一家美資企業(yè)內(nèi)訓(xùn)文檔一家美資企業(yè)內(nèi)訓(xùn)文檔11.6TOOL?100PPMQUALITYPROCESSOS&D*SequentialInspectionMainProcessControlTimeCheckQualityAuditReviewMeeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D:Over,Shortage&Defect100PPM1.6TOOL?100PPMQUALITYPROC22.6TOOL-1/OS&DActivityAsystemtoimprovequalityofcomponentsfounddefectivebymonitoring,analyzing&actingonactualrealtimedata&materialsuppliedbysuppliers.OS&DImageEstablishfullinspectionsystemEstablishqualityinformationsystem-Realinformationsystem.Realdata.Realmaterial-ComputerizedOS&DmanagementEstablishvendorappraisalsystem-Qualitycontract(agreementoftargetquality)-I&PSystemInnovationFlow*I&P:Incentive&PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal&QuickInformationImprovedMaterialInnovationActivitiesAttachtagafterfindingadefectonthelinePlacecollectionboxfordefectivesinthelineCollectrejection&analysisofsamefromIQCmembersDisplayrejectionduetosupplierRequestforurgentdeliveryinexchangeoftotalrejection.Suppliermustreceiverealinformationandhaveimprovementmeeting(once/week)=>Q-managerattendReceiveimprovedmaterial&follow-up100PPM2.6TOOL-1/OS&DActivityAsy32.6TOOL-1/OS&DActivity(RULE)PRODUCTIONPURCHASEIQCMATERIALSUPPLIERActivities-Finddefectiveparts-Attachtag.Supplierdefect:Red.Transportation:Blue.Workdefect:Yellow-Storedefectiveparts-IssueOS&DNCR(once/day)-Provideadditionalpartsinlieuofdefectedq’ty.Emergencydelivery-HoldimprovementM/Twithsupplier.SunriseM/T-Collectthedefectiveparts(once/day)-Analyzeandevaluatethecauseofrejection..Classifythereasontheirtypeslikeinternalworkerrorortransportationorvendor-Recordandmanagecurrentdefectstatusandfeedback-Displaythedefectiveparts-Organizethereceipt/issuingofalternatedpartstotheline-Receivethedefectiveparts-Analyzethereason-Holdimprovementmeeting.Dailymeeting.Weeklyinnovationmeeting(Q-managerattend)-Monthlyevaluationmeeting(Q-managerattend)MaterialWorkdefectVendordefect&TransportationReturnDataReplacementfordefectiveparts100PPM2.6TOOL-1/OS&DActivity(RU4Self-inspectionCheck-listPreparedByCheckedByApprovedByMACHINE/MODELBUYERORIGINDATEREVISEDDATEPROCESSNAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTIONMETHODREVISIONNO100PPMSelf-inspectionCheck-listPrep5*OS&DStickers1.SUPPLIERDEFECT2.WORKMANSHIPDEFECT100PPM*OS&DStickers1.SUPPLIERDE6OS&DReportPreparedByCheckedByApprovedByProductionLine:DATE://S/NoPartNamePartNoDefectDescriptionVendorProd.QCWorkmanshipProd.QCTotalDefectStatusVendorNameQCSupervisorManagerPRODRemarksOS&DReportPreparedCheckedAppr7Pro-Inspec-tion3.6TOOL-2/SequentialinspectionTofilteralltherejectiononthelinebyinspectingpre-processedworktotally(100%)atthenextprocess.SequentialinspectionimageAftercheckingpre-processedwork,doownprocessactivitiesStartAssemblyLine1stProcess2ndProcess3rdProcessInspect100%inassemblyprocessSequentialinspectionimage-Settingsequentialinspectionpointsofeachprocess-Checkpre-processwork-Attachatagonthedefectedposition-Feedbacktotheconcernedoperator-Recordandmanagerepairhistory-Notifythedefectivecontentstooperatorsinthereviewmeeting-MakecountermeasuresWork-ingPro-Inspec-tionPre-Inspec-tionWork-ingPro-Inspec-tionPre-Inspec-tionWork-ing100PPMPro-3.6TOOL-2/Sequentialin8*SequentialinspectionGuideITEMPROCESSNAME<CHECKPOINT>Sequentialinspectionguide100PPM*SequentialinspectionGuideI9*SequentialinspectionSticker100PPM*SequentialinspectionSticke10Individualresult-SequentialinspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy12345678910111213141516171819202122232425262728293031PtPtPtPtPtPtPtPtPtIndividualresult-Sequential11RepairRecordNOFaultSHOP/:DATE://PreparedByCheckedByApprovedByCauseActionTakenItemQtyConcernedOperationTOTALPROD.QTY%REPAIRRemarks100PPMRepairRecordNOFaultSHOP/:124.6TOOL-3/MainProcessControlEstablishvisualmanagementformainprocess(Heavyrejection,Customercomplaints,criticaletc.)andconcentrateonimprovementactivitylikeFoolProof.MainProcessOperation-Installsignboardssuchas:.Majorprocess:CustomerComplain,LineDefect.Specificprocess:TimeCheckprocess,Customer’srequirement.Criticalprocess:Criticalitems,Standarditems-Registerdefectiveprocess:Whendefectoccurs-Withdrawmainprocess:whennodefectoccurs-Ifrejectionoccursestablishcountermeasure:attachtheprocess-TDRE*activitywhendefectoccurscontinuously-Makeapermanentcountermeasure:FoolProof-Establishcheck&appraisalsystem*TDRE:TearDown&Re-Engineering100PPM4.6TOOL-3/MainProcessCont13*SignBoardMAJORPROCESSSPECIFICPROCESSCRITICALPROCESS550MM145MM100PPM*SignBoardMAJORPROCESSSPECI14MainProcessControlSheetProductionQ’tyDefectiveQ’tyDefectiveRateDate12345678910111213141516171819202122232425262728293031TotalDefectRate(ppm)1,0002,000<DRAWING><CONTROLPOINT>SHOPPROCESSNAMECATEGORYOPERATOROPENINGDATESUPERVISORTARGET100PPMMainProcessControlSheetProd155.6TOOL-4/TimeCheckToassurecomponentqualitywhichareprocessedinhouse,checkmaincontrolpointregularlyTimeCheckImageFlowChartActivity-Checkqualityperiodicallyandtakeaction-Initialinspection:.Assureinitialsettingcondition-Intermediateinspection:Check4Mvariation.Correctspecificationvariationof4Matmidofproductionday-Finalinspection:AssurethequalityoffinishedproductDecidecheckpointTakesampleCheckKeepsampleRecordingInitialIntermediateFinalEverytwohourOKNGStopproduction&checkearlyLotRecheckall(100%)Changeworkingcondition&repair-Isolaterejectedlot-Stopthedefectiveinputtothenextprocess-Decidelimitlevelandsegregate-Repairordisposal-Findoutdefectcause-Establishpermanentsolutionwithconcerneddept.100PPM5.6TOOL-4/TimeCheckToassu16TIMECHECKSHEET<WEEKLY>CHECKEDBY(SUPERVISOR):APPROVEDBY(MANAGER):LINEPROCESSNAMEDURATION(//)~(//)CYCLEEVERY()HROPERATOR’SNAMESUPERVISOR’SNAMENoCheckitemsSignaturebysupervisorMON(/)TUE(/)WED(/)THU(/)FRI(/)SAT(/)09:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:00Specs100PPMTIMECHECKSHEET<WEEKLY>CHECKE17*TimeCheckProcessBoardTIMECHECKPROCESS550MM145MMTIMECHECKBOARDTimeCheckSheet09:00~11:0011:00~01:0002:00~04:0004:00~06:00LINE:________ITEM:_________OPERATORSUPERVISOR100PPM*TimeCheckProcessBoardTIME186.6TOOL-5/Q-AUDITWewillcomparetherequiredqualitylevel&thequalitylevelofourproducts/processesandthennarrowthegap.FlowChartSelectmodelFindproblems/RegistertaskDoQ-AuditKeepRecordImprovementManagetillinnovatedProcessClassStep1Step2Step3OutgoingAuditStep1+LineAuditStep2+Process(Parts)AuditMAINFOCUSRem-arks-Understandcustomer’sneedsEstablishoutgoinginspectionparameters.Do100%inspectionFindoutweakpoint&improve.Establishlineprocessparameters.Doregularaudit.Findoutlineproblems&improve.-Findoutprocessorpartsproblem&solvethempermanentlyRegularAuditbyQAalongwithproduction&sometimesfromCustomer.100PPMEstablishcontrolParameters.6.6TOOL-5/Q-AUDITWewillco197.6TOOL-6/ReviewMeetingWemustnaturalizeourselvestopreventdefectinput&improvementofsuchdefectsthroughsystematicreview.DailyMeetingWeeklyMeetingMonthlyMeeting-Describeprocess&partsdefectwithactualmaterial-Conductedbysupervisorwithalloperators-Dodaily-Weeklymeetingtomakecounter-measure(OS&D,LineRejection)-Supervisor&Manager-Onceperweek-Reviewmonthlytarget&result,establishnextmonthplan-Supervisor&AllManagers-Oncepermonth100PPM7.6TOOL-6/ReviewMeetingWe20QualityReviewReport<Daily>LINEDATE//PreparedbyAPPROVALPreparedbyCheckedbyHODLQCStatus1.Rejectionrate(/)~(/)ProdQ’tyRejQ’tyPPMAPCusedAPCrejPPMrej2.Worst5items(Customer/Line)12345Problem&CauseCountermeasureDateResp.SignAPCSHOPQualityReviewReport<Daily>LI21REJECTIONSTATUSMONTH12345678910111213141516171819202122232425262728293031TotalProductionQ’tyAPCusedQtyRejectionQ’tyAPCRej.RateDateRate(Unit:PPM)50100150200300APCrej.QtyShopRejectionRate<DAILY>APCTARGETREJECTIONSTATUS12322MonthlyLineRejectionRate2004REJECTIONRATE(PPM)JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC50100150200ProdQ’tyAPCusedRej.Q’tyAPCRej.RateAPCrej.ShopRej.RateAPCTARGETMonthlyLineRejectionRate200231-1 6SigmaConceptσlevelPPM63.45 233

4 6210

3 66,807

2 308,537ProcessDefectsCapabilityOpportunitySweetFruits(PerfectDesign)Bulkoffruits(Optimization)Lowerfruits(7QCtools)Groundfruits(Straightviewpt)1-1 6SigmaConceptσlevelPPM241-1 6SigmaConcept-I3SigmaLevelCompany6SigmaLevelCompany10~15%ofsalesisfailurecostHaving66,807defectsperMillionDependsonthedetectionofdefectsBelievesthathighQualityisexpensiveDoesn’tfollowsystematicapproachBenchmarkingagainstcompetingcompaniesBelieves99%isgoodenoughDefinesCTQ’sinternally5%ofsalesisfailurecost3.4defectsperMillionFocusonprocessnottoproduceDefectsBelievesthathighQualitycreateslowcostUsesD-M-A-I-CKnowhowBenchmarkingtobetheBestintheWorldBelieves99%isunacceptable.DefinesCTQ’sfromcustomerpointofview1-1 6SigmaConcept-I3Sigma251-1 