM)5a过滤工艺控制负责人

Diamond5b-7 ProductEngineering钻石5b-7产品工程6InsertSampleCountermeasureCardHere此处插入对策卡样卡77DiamondProcessStages

流程的各步骤Stages1&2oftheprocessareusedtodetermineiftheProductionorganizationisrunningtheassemblyprocesstodesignintent.1、2步是用来确定生产部门运行的装配流程满足设计内容。

Theinitialinvestigation(Stage1)isdonewherethedefectwasidentified.最初的调查(第一步)应在发现缺陷的地方开始Stage2isonlyusedwhentheinvestigationinStage1determinedthatthecauseoftheproblemwasfromanupstreamsource.第2步只能当第一步的调查,确定问题是来源其他方面时,才可开始Iftheprocessisn’tbeingmanagedtodesignintent,thenitmustbecorrectedandvalidated,priortoaskingforEngineeringassistance.如果工艺没有满足设计内容，当需要工程方面的协助前，必须进行纠正并要有效。Engineeringreferral(Stage3)occurswhenthemanufacturingprocessdoesmeetdesignintentandtheproblemstillexists.当制造过程满足设计内容并且问题依然存在时，第3步开始。8¨1-CorrectProcess正确的过程

ArethecorrectBestPeoplePracticesheetsposted?是否有正确的操作指导文件？

AretheBestPeoplePracticesbeingfollowed?是否执行操作文件？

IstheoperatorsKeyPointChartbeingfollowed?是否满足关键操作点控制图

Arethecorrectdocumentspostedontheoperationcertificationboard?是否在操作示板上有正确的文件

IsthejobbeingperformedtothePAD’s?是否按照PAD操作

Cananyofthesecausetheproblem?以下的问题有可能产生问题吗？Stages1&2ProductionCorrects正确的生产Production¨2Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件的质量8¨1-CorrectProcess正确的过程

Hasamandatorysequencebeenidentified?Isitbeingfollowed?是否强制的操作序列号已识别，是否执行了

Isthejobbeingdonethesameonbothshifts?在各班次中操作工作是否一致

Doestheoperatorunderstandwhattheproductstandardsare?操作者是否理解产品标准

Isittheregularoperator?Hastherebeenalotofturnoveronthejob?是否为固定操作工？是否此操作有很多轮换人员

Hastheoperatorbeenproperlytrained?操作者是否正确培训过

Arethevisualaidscurrent?目前是否有目视化的辅助措施

Doestheoperatorunderstandthequalityoutcomesofher/hisjob?操作者是否知道他/她的岗位的产品的输出质量

Doestheoperatorknowhowtocommunicatewhenhe/shehasaproblem?操作者是否知道当他/她的岗位出现质量问题时如何传递沟通信息？Cananyofthesecausetheproblem?以下的问题有可能产生问题吗？Stages1&2ProductionCorrects正确的生产Production¨2Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量9

Arethecorrecttools&fixturesbeingused?(bothshifts)

是否使用正确的工具/夹具(各班次)

Arethetoolssettothespecifiedtorque?

工具是否设置成规定的扭矩

Aretheyproperlycalibrated?是否进行适当的校准

Arebothshiftsusingthesametool?

是否各班次用同样的工具

Arethebitsorsocketsworn?是否螺丝刀或套筒已磨损

Hasanextraairhosebeenattachedtothetool?

是否在工具上有多余的空气管

IsthetooltiedtotheAndonsystem?工具是否与暗灯相连

HasthetoolbeenputonBypass?是否工具被旁路

Dothetools&fixtureshavemutilationprotection?是否工具/夹具有损毁保护

Hastheworkstationbeenerrorproofed?

工位是否有防错设施

Doestheworkstationlayoutallowtheoperatortoworkeffectively?

是否工位的布置适合操作者有效的工作

HasthePreventiveMaintenancebeendone?(checklog)

是否进行了预防性维修(检查表)

Aretoolsfunctioningcorrectly?

