FTQ-中英文（課堂PPT）

1、Company ConfidentialFirst Time Quality PPMTIME2First Time QualityTraining ModuleTraining Objectives 培訓(xùn)目標(biāo):uTo Understand 理解What First Time Quality Is 什么是一次下線合格率?Why It Is Important 一次下線合格率的重要性Why We Need to Measure It 為什么需要對(duì)一次下線合格率進(jìn)行測(cè)量?How to Calculate It 如何計(jì)算?What the FTQ Deployment Process is 怎樣進(jìn)行F

2、TQ?What the Basic Quality Tools Are 基本質(zhì)量工具是什么?How to Apply the Quality Tools 怎樣運(yùn)用基本質(zhì)量工具?What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 每個(gè)工廠應(yīng)該監(jiān)控和匯報(bào)什么?3First Time QualityTraining ModuleuWhat is First Time Quality? 什么是一次下線合格率?First Time Quality is a measure o

3、f the number of pieces rejected in a manufacturing process versus the total number of pieces attempted 一次下線合格率是測(cè)量制造過程中不合格品數(shù)與總產(chǎn)品數(shù)的比值.REJECTS4First Time QualityTraining ModuleuWhy is FTQ important? 一次下線合格率的重要性Because if we dont make good parts the first time, we have to inspect in quality 因?yàn)槿绻覀兊谝淮螞]有生

4、產(chǎn)出好的產(chǎn)品,我們就必須進(jìn)行檢驗(yàn).We know inspection is at best 85% effective 我們知道檢驗(yàn)最多只有85%的有效性.Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因而,如果任何時(shí)候一次下線合格率大于0,我們都需要依賴檢驗(yàn)來保護(hù)客戶.To reduce manufacturing costs 降低制造成本To eliminate waste through the value stream and meet

5、customer requirements (take time) 通過價(jià)值流和滿足客戶要求來消除浪費(fèi).5Catch DefectsFilterInspection misses some defects 檢驗(yàn)會(huì)遺漏一些缺陷檢驗(yàn)會(huì)遺漏一些缺陷Defects not caught漏網(wǎng)缺陷漏網(wǎng)缺陷Voice of the Customer 客戶的聲音客戶的聲音Problem問題問題DDThe Role of InspectionDInspection is like a filter 檢驗(yàn)好比一個(gè)篩子檢驗(yàn)好比一個(gè)篩子612Catch & Count defects抓住并計(jì)算缺陷抓住并計(jì)算缺

6、陷React to ALARM LIMITS超過警戒線的反應(yīng)超過警戒線的反應(yīng)Follow Reaction Plan執(zhí)行反應(yīng)計(jì)劃執(zhí)行反應(yīng)計(jì)劃Voice of the Customer客戶的聲音客戶的聲音The Role of First Time Quality ProcessReaction PlanZERO Defects Forward7Analyze Data分析數(shù)據(jù)分析數(shù)據(jù)Understand Defects and Decide the Order of Priority:理解缺陷并決定優(yōu)先次序理解缺陷并決定優(yōu)先次序Assign problems toCross-Functiona

7、l Group:向跨功能小組提出問題向跨功能小組提出問題Select and Plan the Improvement: 1.Right Information 2.Right Cause 3.Right Timing選擇并計(jì)劃改善問題選擇并計(jì)劃改善問題 正確的信息正確的信息 正確的原因正確的原因 正確的時(shí)間選擇正確的時(shí)間選擇Fix the Biggest Problems First:首先找到最大的問題所在首先找到最大的問題所在12ABCDProblems1 2 1 2 ResponsibleTeam WorksProblems相關(guān)團(tuán)隊(duì)負(fù)責(zé)解決問題相關(guān)團(tuán)隊(duì)負(fù)責(zé)解決問題DEFECT1. -2.