6SigmaConcept-II3SigmaLevelCompany6SigmaLevelCompany54,000wrongdrugprescriptions/yearUnsafedrinkingwater2hrs/monthNotelephoneservicefor27min/week5Shortorlonglandingsattheheatheroairportinaday.1,350incorrectsurgicaloperations/week.54,000lostarticlesofmailloss/hr.1wrongdrugprescriptionin25years.Unsafedrinkingwaterfor16years.Notelephoneservicefor6secfor100years1shortorlonglandingsatHeatheroairportin10years.1incorrectsurgicaloperationfor20years.35lostarticlesofmail/year.1-1 6SigmaConcept-II3Sigma261-2 6SigmaConcept(Aspectoftools)StepsToolsDefinitionMeasurementAnalysisImprovementControlProcessMappingLogicTreeParetoAnalysisQFD,FMEAGageR&RRationalsubgroupingsProcessCapabilityHypothesisTestingRegressionGraphanalysisDOE(DesignofExperimentDirectImprovements13) SPC1-2 6SigmaConcept(Aspect271-3 UnderstandingBasicconceptsofStatistics“Z“isthemeasureofprocesscapabilityZ=3Z=61σμ2σ3σLSLUSL1σμ2σ3σLSLUSL4σ5σ6σThereareequalnoOfS.DonbothsidesSoforZ=3,thetoleranceBandisdividedinto6S.DForZ=6,thetoleranceBandisDividedinto12S.DAsnumberofS.DincreasesThecurvenarrowsdown&soProcesscapabilityincreases&Thusdefectdecreases.Cp>2.0Cpk>1.51-3 UnderstandingBasicconce28一家美資企業(yè)內(nèi)訓(xùn)文檔一家美資企業(yè)內(nèi)訓(xùn)文檔291.6TOOL?100PPMQUALITYPROCESSOS&D*SequentialInspectionMainProcessControlTimeCheckQualityAuditReviewMeeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D:Over,Shortage&Defect100PPM1.6TOOL?100PPMQUALITYPROC302.6TOOL-1/OS&DActivityAsystemtoimprovequalityofcomponentsfounddefectivebymonitoring,analyzing&actingonactualrealtimedata&materialsuppliedbysuppliers.OS&DImageEstablishfullinspectionsystemEstablishqualityinformationsystem-Realinformationsystem.Realdata.Realmaterial-ComputerizedOS&DmanagementEstablishvendorappraisalsystem-Qualitycontract(agreementoftargetquality)-I&PSystemInnovationFlow*I&P:Incentive&PenaltyFACTORYSUPPLIERSImprovementActivitiesDefectFoundReal&QuickInformationImprovedMaterialInnovationActivitiesAttachtagafterfindingadefectonthelinePlacecollectionboxfordefectivesinthelineCollectrejection&analysisofsamefromIQCmembersDisplayrejectionduetosupplierRequestforurgentdeliveryinexchangeoftotalrejection.Suppliermustreceiverealinformationandhaveimprovementmeeting(once/week)=>Q-managerattendReceiveimprovedmaterial&follow-up100PPM2.6TOOL-1/OS&DActivityAsy312.6TOOL-1/OS&DActivity(RULE)PRODUCTIONPURCHASEIQCMATERIALSUPPLIERActivities-Finddefectiveparts-Attachtag.Supplierdefect:Red.Transportation:Blue.Workdefect:Yellow-Storedefectiveparts-IssueOS&DNCR(once/day)-Provideadditionalpartsinlieuofdefectedq’ty.Emergencydelivery-HoldimprovementM/Twithsupplier.SunriseM/T-Collectthedefectiveparts(once/day)-Analyzeandevaluatethecauseofrejection..Classifythereasontheirtypeslikeinternalworkerrorortransportationorvendor-Recordandmanagecurrentdefectstatusandfeedback-Displaythedefectiveparts-Organizethereceipt/issuingofalternatedpartstotheline-Receivethedefectiveparts-Analyzethereason-Holdimprovementmeeting.Dailymeeting.Weeklyinnovationmeeting(Q-managerattend)-Monthlyevaluationmeeting(Q-managerattend)MaterialWorkdefectVendordefect&TransportationReturnDataReplacementfordefectiveparts100PPM2.6TOOL-1/OS&DActivity(RU32Self-inspectionCheck-listPreparedByCheckedByApprovedByMACHINE/MODELBUYERORIGINDATEREVISEDDATEPROCESSNAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTIONMETHODREVISIONNO100PPMSelf-inspectionCheck-listPrep33*OS&DStickers1.SUPPLIERDEFECT2.WORKMANSHIPDEFECT100PPM*OS&DStickers1.SUPPLIERDE34OS&DReportPreparedByCheckedByApprovedByProductionLine:DATE://S/NoPartNamePartNoDefectDescriptionVendorProd.QCWorkmanshipProd.QCTotalDefectStatusVendorNameQCSupervisorManagerPRODRemarksOS&DReportPreparedCheckedAppr35Pro-Inspec-tion3.6TOOL-2/SequentialinspectionTofilteralltherejectiononthelinebyinspectingpre-processedworktotally(100%)atthenextprocess.SequentialinspectionimageAftercheckingpre-processedwork,doownprocessactivitiesStartAssemblyLine1stProcess2ndProcess3rdProcessInspect100%inassemblyprocessSequentialinspectionimage-Settingsequentialinspectionpointsofeachprocess-Checkpre-processwork-Attachatagonthedefectedposition-Feedbacktotheconcernedoperator-Recordandmanagerepairhistory-Notifythedefectivecontentstooperatorsinthereviewmeeting-MakecountermeasuresWork-ingPro-Inspec-tionPre-Inspec-tionWork-ingPro-Inspec-tionPre-Inspec-tionWork-ing100PPMPro-3.6TOOL-2/Sequentialin36*SequentialinspectionGuideITEMPROCESSNAME<CHECKPOINT>Sequentialinspectionguide100PPM*SequentialinspectionGuideI37*SequentialinspectionSticker100PPM*SequentialinspectionSticke38Individualresult-SequentialinspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy12345678910111213141516171819202122232425262728293031PtPtPtPtPtPtPtPtPtIndividualresult-Sequential39RepairRecordNOFaultSHOP/:DATE://PreparedByCheckedByApprovedByCauseActionTakenItemQtyConcernedOperationTOTALPROD.QTY%REPAIRRemarks100PPMRepairRecordNOFaultSHOP/:404.6TOOL-3/MainProcessControlEstablishvisualmanagementformainprocess(Heavyrejection,Customercomplaints,criticaletc.)andconcentrateonimprovementactivitylikeFoolProof.MainProcessOperation-Installsignboardssuchas:.Majorprocess:CustomerComplain,LineDefect.Specificprocess:TimeCheckprocess,Customer’srequirement.Criticalprocess:Criticalitems,Standarditems-Registerdefectiveprocess:Whendefectoccurs-Withdrawmainprocess:whennodefectoccurs-Ifrejectionoccursestablishcountermeasure:attachtheprocess-TDRE*activitywhendefectoccurscontinuously-Makeapermanentcountermeasure:FoolProof-Establishcheck&appraisalsystem*TDRE:TearDown&Re-Engineering100PPM4.6TOOL-3/MainProcessCont41*SignBoardMAJORPROCESSSPECIFICPROCESSCRITICALPROCESS550MM145MM100PPM*SignBoardMAJORPROCESSSPECI42MainProcessControlSheetProductionQ’tyDefectiveQ’tyDefectiveRateDate12345678910111213141516171819202122232425262728293031TotalDefectRate(ppm)1,0002,000<DRAWING><CONTROLPOINT>SHOPPROCESSNAMECATEGORYOPERATOROPENINGDATESUPERVISORTARGET100PPMMainProcessControlSheetProd435.6TOOL-4/TimeCheckToassurecomponentqualitywhichareprocessedinhouse,checkmaincontrolpointregularlyTimeCheckImageFlowChartActivity-Checkqualityperiodicallyandtakeaction-Initialinspection:.Assureinitialsettingcondition-Intermediateinspection:Check4Mvariation.Correctspecificationvariationof4Matmidofproductionday-Finalinspection:AssurethequalityoffinishedproductDecidecheckpointTakesampleCheckKeepsampleRecordingInitialIntermediateFinalEverytwohourOKNGStopproduction&checkearlyLotRecheckall(100%)Changeworkingcondition&repair-Isolaterejectedlot-Stopthedefectiveinputtothenextprocess-Decidelimitlevelandsegregate-Repairordisposal-Findoutdefectcause-Establishpermanentsolutionwithconcerneddept.100PPM5.6TOOL-4/TimeCheckToassu44TIMECHECKSHEET<WEEKLY>CHECKEDBY(SUPERVISOR):APPROVEDBY(MANAGER):LINEPROCESSNAMEDURATION(//)~(//)CYCLEEVERY()HROPERATOR’SNAMESUPERVISOR’SNAMENoCheckitemsSignaturebysupervisorMON(/)TUE(/)WED(/)THU(/)FRI(/)SAT(/)09:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:00Specs100PPMTIMECHECKSHEET<WEEKLY>CHECKE45*TimeCheckProcessBoardTIMECHECKPROCESS550MM145MMTIMECHECKBOARDTimeCheckSheet09:00~11:0011:00~01:0002:00~04:0004:00~06:00LINE:________ITEM:_________OPERATORSUPERVISOR100PPM*TimeCheckProcessBoardTIME466.6TOOL-5/Q-AUDITWewillcomparetherequiredqualitylevel&thequalitylevelofourproducts/processesandthennarrowthegap.FlowChartSelectmodelFindproblems/RegistertaskDoQ-AuditKeepRecordImprovementManagetillinnovatedProcessClassStep1Step2Step3OutgoingAuditStep1+LineAuditStep2+Process(Parts)AuditMAINFOCUSRem-arks-Understandcustomer’sneedsEstablishoutgoinginspectionparameters.Do100%inspectionFindoutweakpoint&improve.Establishlineprocessparameters.Doregularaudit.Findoutlineproblems&improve.-Findoutprocessorpartsproblem&solvethempermanentlyRegularAuditbyQAalongwithproduction&sometimesfromCustomer.100PPMEstablishcontrolParameters.6.6TOOL-5/Q-AUDITWewillco477.6TOOL-6/ReviewMeetingWemustnaturalizeourselvestopreventdefectinput&improvementofsuchdefectsthroughsystematicreview.DailyMeetingWeeklyMeetingMonthlyMeeting-Describeprocess&partsdefectwithactualmaterial-Conductedbysupervisorwithalloperators-Dodaily-Weeklymeetingtomakecounter-measure(OS&D,LineRejection)-Supervisor&Manager-Onceperweek-Reviewmonthlytarget&result,establishnextmonthplan-Supervisor&AllManagers-Oncepermonth100PPM7.6TOOL-6/ReviewMeetingWe48QualityReviewReport<Daily>LINEDATE//PreparedbyAPPROVALPreparedbyCheckedbyHODLQCStatus1.Rejectionrate(/)~(/)ProdQ’tyRejQ’tyPPMAPCusedAPCrejPPMrej2.Worst5items(Customer/Line)12345Problem&CauseCountermeasureDateResp.SignAPCSHOPQualityReviewReport<Daily>LI49REJECTIONSTATUSMONTH12345678910111213141516171819202122232425262728293031TotalProductionQ’tyAPCusedQtyRejectionQ’tyAPCRej.RateDateRate(Unit:PPM)50100150200300APCrej.QtyShopRejectionRate<DAILY>APCTARGETREJECTIONSTATUS12350MonthlyLineRejectionRate2004REJECTIONRATE(PPM)JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC50