质量控制介绍.ppt

1、First Time Quality一次下线合格率,2,First Time Quality,What First Time Quality Is 一次下线合格率是什么? Why It Is Important 它的重要性在于? Why We Need to Measure It 我们为什么要去测量它? How to Calculate It 如何进行计算? FTQ Deployment, Evaluation and Improvement Process FTQ调度,评估及改进程序 Responsibilities 职责 The Structured Approach Steps 结构化改

2、进步骤 The Basic Quality Tools 基本质量工具 How to Apply the Quality Tools 工具使用方法 Monitoring and Reporting 检测及报告 Class Exercise,3,What is First Time Quality? 一次下线合格率是什么? First Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted. 一次

3、下线合格率是指在一次生产过程中所产生的不合格品与总产量的比值,First Time Quality,4,Define ALARM LIMITS 确定警戒线 Catch and Count Defects 捕捉并计算不良品 React to ALARM LIMITS 对警戒作出反应,Follow Reaction Plan 根据应对计划,Voice of the Customer 客户反馈,First Time Quality,Initiate Structured Problem Solving 开始结构化问题的解决,ZERO Defects Forward,A structured appr

4、oach,5,FTQ can be viewed as a two phase approach: FTQ可以分为两个步骤 Immediate action and containment 快速反应及解决 Whenever alarm limits are exceeded 一旦超过警戒线,及时做出反应 Helps ensure customer protection 提供帮助来保护客户 Continual Improvement 持续的改进 Management objective to reduce quantity of rejects and operational cost 管理目标

5、是不断的减少不良品,降低生产成本 Leadership MUST ensure, support and follow-up with implementation of FTQ in their facility to be successful 领导者必须保证,支持并遵循FTQ,以使其在工厂成功运用.,First Time Quality,6,Why is FTQ important? FTQ为什么重要? Because if we dont make good parts the first time, we have to “inspect in” quality 因为如果我们不能一次

6、产出合格品,我们就必须对产品质量进行多次检验 We know inspection is at best 85% effective 检验至多在85%的情况下是有效的 Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因此,当FTQ不为0时,我们只有依靠检验来保护客户的利益 To reduce manufacturing costs and defects through continual improvement (FTQ Tracker or St

7、ep Down Chart are tools to utilize) 通过使用FTQ追综表或SDC表,持续的改进可以降低生产成本,减少不良品. To monitor process stability and react quickly to potential issues (Alarm limits and process monitoring sheets) 通过警戒线表及过程监控表,我们可以监控过程的稳定性并对潜在问题快速应对,First Time Quality,7,FTQ should be viewed as a tool to facilitate operational i

8、mprovement in: FTQ应被视为用来促进生产改进的工具 Quality 质量 Cost 成本,First Time Quality,8,into this!,to turn this,FTQ is Key to our Success FTQ是我们成功实现财富增值的秘诀,First Time Quality,9,Why does FTQ need to be measured? 为什么FTQ需要被测量 Main Reasons: 主要原因: It is the early signal that a process is out of control 它对异常过程作出早期反映信号.

9、 It allows us to respond to problems internally before they reach our customers 它让我们在顾客发现问题前在内部做出反应. It measures improvement from corrective actions implemented 它可以对矫正措施的效果进行评估监测 If we dont fix our quality problems internally, we will never be able to fix our external customer issues 如果我们不能在内部解决质量问题

10、的话,我们也不会有能力去解决外部的客户问题.,First Time Quality,10,Filter 过滤器,Inspection misses some defects 检查漏掉了一些不良品,Defects not caught 漏掉的不良品,Problem 问题,D,Inspection is like a filter. 检查就像过滤器,The fatal flaw of inspection 检查的致命缺陷,First Time Quality,11,How is First Time Quality calculated? FTQ如何计算 FTQ is reported in pa

11、rts per million (PPM) defective FTQ以每百万产品不良率来报告 It can be measured at any step in the manufacturing process where parts are rejected especially where the defect is originated. 它可以在生产过程中产生不合格品的任何一个步骤进行测量,尤其是不良品的起源 It is calculated by counting the number of pieces rejected versus the total number of p

12、ieces attempted 它的计算方式是不良品总数与总产量的比 The total number of pieces attempted includes all good pieces produced plus all pieces rejected 总产量包括所有合格品与所有不良品. Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不良品包括所有还未流入下一工序的废料和重

13、工品.具体计算方式如下: Number of Pcs. Rejected 不良品总数 Total Number of Pcs. Attempted 总产量,X 1,000,000 = FTQ PPM,First Time Quality,12,How is First Time Quality calculated? 一次下线合格率如何进行计算? An example at the cell level: 举个电池的例子 Cell “A” has six operations A类电池需要六个工序 Reject data is collected at operations 3 and 6.