8、 -3. -HourGlassThe Role of First Time Quality Process43232211118Inspection ExerciseTHE NECESSITY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARMLIVESTOCK IS FOREMOST IN THE MINDS OF FARMOWNERS. SINCE THE FOREFATHERS OF THE FARMOWNERS TRAINED THE FARMHANDS FOR THE FIRST-C

9、LASS FARMS IN THE FATHERLY HANDLING OF FARMLIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULDCARRY ON WITH THE FAMILY TRADITION OF TRAININGFARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOODFUNDAMENTAL FARM MANAGEMENT. Count the Number of

10、Fs contained in the paragraph below (60sec)數(shù)一下下面總共出現(xiàn)了幾個(gè)數(shù)一下下面總共出現(xiàn)了幾個(gè)“F”（60秒）秒）9Inspection ExerciseTHE NECESSITY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARMLIVESTOCK IS FOREMOST IN THE MINDS OF FARMOWNERS. SINCE THE FOREFATHERS OF THE FARMOWNERS TRAINED THE FARMHANDS F

11、OR THE FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARMLIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULDCARRY ON WITH THE FAMILY TRADITION OF TRAININGFARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOODFUNDAMENTAL FARM MANAGEMENT. Total

12、of 36 Fs10First Time QualityTraining ModuleuWhy does FTQ need to be measured? 為什么需要測(cè)量FTQMain Reasons 主要原因:It is the first signal that a process is out of control 它是過程失控最先發(fā)出的信號(hào)It allows us to respond to problems internally before they reach our customers 它使我們能夠在問題到達(dá)客戶之前先在內(nèi)部作出反應(yīng).It measures improvemen

13、t from corrective actions implemented 通過執(zhí)行糾正措施后來衡量問題改善的情況.uIf we dont fix our quality problems internally, we will never be able to fix our external customer issues 如果我們不能在內(nèi)部找到質(zhì)量問題,我們就不能確定外部客戶的問題.11First Time QualityTraining ModuleuHow is First Time Quality calculated? 如何計(jì)算FTQFTQ is reported in part

14、s per million (PPM) defective FTQ反映每一百萬個(gè)產(chǎn)品中的缺陷產(chǎn)品數(shù).It can be measured at any step in the manufacturing process where parts are rejected 可以在有拒收產(chǎn)生的制造過程的任何一步測(cè)量FTQ.It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 通過以不合格品數(shù)除以總數(shù)來計(jì)算.The total number of pi

15、eces attempted includes all good pieces produced plus all pieces rejected 總的產(chǎn)品數(shù)包括生產(chǎn)出來的所有合格品數(shù)和不合格品數(shù)之和.Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不合格品數(shù)包括所有報(bào)廢和經(jīng)過返工后合格的產(chǎn)品數(shù). 公式:Number of Pcs. Rejected不合格品數(shù)Total Number

16、 of Pcs. Attempted總產(chǎn)品數(shù)X 1,000,000 = FTQ PPM12First Time QualityTraining ModuleuHow is First Time Quality calculated?如何計(jì)算FTQ?An example at the cell level: Cell “A” has six operations A單元有6個(gè)操作工序Reject data is collected at operations 3 and 6 在第三和第六工序收集到不合格品數(shù)據(jù)Cell “A” produced 1040 good pieces during th

17、e first hour of production.第一個(gè)小時(shí)A單元共生產(chǎn)良品1040件At OP.3, 28 pcs. were rejected. 第三工序發(fā)現(xiàn)28件不合格品At OP.6, 16 pcs. were rejected. 第六工序發(fā)現(xiàn)16件不合格品What is the FTQ in PPM for Cell A? A單元FTQ的PPM是多少?28 + 16 1040 + 28 + 16 123456X 1,000,000 = 40590 PPM FTQ2816Tally Sheet13First Time QualityTraining ModuleuWhat is t

18、he First Time Quality Improvement Process? 什么是FTQ改善過程?FTQ process defines a common process to be used by all Delphi manufacturing plants to meet the business plan requirements and drive defect-free manufacturing FTQ是Delphi 工廠常用的以達(dá)到商業(yè)計(jì)劃要求和無缺陷生產(chǎn)要求的一個(gè)方法.The FTQ process defines FTQ定義:Process Steps 流程步驟S

19、takeholders 有關(guān)系的人Deployment Chart (functional flow chart) for identifying lead functions 用于識(shí)別重要功能的布置圖表(功能流程圖)Control Plan for Tracking Implementation 控制計(jì)劃和跟蹤執(zhí)行14IDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENT執(zhí)行改善執(zhí)行改善EVALUATE評(píng)估評(píng)估INSTITUTION- ALIZE LESSONS LEARNED系統(tǒng)化經(jīng)驗(yàn)教訓(xùn)系統(tǒng)化經(jīng)驗(yàn)教訓(xùn)TOOLS FOR IDE

