問題解決流程通用版

1、JCI Tracking Number : INFINEON 04-01Customer Number :Customer Response Due Date:18/9 Problem Solving Document (PSD)TrackProgress, indicate completion date STEP012345678ACTIONAwarenessTeamChart ContainDiagnose Action VerifyPrevent Closure-0 AProblem Awareness:Quality issue seen on transistor BCR505 N

2、PN.Detection location: IC testFailure mode: no current through transistor Analysis: PNP transistor mounted instead of NPN transistor (Ref BCR 555 PNP?)JCAE ref: 185859658Infineon P/N: BCR 505 E6327 Q62702C2354Date code: 04 30Lot number: 97248031Qty: 4 (cards)Qty reels isolated: 2 (6K)Note: component

3、 marking on PNP (wrong parts) is “XW S47” (same as BCR505 NPN)SMT line checkings: no abnormality identifiedRoot cause suspected: mixing of 2 references (NPN and PNP) inside a same reelPart (+NS/sffsfsumber) :Deviation :Root Cause known yet (check ECHO) ? And verified?Is eliminating the root cause re

4、alistic right now?Standard / Spec.Immediate containment actions required / taken ?ActualJCI Witness(es) :Detail of problem(What exactly do we see, feel, hear and smell?)Quantity found / Quantity checked :Recurring Issue? Yes / No (circle one)If yes add old PSDRank =123(circle one)Rank 1 =Rank 2 =Ran

5、k 3 =Safety item or due to part complete vehicle out of std.Part out of standard, vehicle in standard.Part/Vehicle in standard but show variation or need improvement(s)Product: Safety / Regulations / Functional / Comfort / Appear. Non-product: Quantity / Sequence / Service / Documents Others: (circl

6、e one)Make first draft of the IS / IS NOT worksheet ( page 2) and get a better understanding of the problem. Now you can invite the right people.1 ADefine the Team 1 BClosure & Sign off (see section 8B)FunctionNameSignatureDateWW-LOS-FR-14-01-E / Rev 02 01/00 Johnson Controls AutomotiveNeed more PSD

7、 folders? Phone +49 2174 65 32710 B IS / IS NOT WorksheetBase all answers on facts only, write NMD (need more data) when facts are not available (yet). Add supporting documents.ISIS NOTWhat are the DIFFERENCES?What did CHANGE?PotentialCAUSESTestCausesWhatWhat part (system) has the problem? What is t

8、he deviation?What are the most similar parts without the problem? What other deviation on the part could you expect?(if present add in the left column)1 2 3 1 2 3 WhereWhere was the part when the deviation was detected the first time?Where on the part did the deviation occur?Where else could the dev

9、iation be detected?(if detected add in the left column)What are the adjacent locations on the part or the adjacent parts without the deviation?1 2 3 1 2 3 WhenWhen was the deviation first noticed? (in calendar time and in the “l(fā)ife cycle”)What is the pattern? (one time event, stable, increasing, dec

10、reasing, random or cyclical) ?What earlier date and/or phase could the problem occur? (if detected add in the left column)Since the detection, what other occurrence could you expect?1 2 3 1 2 3 ExtendHow many parts have the deviation (number and ppms)?Who is affected yet? How much did it cost so far

11、? Will it increase, decrease or stabilize by itself?How many more or less could you expect?What could be worse / better, under what circumstances?1 2 3 1 2 3 2Define Measurement(s) and Overview Trend ChartWhat characteristic and what reporting unit: (ex. length in mm according spec. . or ippm or ) W

12、hat time period: (use this chart for a general overview) back-up with detailed charts where possible What is the goal: (ex.140 +/- 2 mm, 0 ippm)Use trend chart to track occurrences. Indicate with “C” when containment - and “P” when permanent actions are implemented.(add line number from the action p

13、lan in section 5) Start with a summary of the available history and continue until the final Sign-off (see section 8)QTYWhenC/P action #QTY in PlantQTY in TransitQTY at customerTOTALQTY made3Contain symptomsContainment actions:List the containment actions taken so far (actions that prevented the par

14、ts to escape toward the customer) Add existing list if possibleVerify their effectivenessIf required list additional actions in section 5 and 64Root Cause Analysis MaterialMethodMaterialMethodProblemMachineManMachineManHow Made? Why Shipped?List occurrence cause / path this sideList escape cause / p

15、ath this side Circle the most likely causes (max. 3) from each side above. For the 3 best causes of the left side (How made), stair-step by asking why as long as you get more precise information. Probably you found the root-causes. Number the 3 most likely root-causes and check if they can explain a

16、ll differences and changes by using the last column on the IS / IS NOT worksheet. For the right side (Why Shipped), check if the root causes are addressed in the containment actions.5Select Corrective actions6 Implement, Verify and Validate ActionsNFault / ItemContainment / Permanent countermeasureA

17、ctionC or PHow to VerifyVerifyDate PlanTeam MemberResponsibleValidat. PlanValidat.ActualStatus123456789101112131415Action identifiedAction implemented, verification in progressAction verified, validation in progressAction validatedDefinitions : VERIFY = Prove intended outcomeVALIDATE = Confirm and a

18、gree effectiveness over time7Prevent Occurrence in Similar Cases or Future Reoccurrence7AList similar products / systems with the potential for the same defect.Begin a new Problem Solving Document for eachProcess / ItemResponsibilityPSD # / Planned Validation Date 7BReview the following Attach copie

19、s of the revised documents.Shade ifnecessaryResponsibilityReview Completion DatePlanned ActualoQuality AlertoODS oControl PlanoFlow DiagramoProcess Change RequestoInspection StandardoChange Authorization oPFMEA / DFMEAoCustomer Part SubmissionoBOS change proposal formoOther:oAll relevant BOS procedures consul