14、在工序3和6中采集到了不良品数据 Cell “A” produced 1040 good pieces during the first hour. 在第一个小时内生产了1040个合格品 At OP.3, 28 pcs. were rejected. 在工序3,28件不合格品 At OP.6, 16 pcs. were rejected. 在工序6,16件不合格品 What is the FTQ in PPM for Cell A? A类电池的百万一次下线合格率是多少? 28 + 16 44 1040 + 28 + 16 1084,1,2,3,4,5,6,= X 1,000,000 = 40,

15、590 PPM FTQ,28,16,Tally Sheet 计数图,First Time Quality 一次下线合格率,13,First Time Quality,What First Time Quality Is FTQ是什么 Why It Is Important 它为什么重要 Why We Need to Measure It 我们为什么要去测量它 How to Calculate It 如何进行计算 FTQ Deployment, Evaluation and Improvement Process FTQ的调度,评估及改进程序 Responsibilities 责任 The St

16、ructured Approach 结构性方法 The Basic Quality Tools 基本质量工具 How to Apply the Quality Tools 如何使用质量工具 Monitoring and Reporting 检测与报告 Class Exercise,14,FTQ Improvement Process FTQ改进程序,Stakeholder involvement 投资者参与模式,15,LEAD,SUPPORT,Typical Responsibilities Flowchart 典型的职责流程图,FTQ Improvement Process FTQ改进程序,

17、16,SQ or SDE Responsibilities 质量工程师职责 Ensure supplier understands, and if necessary, obtains appropriate training on the FTQ Improvement process 确保供应商明了FTQ ，如有必要，要接受关于FTQ改进程序的适当培训 Monitor implementation progress during FTQ activities 在FTQ活动中进行进程的监控 Conduct 5 step site evaluation for FTQ implementati

18、on 对FTQ的执行，进行步评估 Set stage for improvement activities 为改进行动奠定基础 Outline plan of attack 批评的大致计划 Document improvement plan ( i.e. through an A3) 文件改进计划（如：通过A3）,FTQ Implementation FTQ执行,17,SELECT 选择,CONTAIN 抑制,CORRECT 矫正,PREVENT 预防,FTQ Improvement Process Overall 全面的FTQ改进程序,18,Define ALARM LIMITS 确定警戒限

19、 Catch and Count Defects 捕捉并清点不良 React to ALARM LIMITS 反应,Follow Reaction Plan,Voice of the Customer 客户反馈,First Time Quality,Initiate Structured Problem Solving 开始程式化问题解决,ZERO Defects Forward,A structured approach,19,FTQ Improvement Process FTQ改进程序,Define alarm limits and reaction plan 确定警戒限及反应计划 Al

20、arm limits must be based on current process reject data or available data from Machine qualification runs, Run at Rate, historical data, etc. 警戒必须基于现工序的不良数据或是从机器在一定功率下运行产生的历史数据，等 Need to collect data long enough to ensure you understand the types and quantities of defects that fall out from your cur

21、rent process. Limits for common cause (chronic) rejects may be statistically calculated 必须经过足够长时间的数据收集，我们才能确定从现运行程序中漏掉的不良品的种类和数量一些共同原因产生的不良也可通过这些统计被找出 Understand process and expected defects (what types and quantities of defects)了解程序和预估不良（不良品的种类和数量） Determine the process normal range of variation by

22、 charting the reject data over time通过对不良数据制表认知，确定程序的正常变化幅度,20,FTQ Improvement Process FTQ改进程序,Define alarm limits and reaction plan 确定警戒限及反应计划 Limits for special cause (non chronic) rejects must be set at one piece 突发原因产生的不良显示必须在一产生时就做出调整 Limits must be communicated to operators so they can react 限定

23、还必须与操作员交流清楚以便他们能及时反应 If alarm limits are exceeded, there must be a documented reaction plan which includes containment of product and process corrections. 如果警戒限被超，要有书面的反应计划包括生产抑制以及程序更正 Employees may find clever ways to identify abnormal process state as the process matures 随着程序的成熟，职工也会发现识别异常的巧妙方法 Th

24、e immediate action taken is the most important step in containing the problem until it has been eliminated and verified 遏制问题的最重要的步骤是快速采取行动直到问题被消除并核实,21,Quality Alarm Limit: 品质警戒限,Example: Rejected Parts Counter例：不合格品的计数,The counter is flipped for each defect. The color will change from green to yell

25、ow to red. 在每个不良品上要附上这种卡片颜色有绿黄红三种 Yellow indicates action required and red will stop the process. 黄色表示要采取行动，而红色表示停止工序 Small white tags are placed with each defective part to identify the specific defect. 每个不良品上会有一个白色小标签注明不良原因,22,Identify and count rejected parts 识别及清点不良品 Operators must have sufficie

26、nt tools and skills in order to identify product discrepancies 操作员必须有足够的工具及技能来识别产品缺陷 It is recommended that rejected parts be removed from the cell station at a defined frequency so they may be counted and categorized by defect or rework code 不良品应定期从工作区移开，以便进行计数并不良品号码登记 Tools to enhance the operator

27、s ability to identify product discrepancies include: 用来增强操作员识别产品差异的工具包括： Boundary Samples 对比样品 Illustrations 图表 Photographs 照片 Gages 计量器 Tools for counting rejected parts include: 清点不良品的工具有： Parts Counters 计数器 Tally Sheets 计数表 Sized Containers 定容器,FTQ Improvement Process FTQ改进程序,23,Implement Alarm R

28、eaction Plan if Limit Exceeded 如果超过警戒限，执行反应计划 Reaction Plan:反应计划,FTQ Improvement Process FTQ改进程序,24,Record Data 记录数据 Data must be recorded and plotted over time: 要按时记录数据并绘制数据图 At the cell level, the number of pieces rejected shall be recorded by defect category at a defined frequency. This data must

29、 be used to react to abnormal process conditions (process monitoring) 每个作业区都必须用不良记录表以一定频次来记录不良品数目数据必须用来对异常程序作出反应（程序监测） Since the area of opportunity varies from sample to sample, the reject count must be converted into a rate (FTQ PPM) prior to charting 因为样品与样品的 Each area should have a performance t

30、racking board that would reflect the manufacturing FTQ information by shift,FTQ Improvement Process FTQ改进程序,25,Analyze Data 分析数据 The basic quality tools are: 基本的品质工具 Flow Charting流程图 Check Sheets报帐单 Pareto柏拉图 Cause and Effect因果图 Run Chart Histogram柱状图 Scatter Diagram散布图 Control Chart控制图,FTQ Improvem

31、ent ProcessFTQ改进程序,26,Initiate Structured Problem Solving 开始程式化问题解决 Understand Defects and Decide the Order of Priority: 了解不良并确定优先顺序 Assign problems to Cross-Functional Group: 向独立功能性小组提交问题 Select and Plan the Improvement: 1 Right Information 2 Right Cause 3 Right Timing 选择并计划改进:1 正确的信息 2 正确的原因 3 正确的

32、时间 Fix the Biggest Problems First: 先解决最大的问题,Problems,1,2,1,2,Responsible Team Works Problems 负责小组指出问题,DEFECT 1. - 2. - 3. -,4,3,2,3,2,2,1,1,1,1,First Time Quality Process一次下线合格率程序,27,Analyze Data 分析数据,Problem Identification 问题识别,Problem Analysis 分析问题,Flowchart 流程图 Brainstorming 头脑风暴,Pareto Chart 柏拉图

33、 Cause & Effect 因果图 Control Chart 控制图 Check Sheet 报帐图 Run Chart 趋向图 Stratification 分层图,Histogram 柱状图 Scatter Diagram 散布图 Process Capability 加工能力,Charts can be used for different purposes in various stages of the problem-solving process 在问题解决程序中许多阶段,图表都可以用于不同的目的. The tools included in the intersectin

34、g portion of this diagram can be used in both the problem identification and problem analysis phase of problem solving 位于上图交叉部位的工具既可以用于问题的识别也可用于问题的分析.,FTQ Improvement Process FTQ改进程序,28,Select and Plan Improvement选择和计划改进 After FTQ problems have been identified through data analysis, improvement plan

35、s must be developed 通过数据分析FTQ问题被界定后，改进计划必须被制定 A recommended template has been provided to track implementation status of corrective actions (FTQ Tracker or Step Down Chart) 跟踪纠正行动执行状况推荐模板被提供（FTQ跟踪或趋势图） To be make problem solving truly effective, standard work must be utilized. Standard work is like a recipe: varying method and content will not yield same results!对于被有效解决的制造问题，必须形成工作标准。工作标准就象一个处方：不同的工作方法和内容将得出不同的结果,FTQ Improvement Process,29,Implement and Evaluate执行和评价 Once the Corrective Act