20、NTIFICATION用于識(shí)別的工具用于識(shí)別的工具: - PROCESS CONTROL PLAN過程控制計(jì)劃過程控制計(jì)劃 - BOUNDARY SAMPLES邊界樣品邊界樣品TOOLS FOR COUNTING用于計(jì)數(shù)的工具用于計(jì)數(shù)的工具: - PARTS COUNTERS產(chǎn)品計(jì)數(shù)器產(chǎn)品計(jì)數(shù)器 - TALLY SHEETS計(jì)數(shù)表計(jì)數(shù)表 - SIZED CONTAINERS有尺寸大小的容器有尺寸大小的容器 TOOLS工具工具: - PARETO直方圖直方圖 - CAUSE & EFFECT (FISHBONE) 原因和結(jié)果原因和結(jié)果(魚骨圖魚骨圖) - CONCENTRATION DI

21、AGRAM集合表集合表 - FLOW CHART流程圖流程圖 - HISTOGRAM柱狀圖柱狀圖 - SCATTER DIAGRAM散布圖散布圖 - CHECK SHEET檢查表檢查表 - 5 WHYS 5個(gè)為什么個(gè)為什么EXAMPLES例子例子: - CROSS-FUNCTIONAL TEAMS跨功能小組跨功能小組 - CHANGE BOARDS變化看板變化看板 - RPN REDUCTION降低降低RPN - STATISTICAL ENGINEERING PROJECTS統(tǒng)計(jì)工程方案統(tǒng)計(jì)工程方案 ACTION PLAN行動(dòng)計(jì)劃行動(dòng)計(jì)劃: - WHAT, WHEN, WHO事件事件,時(shí)間時(shí)

22、間,人物人物TOOL工具工具: - ACTION PLAN 行動(dòng)計(jì)劃行動(dòng)計(jì)劃TOOLS工具工具: - PFMEA過程流程圖過程流程圖 - PROCESS CONTROL PLAN 過程控制計(jì)劃過程控制計(jì)劃- LOOK-ACROSS-CHART 瀏覽表瀏覽表- 5 WHYS 5個(gè)為什么個(gè)為什么 SELECT & PLAN IMPROVEMENT 選選擇和計(jì)劃改善擇和計(jì)劃改善NEW LEVEL OF QUALITY? 新的質(zhì)量水平新的質(zhì)量水平DEFINE REACTION PLAN & ALARM LIMITS 定義反應(yīng)計(jì)定義反應(yīng)計(jì)劃和警戒線劃和警戒線RECORDDATA 記錄數(shù)據(jù)

23、記錄數(shù)據(jù)TOOLS工具工具: - CONTROL CHART控制圖控制圖ANALYZE DATA分析數(shù)據(jù)分析數(shù)據(jù) TOOL工具工具: - RUN CHART 運(yùn)行圖運(yùn)行圖 - GATE CHART 門圖門圖ALARMEXCEEDED是否超過警戒是否超過警戒? IMPLEMENTALARMREACTIONPLAN 執(zhí)行報(bào)警反應(yīng)計(jì)劃執(zhí)行報(bào)警反應(yīng)計(jì)劃YESNONOYESIDENTIFY確認(rèn)確認(rèn)ANALYZE分析分析PLAN計(jì)劃計(jì)劃EVALUATE評(píng)估評(píng)估IMPLEMENT執(zhí)行執(zhí)行FTQ Improvement Process識(shí)別和清點(diǎn)有識(shí)別和清點(diǎn)有差異的產(chǎn)品差異的產(chǎn)品15FTQ Improvemen

24、t ProcessStakeholder FootprintPlant A Plt B Plt CCELL1234578N6OPERATOR操作人員操作人員OPERATOR操作人員操作人員OPERATOR操作人員操作人員OPERATOR操作人員操作人員OPERATOR操作人員操作人員TEAM LEADER小組領(lǐng)導(dǎo)小組領(lǐng)導(dǎo)CROSS- FUNCTIONAL TEAM跨功能小組跨功能小組MEMBERS成員成員: - TEAM LEADER小組領(lǐng)導(dǎo)小組領(lǐng)導(dǎo) - OPERATIONS/MANUFACTURING操作操作/制造人員制造人員 - QUALITY ENGINEER質(zhì)量工程師質(zhì)量工程師 - P

