解決質量問題的標準化反應模式

1、 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 1快速反應程序快速反應程序解決質量問題的標準化反應模式 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 2 是一個體系運用可視的方法顯示重要的信息以解決重大的外部的、內部的質量失效問題。快速反應快速反應是否存在一個每天的領導層會議？ 快速反應會議可以是一個1020 分鐘的站立式會議，地點可以在車間或生產會議室。 1998 Gener

2、al Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 3 過程的責任人必須來自制造部門。 在一天的開始，質量小組應該識別前24小時所發(fā)生的重大質量問題 ，可以從一下幾個方面考慮:- 客戶關注的問題- 供應商所關注的問題- 造成停線的 (內部/客戶)問題- 出廠審核 / 審核問題- 其他內部質量問題研討會小組首先應該定義什么樣的質量問題是重大的質量問題。當業(yè)務經理不在場時，會發(fā)生什么呢？ 在每天的制造評估會議上領導層應該審核一下方面:- 和小組成員一起審核重大的質量問題- 指定相關人員負責問題的解決- 指派下次會議

3、報告的責任人 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 4要求要求 (續(xù)續(xù)): 責任人應該負責保證所有的問題及時被解決并且滿足退出標準。 責任人的報告應包含以下幾個方面的更新：- 快速反應跟蹤表- 標準化操作指導書- 問題解決表 - 過程失效模式分析- 控制計劃- 層級審核- 全員通告 Workforce Notification - 其他適用文件必要時在快速反應跟蹤表上必要時，按照快速反應跟蹤表的規(guī)定匯報給管理層 1998 General Motors Corporation.

4、All rights reserved.QSB WORKSHOP REV. 091304 5 快速反應跟蹤表快速反應跟蹤表 (Example)EXIT CRITERIA Overall StatusIssue NumberIssue DescriptionDate OpenedUnit I.D. #OwnerNext Date (of Owner Report out to Staff)ContainmentPFMEA / CPError ProofingStandard WorkLayered AuditDate ClosedY1Engine out of time10/10/2000N/A

5、McGrath11/29/2000GGYGYG2Burrs on front face of block10/10/2000N/ASmithCLOSEDGGN/AN/AG10/11/2000R3Injector harness placement10/10/2000N/AMcGrath11/29/2000GGRGGY4Reversed thrust bearing10/11/2000N/AMcIntosh11/29/2000GGYGGY8Missing Upper Bearing Shells11/20/2000N/AMcIntosh11/30/2000GGGYGR9Paint dots fo

6、und on loose & mis-built parts11/21/2020N/ACarpenter11/30/2000GN/AN/ARRR10Loose 7mm bolt on front cover11/26/2000N/ADavis12/4/2000RRRRREXIT CRITERIA STATUS KEYRRequired but not initiatedYInitiated but not completeGCompleteN/ANot ApplicableGQP-029b要評估的要點要評估的要點:責任人責任人退出標準退出標準全面情況全面情況優(yōu)化目視管理，將這個表格盡可

7、能大的顯示在會議室( ex.: 4 x 8 dry erase board ) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 6No Quality DisruptionsInternal Quality Disruption(defined locally)Customer Quality Disruption(eg. PRR, Pull, Spill)每日質量圖LEGEND:月年一月一月2004作世界上最好的動作世界上最好的動力總成力總成3129283021222324252627

8、1213141516171819202345678910111GreenYellowRed(舉例)領導層將展示一個可視的質量狀況領導層將展示一個可視的質量狀況要求要求 (continued): 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 7不合格產品的控制不合格產品的控制遏制 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 8Establish a method to ensu

9、re that product that does not conform to specified requirements is:-防止無意識使用或安裝- Prevented from unintended use or installation- 用統一的標簽清楚識別 Clearly identified using consistent labeling 用目視管理方法建立統一的識別程序 (Example) 用明亮色彩作為首選的識別方法 - 紅色廢品 - 黃色可疑品 - 綠色合格品不合格產品的控制不合格產品的控制 1998 General Motors Corporation. All

10、 rights reserved.QSB WORKSHOP REV. 091304 9標簽內容IN THIS SECTION IS AT LOCAL DISCRETION標簽內容IN THIS SECTION IS AT LOCAL DISCRETIONPLT001可疑品或待處可疑品或待處理品理品半成品或合格半成品或合格品品紅標簽表示廢品。 黃色標簽表示可疑產品或待處理的材料，需要返工的材料或需要進一步檢查的材料綠色或其他顏色的標簽表示產品是可接受的 (紅色和黃色除外). .廢品廢品PLT002PLT003標簽內容IN THIS SECTION IS AT LOCAL DISCRETION 1

11、998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 10要求要求:不合格產品的控制不合格產品的控制 領導層應開發(fā)，組織并維護一個統一的體系來控制不合格品. 將不合格產品隔離. 隔離區(qū)域將被標識 - 廢料箱- 返工臺- 返工產品標簽- 溢出遏制區(qū)域 遏制工作表將被完成并用于：-提供一個系統的方法遏制全部可疑品 -確定不合格產品的檢查范圍 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 11

12、 CONTAINMENT WORKSHEET(Example)DEPARTMENT:DEPARTMENT CONTAINMENT OWNER:DATE:LaboratoryG. Hall1/6/2003PRODUCT NAME / NUMBER:10066044PRODUCT NONCONFORMANCE:Burr on flange PRODUCT CONTAINMENT SCOPEIDENTIFY ALL AREAS WHERE SUSPECT PRODUCT COULD BE LOCATEDPOTENTIALAREASUSPECT PROD.VERIFICATIONLOCATIONQTY

13、.VERIFIEDFOUND? QTY?RESPONSIBILITYLaboratory6K.C.6T. BrownWIP Storage Areas1000P.S.1000P. SmithOutside Processing - (Plating)1000C.J.1000C. JonesScrap Bins42K.C.42C. JonesRework Areas0B.T.0C. JonesSEGREGATE SUSPECT PRODUCT TO (location, as feasible):2548 pcs to Containment AreaSORT METHOD (eg. visua

14、l, gage, mating part):Visual for burrsSORT CRITERIA (clear pass / fail standards):Max Burr per standardI.D. METHOD CONFORMING (eg. mark, tag, sign):White paint dot near defect areaI.D. METHOD NONCONFORMING (eg. mark, tag, sign):Mark defect with red paint.K.C.P.S.B.T.000Shipping DockHeat TreaterAt Cu

15、stomer000TOTAL FOUND2548 2548P. SmithReceiving500P.S.500C. JonesC. JonesC. JonesC. JonesC. JonesC. JonesIn TransitService Parts Operations00B.T.P.S.00What if potentialquantitydoes not equal total found? When do you call the customer? 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP

16、REV. 091304 12要求要求 (續(xù)續(xù)): 分界點檢驗采用:- 對于遏制范圍內的產品100檢查- 在根本原因找到之前，持續(xù)時間由領導層決定 對于產品遏制問題，箱子將標識成 :- 紅色不合格產品 - 黃色可疑品- 綠色分界點后的合格產品 從被認可的工藝流程上拿走的產品返回時應在離開點或之前. 全部控制計劃都要執(zhí)行檢查和測試. 注意： 如果不可能在離開點或之前返回，使用經認可的重做流程以保證一致性. 要明確脫離返工，返修和遏制區(qū)產品的程序與授權. 產品遏制問題要經領導層評估. 1998 General Motors Corporation. All rights reserved.QSB W

17、ORKSHOP REV. 091304 13 標準化工作標準化工作(方法和順序方法和順序)“標 準 化 是 通 往 不 斷 改 進 之 路.”W.E. Deming,七月 15, 1992 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 14(舉例) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 15目的目的: 對所有的操作實施標準化的方法和順序。標準化工作標準化工作 (方法方法

18、& 順序順序)范圍范圍: 裝配區(qū) 制作過程 發(fā)運 / 收料 返修/返工區(qū) 所有的操作 其他支持功能 (例如：檢查) 職責職責: 一個或兩個責任人- 制造工程人員- 生產經理 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 16 精益組織. 識別那些能增值的工作. 一個有效的生產順序. 持續(xù)改進. 在過程內部減少變差. 減少浪費，解決問題和質量控制. 審核操作員與工作指導書一致 層級審核. 確保操作者統一履行相同任務和程序.標準化的工作提供了一個基礎標準化的工作提供了一個基礎: 1

19、998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 17多功能小組應確定并列出所有要實施標準化的工序Multi-disciplinary team(s) shall identify and list all operations to implement standardized work怎樣劃分優(yōu)先順序的例子怎樣劃分優(yōu)先順序的例子:- 涉及客戶質量的問題 - 定義工作順序和方法的必要性- 離線返工Off-line Rework- 高的RPN- 員工流動Employee Flow-throu

20、gh多功能小組定出標準化工作的指導書并張貼到每一工位.新員工要被培訓使用標準化工作（標準操作員培訓）要求要求: 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 18標準化操作標準化操作Standardized Operations客戶周期時間客戶周期時間工作順序工作順序在制品的標準化在制品的標準化標準化操作標準化操作步棸步棸TAKT TIME 生產出一個單位的時間Time in which a singleunit is to be produced操作工的移動OperatorMovem

21、ents相同順序相同動作每一循環(huán)工作需要的最小庫存Minimum stock necessaryto do work in the samesequence with the same movements, every cycle 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 19列出客戶周期時間的理由列出客戶周期時間的理由: 使領導層確信業(yè)務如批準的那樣在運轉Assures leadership that operation is running as approved 可減少生產過

22、剩 Overproduction can be reduced 改進生產調度 Improves production scheduling 操作員可介入到決策過程Operator involved in decision making process 設備顯示出磨損跡象時操作員能知道Operator knows if equipment is showing signs of wear. 安排維護與修理時間 Maintenance and repair time allocated 清掃成為生產流程的一部分Clean-up becomes part of the production proc

23、ess 質量檢查變成日常事務Quality checks built into the daily routine 為實施分層審核而安排時間Time allocated for conducting Layered Audits 目視管理元素 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 20顯示工作順序的理由顯示工作順序的理由: 所有的操作每次都以相同的方式完成All operations are performed the same way every time 減少組分被遺漏的風

24、險Reduces the risk of components being left out 沒有操作被遺漏或忽略No operations are skipped or omitted 提醒進行質量檢查及頻率Quality checks and frequency are called out 很容易確定方法改進Process improvements are easily identified 新手培訓更一致Training new operators is more consistent顯示標準工作程序的原因顯示標準工作程序的原因: 操作員控制再填充箱柜的頻率Operator contr

25、ols frequency of refilling bins 警告材料管理員短缺或過量庫存Alert material handler of shortages or excess inventory 減小由于原料儲運損耗而造成的設備停工期Reduces equipment downtime due to stock outages 工作區(qū)域減少混亂 減少在制品 允許材料管理員處理他們的時間Allows material handler to manage their time 1998 General Motors Corporation. All rights reserved.QSB

26、WORKSHOP REV. 091304 21 Standardized Operations Worksheet And Layout標準化操作工作表和布局標準化操作工作表和布局STEPNO.WORKSTATION AREA DRAWN TO SCALEOPERATION: FROM:_QUANTITY PER SHIFT:_CUSTOMER CYCLE TIME:_ TO: _SHIFT:_OPERATOR CYCLE TIME:_WORK ELEMENTELEMENT TIMESTANDARD IN-QUALITYCRITICALHAND WORKMACHINEWALKPROCESS S

27、TOCKCHECKOPERATIONSAFETYCQTOTAL(Example)標準化的操作工作表和計劃應包括Standardized Operations Worksheets And Layout shall include:- 工作原理Work Elements- 操作員動作Operator Movement- 操作周期時間Operation Cycle Time 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 22(Example) 1998 General Motors Cor

28、poration. All rights reserved.QSB WORKSHOP REV. 091304 23Best People Practices ChartAddress: AA-007L i n e : 1S h i ft: AL LI te m #123456789101112I te mF ir stS e co n dT h i rdA38 938 9N/AB55N/AC99N/A40 340 3079 %79 %0%S ta n d a rd Da i ly R o u tin e ( M i n u te s p e r S h ift)S h iftE le m e

29、n tsS tart m a c h ine c y c le for A B CD E /R unn er an d R unn erT ape run ne r w ith b lue ta pe and m a s k ing tap eG et A B CD E from W IP t ableT ran s fer A B CD E / Run ne r to A B CD E / Run ne r/A B CD E fix t ure on as s em bly m ac h ineL oad Ru nn er onto as s e m b ly m ac hineAre a

30、: L 6 H e a d A sse m b lyO pe ra tio n N a m e : He a d AB CD E/R UN NE R/A BC DETO TA L M A N UA L T IM E : 45. 78 s ecP a rt P ro d u ctio n P ro ce d u reE le m e n tsL oad /Un loa d m ac hine A A -0 07C art han dling for Run ners R ec o rd pro duc tion do wtim e /s c rapT o ta l M in u te s U s

31、e d :T o ta l U til iz a tio n :U nlo ad A B CD E /R unn er/ A B CD E P lac e c lus t er o n rac kL oad A B CD E ont o a s s e m b ly m ac hin eG et A B CD E from W IP tab leL oad A B CD E ont o a s s e m b ly m ac hin eS tart m a c h ine c y c le for A B CD E /R unn er/ A B CD E a nd A B CD E /R un

32、 nerG et Run ne r from c artWork Flow DiagramNote: Operator will be relieved during two 23-minute breaks and one 30-minute lunch.Effective Date:_Manufacturing General Supervisor Approval:_Required Personal Protective EquipmentContact your coach orcoordinator with any changes,questions, or quality co

33、ncerns.1234567891011Remember Safety 1st!Total Current Cycle Time: 65.5 secTarget Cycle Time: 55 sec12RackTape(Example) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 24要求（續(xù)）要求（續(xù)）: 標準化的工作說明書應通過分層審核檢驗任何操作在持續(xù)12個月里由于缺乏堅持標準化的工作說明出現的不一致Standardized work instructions shall be

34、 verified through Layered Audits for any operation which shipped a non-conformance within the last 12 months due to a failure to adhere to standardized work instructions. 多功能小組應根據正在進行的質量成績對標準化的工作說明書做持續(xù)的改進Multi-disciplinary team(s) shall continuously develop/improve standardized work instructions bas

35、ed on ongoing quality performance. 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 25操作員培訓的標準化操作員培訓的標準化操作員的培訓是否經過驗證并操作員的培訓是否經過驗證并記錄在案？記錄在案？ 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 26 操作員標準化培訓要求操作員標準化培訓要求Standardized Operator Trainin

36、gRequirements多功能小組決定每一道工序至少的培訓內容多功能小組決定每一道工序至少的培訓內容A cross functional team shall define the minimum training content for each operation.此組織決定誰來實施培訓此組織決定誰來實施培訓The organization shall identify who will conduct training.培訓員監(jiān)督新操作員的行動，必要時重新培訓以確保標準工作指導被遵培訓員監(jiān)督新操作員的行動，必要時重新培訓以確保標準工作指導被遵循循Trainers shall monit

37、or new operators activities and retrain if necessary to assure Standard Work Instructions are being followed.培訓員通知下道工序潛在的缺陷培訓員通知下道工序潛在的缺陷The trainer shall notify downstream operations of potential defects.此組織應建立必要的文件及跟蹤方法此組織應建立必要的文件及跟蹤方法The organization shall establish required documentation and tra

38、cking methods.培訓者應指導操作員使用標準操作員培訓表培訓者應指導操作員使用標準操作員培訓表Trainers shall instruct operators using the standard operator training sheet. (Example) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 27標準化操作培訓記錄標準化操作培訓記錄(Example)Application: 運用：任何新操作員都應完成下表The following shall be co

39、mpleted with any new operator (for any given operation).審核Review 完成Complete標準化的工作指導Standardized work / job instructions要填充的質量記錄Quality records to be filled out (eg. Check sheets)示范操作和問題回答Demonstrate the operation and answer questions示范測量和回答問題Demonstrate gaging and answer questions新員工是否進行操作并回答問題Have

40、new employee run operation and answer questions講授過去的問題Teach past problems (eg. FMEA, Top Problems List)檢驗首次生產，培訓作為必須Verify first units produced, coach as needed換班時報告，重新檢驗標準化的工作與產品質量Return within the shift, verify std work & product quality again大約1天報告，重新檢驗標準化的工作與產品質量Return in approx. 1 day, veri

41、fy std work & product quality again向下游業(yè)務通報潛在缺陷Notify downstream operations of potential defects雇員簽名Employee Signature _ 培訓員簽名Trainer Signature _Operation Name and # _零件（產品）功能Part (product) function安全/設備操作 Safety/ Equipment Operation 1998 General Motors Corporation. All rights reserved.QSB WORKSH

42、OP REV. 091304 28WorkcellMold / Station #Associate Name:Shift:Date:Training CriteriaAssociate InitialsTrainer InitialsSAFETYFire Exits / Extinguisher LocationSafety Glass PolicyPersonal Protective EquipmentMSDS LocationQUALITYGate trimming TechniqueVisual DefectsScrap ProcedurePAPERWORK Production r

43、eportingScrap ReportingBar Code Scanning / Label VerificationOPERATIONSOperator 1 Work Instructions - Min. 16 Hrs.Operator 3 Work Instructions - Min. 16 Hrs.Packaging Requirements (Regular / Service)WORKCELL ORGANIZATION5S ResponsibilitiesSupply Cabinet Location / ContentsWork Cell Board ReviewEmplo

44、yee SignatureTrainer SignatureDate:Date:Form Ref:Rev.#Date:CommentsTraining Sign - Off Sheet(Example)標準化的操作培訓記錄標準化的操作培訓記錄 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 29 標準化操作員培訓要求操作員跟蹤表應張貼在每一操作位置通過分層審核檢驗操作員跟蹤表應張貼在每一操作位置通過分層審核檢驗Operator Tracking Sheets shall be poste

45、d at each operation and verified through Layered Audits.Scheduling of refresher training for assigned operators is at local site discretion.追加的雇員如果在最近三個月內沒有經過培訓不能執(zhí)行工作追加的雇員如果在最近三個月內沒有經過培訓不能執(zhí)行工作Supplemental employees shall not perform the job unless they have been trained within the last three months.

46、培訓者應定期檢驗質量以確保達到所有的標準。最起碼培訓者應在一個培訓者應定期檢驗質量以確保達到所有的標準。最起碼培訓者應在一個換班與一天內報告。換班與一天內報告。The trainer shall verify quality at a frequency determined necessary to assure all standards are met. At a minimum the trainer shall return within the shift and again within approximately one day.操作員培訓應記錄在操作員培訓應記錄在“操作員培訓

47、跟蹤表操作員培訓跟蹤表”里里Operator training shall be tracked on “Trained Operator Tracking Sheets”. (Example) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 30已培訓操作員跟蹤已培訓操作員跟蹤(Example)Operation Name / # _DEPT. ASSIGNED EMPLOYEESUPPLEMENTAL EMPLOYEELATEST TRAINING DATE AND TRAINER

48、INITIALSLatest Job Instruction Rev. Date 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 31標準化的培訓小結標準化的培訓小結組織應該 建立必要的文件和跟蹤方法 確定操作員培訓負責人。 保證操作員培訓通過“操作員培訓跟蹤表”跟蹤 ensure operator training is being tracked on “Trained Operator Tracking Sheets”. 在每一操作位張貼操作員跟蹤表，通過分級審核檢驗 post o

49、perator Tracking Sheets at each operation, and verify through Layered Audits. schedule refresher training for assigned operators at local site discretion. 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 32降低風險的程序降低風險的程序積極主動積極主動RPN 降低程序降低程序:降低潛在質量失效降低潛在質量失效被動被動對已發(fā)生的質量失效建

50、立防錯裝置對已發(fā)生的質量失效建立防錯裝置 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 33定義定義PFMEA結構化程序適合于與失效模式有關的識別和排除方法A structured procedure for identifying and eliminating process related failure modes.識別每一個過程步驟的分析技術 An analytical technique that identifies for each process step 程序可能不

51、能達到要求的情形 Ways that a process may fail to meet requirements 內在/外部消費者的嚴重度Consequences to the internal / external customer (嚴重度) 失效可能發(fā)生的頻率Frequency that the failure will/could happen (發(fā)生頻率) 當前控制的效果Effectiveness of current controls (預防核可探測度) 原因和結果的排隊Ranking of causes and effects (風險順序數) 1998 General Mot

52、ors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 34REVD DATE :MODEL YEAR / CARLINE :FMEA DATE :PRODUCTION PLANT :FMEA CONDUCTED BY :10 Correct Part - pilot bearingIncorrect part installedMisbuild7Manual: incorrectly selected7No preventionNo detection10 49020Correct Assy - piston and rod

53、 assyIncorrect Piston or reversed pistonLoss of Engine Power; Engine Failure7Machine Vision ID Incorrect3No preventionIn-line Audits6 126PROCESS NAME/ NUMBERPROCESS FUNCTIONPOTENTIAL FAILURE MODEPOTENTIAL EFFECT(S) OF FAILURESEVCLASSPOTENTIAL CAUSE(S)/ MECHANISM(S) OF FAILUREOCCDETRPNPREVENTIONDETEC

54、TIONCURRENT CONTROLSB/P Level: 001, 7-NOV-02Sensor to detect bearing typeShad, B.3/1/0277 4 112New Piston Laser Station.NA 73 242RECOMMENDED ACTION(S)RESPONSIBILITY & TARGET COMPLETION DATEACTION RESULTSACTIONS TAKENSEVOCCDETRPN會出現什么問題What can go wrong?它是怎樣影響客戶的How does it affect customer?多久發(fā)生一次

55、How often does this cause happen?如果問題發(fā)生，有多大可能我們會注意道它How likely are we to notice if this happens?風險程度有多高How high is the risk?PFMEA: 過程失效模式及影響過程失效模式及影響Process Failure Mode & Effects (example)(AIAG PFMEA Third Edition) 1998 General Motors Corporation. All rights reserved.QSB WORKSHOP REV. 091304 35

56、 Effect Criteria: Severity of Effect This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the two severities. (Customer Effect) Criteria: Sev

57、erity of Effect This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the two severities. (Manufacturing/Assembly Effect) Ranking Hazardous wi

58、thout warning Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning. Or may endanger operator (machine or assembly) without warning. 10 Hazardous with warning Very high severity ranking when a

59、potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning. Or may endanger operator (machine or assembly) with warning. 9 Very High Vehicle/item inoperable (loss of primary function). Or 100% of product may have to be scrapped, or veh

60、icle/item repaired in repair department with a repair time greater than one hour. 8 High Vehicle/item operable but at a reduced level of performance. Customer very dissatisfied. Or product may have to be sorted and a portion (less than 100%) scrapped, or vehicle/item repaired in repair department with a repair time betwe