無(wú)刷電機(jī)零件生產(chǎn)改善方案

1、ROB 2015-10-27ROB 2015-10-27無(wú)刷電機(jī)零件生產(chǎn)改善方案背景方案成本控制效果預(yù)測(cè)推進(jìn)計(jì)劃效果確認(rèn)ROB 2015-10-27ROB 2015-10-27改善背景 品質(zhì)不良率（后加工，不良率20%）； 交貨達(dá)成率（上周，CNC車(chē)間50%）； 管理層要求：提高效率，縮減工序，控制成本； 工序方案：舊工藝路線CL1-CL2-CNC1-CNC2-CL-FP；新工藝CL-CNC-CL-FP，需要用數(shù)據(jù)支持其合理性 CNC夾具（FC兩種，CH一種）ROB 2015-10-27ROB 2015-10-27改善方案 成立臨時(shí)性項(xiàng)目組織，架構(gòu)圖（附，第四頁(yè)）； 針對(duì)此項(xiàng)目，生產(chǎn)、品質(zhì)、P

2、MC單獨(dú)立項(xiàng)，報(bào)告每日數(shù)據(jù)（附，第五頁(yè)第十一頁(yè)）； 每日早會(huì)制，會(huì)議時(shí)間1015分鐘； 新增每臺(tái)機(jī)，都必作CPK，以衡量制程穩(wěn)定性（附，第十二頁(yè)）；ROB 2015-10-27ROB 2015-10-27福昌精密制品（深圳）有限公司福昌精密制品（深圳）有限公司項(xiàng)目召集人PMC生產(chǎn)品質(zhì)QE會(huì)議記錄及跟進(jìn)PE技術(shù)支持RD夾具aabbddeeffccROB 2015-10-27ROB 2015-10-27每小時(shí)各工序產(chǎn)出每小時(shí)各工序產(chǎn)出-PMCROB 2015-10-27ROB 2015-10-27WIP狀態(tài)狀態(tài)-PMCROB 2015-10-27ROB 2015-10-27每日品質(zhì)不良報(bào)告每日品質(zhì)

3、不良報(bào)告生產(chǎn)生產(chǎn)ROB 2015-10-27ROB 2015-10-27IPQA制程抽樣控制-1l （Oct 21）：手機(jī)產(chǎn)品1101，IPQA抽樣149次，發(fā)出QAN共8張， QAN率達(dá)5.4%，主要有總厚度超大QAN共1張等等。手機(jī)產(chǎn)品1201，IPQA抽樣137次，發(fā)出QAN共7張， QAN率達(dá)5.1%，主要有通槽止規(guī)通QAN共2張等等。日期日期WK23WK23WK24WK24WK25WK25WK26WK26WK27WK27WK28WK28WK29WK29Oct Oct 1919Oct Oct 2020Oct Oct 2121QANQAN率率1101101 117.7%17.7%8.0%

4、8.0%8.2%8.2%7.5%7.5%5.7%5.7%9.9%9.9%6.0%6.0%3.8%3.8%4.7%4.7%5.4%5.4%1201201 114.5%14.5%7.4%7.4%5.6%5.6%4.1%4.1%7.4%7.4%5.3%5.3%4.0%4.0%7.0%7.0%8.6%8.6%5.1%5.1%不良不良率率1101101 19.3%9.3%5.7%5.7%6.6%6.6%5.5%5.5%3.9%3.9%7.6%7.6%4.4%4.4%3.2%3.2%4.7%4.7%4.0%4.0%1201201 17.5%7.5%2.6%2.6%4.7%4.7%3.0%3.0%4.8%4

5、.8%3.9%3.9%2.6%2.6%5.8%5.8%7.5%7.5%4.6%4.6%ROB 2015-10-27ROB 2015-10-27IPQA制程抽樣控制-2開(kāi)機(jī)狀況：產(chǎn)品產(chǎn)品應(yīng)開(kāi)機(jī)臺(tái)應(yīng)開(kāi)機(jī)臺(tái)實(shí)開(kāi)機(jī)臺(tái)數(shù)實(shí)開(kāi)機(jī)臺(tái)數(shù)工序工序日期日期17-Oct18-Oct19-Oct20-Oct21-Oct白班白班夜班夜班白班白班夜班夜班白班白班夜班夜班白班白班夜班夜班白班白班夜班夜班1101CNC21613150 00131410151515CNC377700776677停機(jī)原因停機(jī)原因待料待料QANQAN調(diào)機(jī)調(diào)機(jī)未加班未加班未加班未加班待料待料QANQAN調(diào)機(jī)調(diào)機(jī)待料待料QANQAN調(diào)機(jī)調(diào)機(jī)QANQA

6、N調(diào)機(jī)調(diào)機(jī)QANQAN調(diào)機(jī)調(diào)機(jī)1201CNC221101900141812161418CNC388700888788停機(jī)原因停機(jī)原因待料待料QANQAN調(diào)機(jī)調(diào)機(jī)未加班未加班未加班未加班待料待料QANQAN調(diào)機(jī)調(diào)機(jī)待料待料待料待料QANQAN調(diào)機(jī)調(diào)機(jī)QANQAN調(diào)機(jī)調(diào)機(jī)ROB 2015-10-27ROB 2015-10-27OQA出貨檢查l （Oct 21）：手機(jī)產(chǎn)品1101，OQA功能結(jié)果:LAR%=67%(6/9),DPPM=89 K(4/45); OQA外觀結(jié)果:LAR%=60%(9/15),DPPM=92 K(134/990)，手機(jī)產(chǎn)品1201，OQA功能結(jié)果:LAR%=70%(7/10

7、),DPPM=60 K(3/50); OQA外觀結(jié)果:LAR%=50%(9/18),DPPM=74 K(92/1250)，區(qū)域區(qū)域項(xiàng)目項(xiàng)目WK23WK24WK25WK26WK27WK28WK29Oct 19Oct 20Oct 21OQA功功能能 LAR%LAR%M150114%51.4%66.7%75.0%66.7%79.2%82.8%100.0%77.8%66.7%M150127%76.3%60.8%61.0%60.7%75.0%76.5%100.0%88.9%70.0%DPPMDPPM（K)K)M15011M150110101357205

8、9395.8141796906789M15012M15012010130012110210525717010302260OQA外外觀觀 LAR%LAR%M150116%41.0%48.9%41.5%41.2%49.1%53.3%50.0%43.8%60.0%M150125%42.6%48.8%44.6%51.9%50.4%52.9%50.0%66.7%50.0%DPPMDPPM（K)K)M15011M150110101138598771839812313112993M15012M150120101113635868.1697778971267

9、411011101產(chǎn)品產(chǎn)品OQAOQA出貨數(shù)出貨數(shù)(K)(K)8.7413.91522.78627.67619.48234.27221.6586.295.5424.2512011201產(chǎn)品產(chǎn)品OQAOQA出貨數(shù)出貨數(shù)(K)(K)5.83912.8120.34630.15818.25837.02636.9243.48.54.25ROB 2015-10-27ROB 2015-10-27客戶IQC檢查結(jié)果l （Oct 21）Oct 21日，客戶IQC檢查2批，兩批均Pass。區(qū)域區(qū)域項(xiàng)目項(xiàng)目WK23WK24WK25WK26WK27WK28WK29Oct 19Oct 20Oct 21客戶客戶IQCM150110M1501101 1抽抽樣總批樣總批數(shù)數(shù)3687377111接收批次接收批次0165244011接收比率接收比率0.0%16.7%75.0%71.4%66.7%57.1%57.1%0.0%100.0%100.0%M150120M1501201 1抽樣總批抽樣總批數(shù)數(shù)3687377111接收批次接收批次0246355111接收比率接收比率0.0%33.3%50.0%85.7%100.0%71.4%71.4%100.