25、ROCESS ENGINEER 工藝工程師工藝工程師 - INDUSTRIAL ENGINEER工業(yè)工程師工業(yè)工程師 - MAINTENANCE設(shè)備維護(hù)設(shè)備維護(hù) - PRODUCT ENGINEER產(chǎn)品工程師產(chǎn)品工程師 - SUPPLIER QUALITY供應(yīng)商品質(zhì)人員供應(yīng)商品質(zhì)人員PRODUCTENGINEERINGMANAGER 產(chǎn)品工程經(jīng)理產(chǎn)品工程經(jīng)理QUALITY MANAGER質(zhì)量經(jīng)理質(zhì)量經(jīng)理MAINTENANCE MANAGER設(shè)備維護(hù)經(jīng)理設(shè)備維護(hù)經(jīng)理OPERATIONS MANAGER制造經(jīng)理制造經(jīng)理PROCESSENGINEERINGMANAGER工藝工程經(jīng)理工藝工程經(jīng)理 PL

26、ANT MANAGER工廠經(jīng)理工廠經(jīng)理PC&L MANAGER物流經(jīng)理物流經(jīng)理CELL工作站工作站16First Time Quality Improvement ProcessDeployment Flow ChartCFT跨功能跨功能小組小組PROCESS過程過程QUALITYENGINEER質(zhì)量經(jīng)理質(zhì)量經(jīng)理OPERATIONS操作人員操作人員PROCESSENGINEER工藝工程師工藝工程師PRODUCTENGINEER產(chǎn)品工程師產(chǎn)品工程師MAINTENANCE設(shè)備維護(hù)設(shè)備維護(hù)INDUSTRIALENGINEER工業(yè)工程師工業(yè)工程師DEFINE REACTIONPLAN &

27、; ALARM LIMITS定義反應(yīng)計(jì)劃和警戒線IDENTIFY & COUNTDISCREPANT PARTS識(shí)別和清點(diǎn)異常產(chǎn)品IMPLEMENT ALARMREACTION PLAN執(zhí)行警戒反應(yīng)計(jì)劃(如果超過警戒線)RECORD DATA記錄數(shù)據(jù)ANALYZE DATA分析數(shù)據(jù)SELECT & PLANIMPROVEMENT選擇和計(jì)劃改善IMPLEMENTIMPROVEMENT執(zhí)行改善EVALUATE評(píng)價(jià)INSTITUTIONALIZELESSONS LEARNED系統(tǒng)性經(jīng)驗(yàn)教訓(xùn)LEAD 負(fù)責(zé)負(fù)責(zé)SUPPORT 支持支持17First Time QualityTrainin

28、g ModuleProcess Step 1 第一步uDefine reaction plan and alarm limits 定義反應(yīng)計(jì)劃和警戒線 You have to start someplace Alarm limits must be based on current process reject data or available data from Run at Rate, historical data, etc. 警戒線必須基于在當(dāng)前工藝下生產(chǎn)的不合格品數(shù)據(jù), 或源于按節(jié)拍生產(chǎn),歷史數(shù)據(jù),等. Alarm limits must be statistically calc

29、ulated 警戒線必須進(jìn)行統(tǒng)計(jì)計(jì)算. Alarm limits must be communicated to operators so they can react 警戒線必須與操作人員進(jìn)行交流溝通. If alarm limits are exceeded, there must be a reaction plan to implement 如果超過警戒線,必須有一個(gè)可執(zhí)行的反應(yīng)計(jì)劃. The reaction plan must clearly define what actions are to be taken 反應(yīng)計(jì)劃必須明確定義所需采取的行動(dòng).IDENTIFY & C

30、OUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINSTITUTION-ALIZE LESSONS LEARNEDTOOLS FOR IDENTIFICATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW

31、 CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHYSEXAMPLES: - CROSS-FUNCTIONAL TEAM S - CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CHART - 5 WHYS SELECT & PLAN IMPR

32、OVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN & ALARM LIMITSRECORDDATA TOOLS: - CONTROL CHARTANALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTDEFINE REACTION PLANS&ALARM LIMITS定義反應(yīng)計(jì)劃定義反應(yīng)計(jì)劃和警戒線和警戒線 18First Ti