工具功能是否正确Stages1&2ProductionCorrectsProduction¨1Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量¨2-CorrectTool正确的工具Cananyofthesecausetheproblem?10IsthePartsRoutingcurrent?零件的的路径径是否否正确确Arethecorrectpartnumbersidentifiedonthematerialracks?是否在料架上上标识有正确确的零件号Arepartsstockedincorrectlocationontherack?在料架上摆放放位置是否正正确Dothepartnumbersontheboxesagreewiththerack?包装盒上零件件号与料架上上是否一致Areallpullcardsavailable?拉动卡是否有有效HasaPAAbeenissuedchangingpartusage?是否有零件用用途改变的PAAHasthePAAexpired?PAA是否过期Iserrorproofingneeded?是否需要防错错措施Isexistingerrorproofingdeviceworkingcorrectly?是否已有的防防错设备运行行正确Stages1&2Production¨1Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正确的工艺过程ProductionCorrectsCorrectPart?正确的零件Production¨2CorrectTool?正确的工具PartsQuality?零件质量¨3-CorrectPart正确的零件Cananyofthesecausetheproblem?11TheReliabilityEngineerisresponsiblefordeterminingifpartshavechangedandoverallpartquality.Ifpartsquality(outofspecification)isdeterminedtobetheproblem’’srootcause,thentheREwill:writePR&R’’stonotifythesupplierthatthereisaproblem.可靠性工程师师确定零件是是否更改过并并对产品全部部质量负责。。如果由于零零件质量(超超差)是根本本原因，那么么应：填写PR&R通知供应商：：workwithSupplierQualitytovalidatethecorrections.同供应商共同同确认纠正措措施setupsortingoperationsandproductionwillsupportsortingofmaterialattheoperation.采取筛选措施施，制造应支支持在工位上上的物料筛选选workwithGroupLeaderstovalidatecountermeasuresorcontainment.同工段长共同同确认对策和和遏制措施Ifpartvariationwithinspecificationistherootcause,thentheREwill:如果果确确认认零零件件在在规规范范内内，，那那么么RE应：：workwiththesupplierandSQAtomovethepartbacktotheneededrangewithinthespecification同供供应应商商共共同同工工作作，，SQA将零件返返回到规规范内需需要的范范围workwithQualityEngineeringtodetermineifanEngineeringChangeisrequiredtoprovideirreversiblecorrectiveaction同质量工工程师合合作，确确定是否否需要工工程更改改这种不不能消除除的纠正正措施Stages1&2Production¨1CorrectProcess?正确的工工艺流程程Rel.Engineer/SQA/SupplierPartsQuality?零件质量量Production¨2CorrectTool?正确的工工具CorrectPart?正确的零零件Production¨3¨4-PartQuality零件质量量12Diamonds1-4inReview钻石1-4步回顾Diamonds1-4areforevaluatingthestabilityoftheprocess.1-4步用来评评价工艺艺过程的的稳定性性Onceaproblemhasbeenidentified,theautomaticresponsemustbetoimmediatelystepthrudiamonds1-4.当问题被被定义后后，1-4步的的负责人人员就自自动确定定下来Itmustbecomeinherentinourproblemsolvingthoughtprocess.这些步骤骤是问题题解决过过程中固固定的流流程Responsibility职责ProcessControlManagers过程控制制负责人人¨5aIsEngineeringsupportrequired?是否需要工程的支持13¨5a-EngineeringFilter5a-工程过滤滤IsEngineeringsupportrequired?需要工程程方面的的支持吗吗5aisasteptofilteroutandresolveless-complexissuesbeforeseekinghelpfromQualityEngineering.5a是一步过过滤出并并将不复复杂的问问题在寻寻求质量量工程帮帮助前解解决TheProcessControlManagerisresponsibleforconductinginitialstudiespriortoescalatingtheissue.过程控制制负责人人负责在在提升问问题前指指导初始始研究Thesestudiesmayincludebutarenotlimitedto:这些研究究应包括括但不局局限在:ProblemDefinitionTree问题定义义树5Whys5个为什么么StatisticalProcessControl统计过程程控制DesignofExperiment(DOE)试验设计计ShaininTechniques(quick&dirty)技术(快快速&脏脏)Ifaftertheinitialstudiesthecauseofvariationhasnotbeendetermined,theissueisreferredtoProductEngineering.TheproblemdefinitiontreeistheminimumexitcriteriatogofromDiamond5ato5b.如果经过过初始研研究，变变差的产产生原因因还没有有确定，，就需要要产品工工程的支支持。问问题定义义树是从从5a-5b的基本方方法。QualityEngineering质量工程5aProblemSolvingToolbox问题解决工具箱Projecttitle:PooradjustmentofRRdoorpanel805-830Leader:PedroArandaAlfaroSponsor:JuanCarlosLiceaArea:VAETCoach:LeonardoCháávezsalcedoInitialdate:oct-04-2002Finaldate:oct-29-2002Problemdescription:ThismonthitwasreportedbytheshippinglotinUSAaproblemofqualityexistedinthe805/830vehicles.TheproblemisthepooradjustmentinRRdoorpanel.Projectsstatement:FindandimprovetheRedXthatproducethepooradjustmentintheRRdoorpanelforthemodel805/830inSilaoAssemblyplant.Strategy:Weinitiatedthisprojectusingthemodeltomodelstrategy,becausetherewasagoodcontrastandgoodleveragebasedonmulti-variseepag6.Measurementsystem:AsmeasurementsystemaForcegagewasused.ThismeasurementsystempassedtheisoplotwithDR=13.6,DM=1.0lbs,andDP=13.6lbs(seepage4)Cluegeneration:Stage1showsthattheRedXdoesn’tliveintheprocess.Thestage2showsthattheRedXlivesinthedoorpanel.Thepaircomparisonshowsthatthedoormoldingisthepartwiththebestcontrast.Statisticalconfirmation:OncewedetectedtheRedXcandidate,IdecidedtodoaBvsCsixpacktrial,inordertoconfirmthedoormoldingistheinfluencetomakethecustomersatisfaction.Thesixpackpassedwith95%ofconfidenceandendcountof6.Irreversiblecorrectiveaction:Tomodifiedtheflange1.5mminlengthtokeepabetterpositionandavoidthatthedoorpaneltakeoutofposition.Improvements:Reducewarrantycosttorepairthedoorpanelcausedbypoorfit(loose)andeliminatetheconditionin100%invehicles805/830models.Theamountofmoneyfromjul01tojul02was11,084.77USD.Lessonslearned:Welearnedthatisnecessarylookingotheralternativesusingotherstrategywhenisnotpossibleinvestmoneybutalwaysfocustoguaranteethecustomerenthusiasm,thereforethisprojectisanexampleofthis.ExecutiveSummary执行总结项目题目：右后门板调调整不好(805/830车型)。。领导；PedroAdrandaAlfaro发起人：JuanCarlosLicea区域：VAET教练：LeonardoChavezsalcedo起使日：2002年10月4日截止日：2002年年10月29日问题描述：本月收到报告告，在美国有有关于门饰板板的质量问题题，右后门饰板调调整不好。(805/830型)项目综述：针对Lilao装配厂805/830车车型的右后门门饰板，发现现并解决其配合不不好的问题。。策略：我们起初应用用车型对车型型策略，因为为多车之间有有很好的对比比度和平衡关关系。(见见见第6页)测量系统：用测力计作为为测量系统。。这种测量系系统通过等量量图。(DR=13.6,M=1.0lbs,P=13.6lbs见第4页线索产生：阶段1表明红红X不在过程中。。阶段2表明明红X产生在门饰板板处。成对比比较表明门型型是成对比较较点。统计确认：一旦我们查到到了候选的红红X，我们决定做BvsC六组数据比较较，这是为了了确认门型影影响客户满意意度。用6对对数据进行比比较具有95%的可信度度和最大累加加值为6.不可撤销的纠纠正措施：为使门边缘加加长1.5mm以保证正确的的位置不偏离离。改进措施：减少保修费用用来修复由于于配合不好产产生的门饰板板问题，并且且100%消消除803/805车型型的缺陷。学到的经验：我们学到了当当投资不会会太多的情况况下，用其它它策略以寻求求可选择的方方法解决问题题。但始终要要关注顾客热热忱。此项目目便是一个这这样的例子。。ProjectDefinitionTree/项目定义树Problemcharacterization问题描述Warrantycondition/保修条件Theproblemispresentedonlyinthereardoor问题只是在后后侧车门出现现BASED:DISTRIBUTONLOTCAMPAINGCURRENT:100%doorpanel805830modelsloose目前状态：805/830型车门饰饰板100%松动。GOAL:eliminate100%thepoorfit.目标：100%消除不良良的配合Projectstatement项目综述Needenergytoreleasethetrimdoorpanel需要用力才能能卸下门饰板板Customeriscallingtheprobleminbothsides客户现在对两两侧都在抱怨怨Efforttorelease(lbs)/释放力(磅)Frequency频率CURRENT现有DESIRED希望Solutiontree项目解决树TARGET:Eliminatecondition100%目标：100%消除除现有问题PASSEDISOPLOTDR=15.2SEEPAG4通过等量图验验证DR=15.2参见第4页PASSEDSTAGE1SOTHEREDXDOESN’TLIVEINTHEPROCESSSEEPAG#7.通过第一阶段段验证，因此此红X不在装配过程程中，参见第第7页。THECOMPONENTSEARCHSTAGE2SHOWSTHATTHEREDXDOESNOTLIVEINTHETRIMDOORPANELSOLIVESINTHERESTOFTHEDOORPANEL.SEEPAG#7./零部件分析阶阶段2显示红红X不是由车门内内饰板造成的的,所以应是是由车门板的的其余部分引引起的,见7页.PAIRCOMPARISONSHOWSTHATTHEDOORPANELMOLDINGHASTHECHARACTERISTICTHATPRODUCETHEDIFFERENCESEEPAG9/配对对比显示示车门饰板饰饰件有造成差差异的特征，，参见第9页页THISISTHEBESTSTRATEGYBASEDONMULTIVARISEEPAG5.这是基于多多重变换比比较得出的的最佳策略略，参见第第5页。PASSEDBvsCWHEREITSHOWSTHATTHEDOORMOLDINGKEEPINPOSITIONTHEDOORPANELSEEPAG10,BUTWECHOICEOTHERCHARACTERISTICTHATKEEPINPOSITIONTHEDOORPANELANDWITOUTINVESTMONEYSEEPAG11&13.通过BC对比试验，，显示车门门饰板饰件件能够使车车门饰板保保持正确位位置，见第第10页。。但是我们们选择能够够保证车门门饰板位置置并且不用用增加投资资的其它特特性，参见见第11和和13页。。Frequency频率GREENYRUNCHARTSEEPAG17/绿Y字流程图参参见第17页。DESIRED希望CURRENT现有BASED:DISTRIBUTONLOTCAMPAINGEfforttorelease(lbs)释放力(磅磅)DM=1.0lbsDP=13.6lbsDR=13.6PassedIsoplotIsoplotAForcegagewasusedasthemeasurementsystem拉力计作为为测量工具具通过ISOPLOT评估POINTTOPOINTTherearenocontrastinthisstrategytherearenodifference.Thereisagoodcontrastbuttheleverageisnotenoughbecausewedon’thavetoolstomeasureit.Thisstrategyprovidegoodcontrastandthebestleveragebasedonmulti-varichartseepag6TherearenocontrastthroughthetimeStrategydiagramPLANTTOPLANTMODELTOMODELTRUCKTOTRUCKSIDETOSIDESAMEPANELSAMEPLANTSAMEMODELSAMETRUCKThereisacontrastbetweentrucktotruckandgoodleveragebutthecontrastisnotenoughbasedonmulti-variseepage6.EVENTTOEVENTSAMEPOINTTherearenocontrastinthisstrategytherearenodifferenceeventtoevent.策略略图图事件件对事件件同一一个个点点点对点同一一块块扳扳同一一侧侧对同一一侧侧同一一台台车车车对车同一一型型号号型号号对型号号同一一个个工工厂厂工厂厂对工厂厂在这这个个对对比比中中,无无差差异异.在这这个个对对比比中中,无无差差异异.在这这个个对对比比中中,有有差差异异.但但无无测测量量工工具具.在车车与与车车的的对对比比中中,有有差差异异.但但不不能能满满足足MULTI-VARI的要要求求..在这这个个对对比比中中,有有差差异异.且且能能满满足足MULTI-VARI的要要求求..在这这个个对对比比中中,无无差差异异.Multi-variNOTE:Thisgraphicshowsthatthebestcontrastismodeltomodel.SideTruckEFFORTTOTAKEOFF(lbs)RLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLCustomersatisfactionlimitBOBWOWModelCCCCAAAAAAAAAAASSSSSSSSSSSSSSSSNOTE:S:SUBURBAN830MODELA:AVALANCHE805MODELC:CADILLAC806MODEL注:S\A\C三种车型最好最坏顾客的满意底底线注:此图显示示出在型号与与型号的对比比中有最大的的差异.松脱力(磅)ComponentsearchNOTE:ThisgraphicshowsthattheRedXsuspectdoesnotliveintheprocessbecauseitpassedthestage#1.Thestage2showsthattheRedXsuspectdoesnotliveinthesealwindow.SotheRedXsuspectlivesinthemoldingdoorpanel.Effort(lbs)BOBWOWSTAGE1STAGE2第一阶段第二阶段最好最坏原状态第一次拆装第二次拆装第三次拆装门窗密封条门饰板门饰板饰条铰链注:这个图显显示因为通过过了第一阶段段的试验,所所以REDX不是由操作造造成.第二阶段的试试验显示门窗窗密封条不是是REDX,门饰板饰条是是REDX要素查找规则Rule1.TherearecompleteseparationbetweentheBOBandWOWvalues.将最好和最坏坏的值完全分分开规则Rule2.DY>V1R设Where:R=RBOB+RWOW2那么thenRBOB=1.9RWOW=1.2R=1.9+1.2=3.1=1.55.22DY=YBOB-YWOW=46.8-8.1=38.7如果ifDY>V1R那么then38.7>(0.89)(1.55)所以so38.7>1.38所以满足规则则1和规则2的要求sopassedRule1andRule2通过问题为每每个单元设定定判定极限Setdecisionlimitsforeachunitbyusingthequestions:DLBOB=YBOB+V2RDLWOW=YWOW+V2R那么Thenudl=48.83DLBOB=46.8+1.31(1.55)=ldl=44.77udl=10.13DLWOW=8.1+1.31(1.55)=ldl=6.07结果Results~~~~~~~PairedComparison备注NOTE:WeconsiderthatthedoorpanelmoldingistheRedXcandidateinthepaircomparisonbecauseistheonlydifferencebetweenpaneltopanel.In805/830vs806models.我们认为门板板装饰件是可可能的RedX,因为在在车型型805/830和和车车型806对比比后只只有门门板有有差异异。WOWBOBDOORMOLDINGREDXCANDIDATEPassedBvsCwith95%ofconfidencethatthemoldingdoorpanelistheRedXwithcompleteseparationandendcountof6.在完完全分分离，，Endcount为5的的情况况下，，以以95%的的置信信度通通过BvS表明门板板装饰件件是RedXBvsCSixpackB=有门饰件件的车Vehicleswithdoormolding.C=没有饰件件的车Vehicleswithoutdoormolding.Req:置信度confidence=95%OnceconfirmedthattheREDXislivinginthedoorpanelmolding,wedecidedtochangeourstrategyfrom““modeltomodel”to““trucktotruck”becausethedoorpanelmoldingisuniqueforCadillacmodels.Inotherwords,findonecharacteristicinthesamedoorpanel805/830modelthatmakesthedifference,becausetherearesomedoorpanelsthatrequirealmost20lbstopulledoutofitpositionfromthedoorandthereareotherswithlessthan10lbstopulledoutofitposition;Thecustomerenthusiasmlimitis18lbs.thisisenoughtokeepthedoorpanelinpositionatlowcost.一旦确定定RedX为门外板板装饰件件，我们们决定改改变策略略，从从车型到到车型变变到卡车车到卡车车，因为为门外板板装饰件件对Cadillac车型来说说是唯一一的。换换句话说说，，同同样的门门板装在在805/830车车型上却却产生了了差异，，原因是是一些门门板从门门上拽出出需要20磅的的力，二二另一些些只需要要小于10磅的的力;顾顾客的的要求是是18磅磅，这已已经足够够保证门门板以较较低的成成本固定定到相应应的位置置。BOBWOWBIGCONTACTAREASMALLCONTACTAREA大间隙BIGGAP小间隙SMALLGAP门边缘DOORFLANGE门边缘DOORFLANGEThemaincharacteristicthatcausedifferencebetweenthedoorpanels805/830modelisth