33、me QualityTraining ModuleProcess Step 2 第二步uIdentify and count discrepant parts 識(shí)別和計(jì)算有差異的產(chǎn)品數(shù)Operators must have sufficient tools and skills in order to identify product discrepancies 操作人員必須有足夠的途徑和技能來確認(rèn)產(chǎn)品的差異.Tools to enhance the operators ability to identify product discrepancies include 用于加強(qiáng)操作人員確認(rèn)產(chǎn)品

34、差異的途徑有:Boundary Samples 極限樣品Illustrations 圖表Photographs 照片Gages 量具Tools for counting discrepant parts include 用于清點(diǎn)差異產(chǎn)品的工具有:Parts Counters 產(chǎn)品計(jì)數(shù)器Tally Sheets 計(jì)數(shù)表Sized Containers 容量固定的容器IDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINSTITUTION-ALIZE LESSONS LEARNEDTOOLS FOR IDENTIFI

35、CATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHYSEXAMPLES: - CROSS-FUNCTIONAL TEAM S - CHAN

36、GE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CHART - 5 WHYS SELECT & PLAN IMPROVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN & ALARM LIMITSRECORDDATA TOOLS: - CONTROL CHARTA

37、NALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTIDENTIFY &COUNTDISCREPANTPARTS識(shí)別和清點(diǎn)識(shí)別和清點(diǎn)有差異的產(chǎn)品有差異的產(chǎn)品19First Time QualityTraining ModuleProcess Step 3 第三步uImplement Alarm Reaction Planif Limit Exceeded 超過警戒線時(shí)反應(yīng)計(jì)劃的執(zhí)行

38、Reaction Plan 反應(yīng)計(jì)劃:IDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINSTITUTION-ALIZE LESSONS LEARNEDTOOLS FOR IDENTIFICATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHB

39、ONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHYSEXAMPLES: - CROSS-FUNCTIONAL TEAM S - CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CH

40、ART - 5 WHYS SELECT & PLAN IMPROVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN & ALARM LIMITSRECORDDATA TOOLS: - CONTROL CHARTANALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTIMPLEMENTALARMREACTIONPLAN執(zhí)行警戒反應(yīng)計(jì)劃

41、執(zhí)行警戒反應(yīng)計(jì)劃Alarm Limit Exceeded 是否超過警戒線?Contain 遏制Investigate 調(diào)查Implement Containment PlanUntil Problem Fixed 執(zhí)行遏制計(jì)劃直到找到問題YesContainment Plan遏制計(jì)劃遏制計(jì)劃20First Time QualityTraining ModuleProcess Step 4 第四步uRecord Data 記錄數(shù)據(jù)Data must be recorded and plotted over time 必須按時(shí)間記錄數(shù)據(jù):What chart should be used 應(yīng)使用什

42、么圖表?Since the area of opportunity varies from sample to sample, the reject count must be converted into a rate prior to charting 如果單位時(shí)間內(nèi)生產(chǎn)的樣品數(shù)有很大不同，在制表時(shí)，需將拒收數(shù)轉(zhuǎn)換為比率.We do this by measuring FTQ in PPM 用PPM計(jì)算FTQPPM is a rate PPM是一個(gè)比率.IDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINS

43、TITUTION-ALIZE LESSONS LEARNEDTOOLS FOR IDENTIFICATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET -

44、5 WHYSEXAMPLES: - CROSS-FUNCTIONAL TEAM S - CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CHART - 5 WHYS SELECT & PLAN IMPROVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN &

45、; ALARM LIMITSRECORDDATA TOOLS: - CONTROL CHARTANALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTRECORD DATA記錄數(shù)據(jù)記錄數(shù)據(jù)21Hours or Days12345678910111213141516171819202122232425Non-conforming 81091198687111211131817129107859

46、1187Sample Size (Avg)18Defectswing mark21542134221312112111wing / body fold3212512225234512456711223wrong paint dot22151235433681131433paint location342123722224wrong or no clip122111311326121143Total nonconforming:810911986871112111318171291078591187Production181819182018171818191819191817181819182

47、01818201819PPM Defectivenp1+np2+.npkwhere np= number nonconformin, k= subgroupsk=SUM(C3:AA3)/25 UCLnp=0UCLnp= 0LCLnp = 0LCLnp= 00510152025123456789 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25UCL= LCL= Nonconformingavg= NP Charting for FTQSubgroups ( Days)npnp0102030405060708090100Defects ParetoU

48、CL=np + 3*(np(1-np/n)LCL=np - 3*(np(1-np/n)n = avg sample size (18)np = number nonconforming k = subgroups (25)_np = np1+np2+.npk k0246810121416182012345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25UCL=16.1LCL=3.4avg= 9.8Alarm Limit Calculation usingnp Chart22First Time QualityTraining ModuleP

49、rocess Step 5 第五步uAnalyze Data 分析數(shù)據(jù)分析數(shù)據(jù)The basic quality tools are 基本質(zhì)量工具基本質(zhì)量工具:Flow Charting 流程圖Check Sheets 檢查表Pareto 柏拉圖Cause and Effect 原因和結(jié)果Run Chart 運(yùn)行圖表Histogram 柱圖Scatter Diagram 散點(diǎn)圖Control Chart 控制圖IDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINSTITUTION-ALIZE LESSONS L

50、EARNEDTOOLS FOR IDENTIFICATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHYSEXAMPLES: - CROSS-

51、FUNCTIONAL TEAM S - CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CHART - 5 WHYS SELECT & PLAN IMPROVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN & ALARM LIMITSRECORDDATA

52、 TOOLS: - CONTROL CHARTANALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTANALYZEDATA 分析數(shù)據(jù)分析數(shù)據(jù)23First Time QualityTraining ModuleProcess Step 5 第五步uAnalyze Data 分析數(shù)據(jù)分析數(shù)據(jù)Problem Identification確認(rèn)問題確認(rèn)問題Problem Analysis分析問題分

53、析問題Charts can be used for different purposes in various stages of the problem-solving process 在解決問題的各個(gè)階段都可使用圖表用于不同的目的。The tools included in the intersecting portion of this diagram can be used in both the problem identification and problem analysis phase of problem solving 交叉部分的工具可同時(shí)用于確認(rèn)問題和分析問題. Flo

54、wchart ChecksheetBrainstorming Nominal Group Technique Pareto ChartCause & EffectRun ChartStratification Histogram Scatter Diagram Control Chart Process CapabilityForce Field AnalysisIDENTIFY & COUNT DISCREPANT PARTSIMPLEMENT IMPROVEMENTEVALUATEINSTITUTION-ALIZE LESSONS LEARNEDTOOLS FOR IDEN

55、TIFICATION: - PROCESS CONTROL PLAN - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHYSEXAMPLES: - CROSS-FUNCTIONAL TEAM S -

56、CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION PLAN: - WHAT, WHEN, WHOTOOL: - ACTION PLANTOOLS: - PFMEA - PROCESS CONTROL PLAN - LOOK-ACROSS-CHART - 5 WHYS SELECT & PLAN IMPROVEMENTNEW LEVEL OF QUALITY?DEFINE REACTION PLAN & ALARM LIMITSRECORDDATA TOOLS: - CONTROL CH

57、ARTANALYZE DATA TOOL: - RUN CHART - GATE CHARTALARMEXCEEDED? IMPLEMENTALARMREACTIONPLAN YESNONOYESIDENTIFYANALYZEPLANEVALUATEIMPLEMENTANALYZEDATA分析數(shù)據(jù)分析數(shù)據(jù)24A histogram is a specialized type of bar chart. Individual data points are grouped together in classes, so that you can get an idea of how freque

58、ntly data in each class occur in the data set. High bars indicate more points in a class, and low bars indicate fewer pointsFTQ Tools- 柱狀圖25Pareto charts are used to display the Pareto principle in action, arranging data so that the few vital factors that are causing most of the problems reveal them

59、selves. Concentrating improvement efforts on these few will have a greater impact and be more cost-effective than undirected efforts.FTQ Tools-柏拉圖26Scatter Plots (also called scatter diagrams) are used to investigate the possible relationship between two variables that both relate to the same event.

60、 A straight line of best fit (using the least squares method) is often included.FTQ Tools-散布圖27The point of making control charts is to look at variation, seeking special causes and tracking common causes. FTQ Tools-控制圖28Flowcharts are maps or graphical representations of a process. They are particularly useful for displaying how a process currently functions or could ideally function. Flowcharts can help you see whether the steps of