遏制和質量門培訓資料教學內容

1、 2010 Dana Limited. This presentation contains copyrighted and confidential information of Dana Holding Corporation and/or its subsidiaries. Those having access to this work may not copy it, use it, or disclose the information contained within it without written authorization of Dana Holding Corpora

2、tion. Unauthorized use may result in prosecution.遏制和質量門培訓資料CLASS ACTIVITY #1 30min Initial Defect課堂活動課堂活動#130分鐘分鐘 最初的缺陷最初的缺陷4BUILDING HONGBAOs建立紅包 Supplier供應商 Receiving進料檢驗 Assembly Coin To Envelope將硬幣裝進紅包 Assembly Note To Envelope將標簽裝進紅包 Assembly Tab To Envelope將紅包封上 Warehouse 倉庫 Shipping 發(fā)交 Custom

3、er客戶Step 1第一步第一步: Stop the Flow of Bad Parts停止不合格品流動停止不合格品流動4Look for the specific defect找具體的缺陷找具體的缺陷4Differentiate the “good” from the “suspect”將合格產品和可疑產品區(qū)分開。將合格產品和可疑產品區(qū)分開。4Establish understandable product standards建立易理解的產品標準建立易理解的產品標準4Begin data collection開展開展數據收集數據收集4Begin sorting or inspection開展

4、分類和檢查開展分類和檢查4Identify and HOLD any questionable parts識別并隔離任何可疑產品識別并隔離任何可疑產品Proper Containment Process Inputs正常的遏制流程正常的遏制流程的輸入的輸入4Action行動: Assure a comprehensive and properly Managed Containment Activity is defined, organized and capable of being implemented within 4 hours if required確保全面的、合適的遏制管理活動

5、被定義，組織，如果需要的話在4小時內實施 Properly designated area合適的指定的區(qū)域合適的指定的區(qū)域 Distinct location 清晰的位置 Proper Lighting, equipment and material flow space 合適的燈光、設備和物料流動空間 Designated Material Locations 制定的物料位置 Verified Good Products 被驗證是合格產品 Verified Bad Product被驗證是不合格產品 Questionable (products awaiting management/cust

6、omer disposition) 可疑產品（等待管理層或者是客戶處置的產品） Products to be sorted產品分類 Proper wall space to post and record results張貼和記錄結果合適的位置 Adequate Space for Procedures and Boundary Samples有放置程序和限度樣件的充足的空間 Well Defined methods 很好的方法很好的方法 How to sort and handle materials如何挑選和處置物料 Defined Part and Container Marking s

7、trategy定義產品和器具的標識策略 Defined Material Quarantine, Capture and return methods定義物料隔離、獲取和回收的方法。 Data Collection and reporting process數據收集和報告流程 Corrective action monitoring methods糾正措施的監(jiān)控方法 Defined Criteria to support Containment Exit定義支持遏制解除的準則CLASS ACTIVITY #1.1 30min Defect Control課堂活動課堂活動#1.1-30分鐘分鐘

8、不合格的控制不合格的控制4BUILDING HONGBAOs建立紅包 Supplier 供應商 Receiving進料檢驗 Assembly Coin To Envelope將硬幣裝進紅包 Assembly Note To Envelope將標簽裝進紅包 Assembly Tab To Envelope將紅包的封上 Containment 遏制 Warehouse 倉庫 Shipping發(fā)交 Customer客戶Explanation of Containment遏制的解釋遏制的解釋4Explaining effective containment 解釋一個有效的遏制 Contained St

9、ateContainment Process遏制的流程遏制的流程4Expectations of effective containment Phases4期望的有效遏制-階段Stop the Flow停止流動Install Filter安裝過濾Protect Customer保護客戶Collect Data & Improve收集數據改進Data 數據Daily Meeting日常會議Track Results跟中結果Clean Pipeline清理途徑Retrieve Suspect 召回可以產品Release Good放行合格產品Key Points關鍵點關鍵點Stop the

10、flow of discrepant parts.停止不合格品的流動Define the containment actions (Sort Rework Dispose). 定義遏制行動（挑選-返工-處置）Collect data and drive corrective actions 收集數據，制定糾正措施Clean the Pipeline清理途徑Define the material identification plan (parts and containers).定義物料識別計劃（產品和器具）Establish the scope of exposure with locati

11、on and return of questionable stock.建立工廠的范圍，召回有問題的庫存Step 2第二步第二步: Define Containment Actions定義遏制行動定義遏制行動CLASS ACTIVITY #2 30min ( Log Sheet )課堂活動課堂活動#2 -30分鐘（記錄表）分鐘（記錄表）4BUILDING HONGBAOs建立紅包 Supplier供應商 Receiving進料檢驗 Assembly Coin To Envelope將硬幣裝進紅包 Assembly Note To Envelope將標簽裝進紅包 Assembly Tab To

12、Envelope將紅包的封上 Containment 遏制 Warehouse 倉庫 Shipping發(fā)交 Customer客戶Step 3第三步第三步: Define Material Identification Plan定義物料識別計劃定義物料識別計劃Clear and easily identifiable (Parts & Containers)清晰的，易于識別的（產品&器具）Identifies parts in different categories識別不同類別下的產品OK Parts that have been sorted 已經分類的合格產品Suspect

13、 Parts that require sorting需要分類的可疑產品Known Bad Parts已識別的不合格產品Questionable parts awaiting disposition有問題的產品-需要處置Step 4第四步第四步: Scope & Location of Questionable Stock問題問題產品的范圍產品的范圍&位置位置Work with Material Control People和物料控制人員一起 Identify the parts and create an inventory識別零件和建立庫存 Adjust inventory

14、 / feedback調整庫存/反饋 Retrieve the parts that need containment召回需要遏制的零件Special Customers Like Service Parts特殊的客戶-備件 Special locations like secondary processors 特殊的位置-二級加工Step 4第四步第四步: Define Containment/Material Return Plan定義遏制定義遏制/物料召回計劃物料召回計劃Suspect material can enter可疑物料能夠進入Material is evaluated and

15、 categorized物料被評估和分類Property marked good material can exit to finished goods標識為合格物料能夠到最終的成品Properly marked bad material can exit to disposal標識為不合格物料進入到處置Uncertain material is held不確定的物料隔離CLASS ACTIVITY #3 30min Trace Multiple課堂活動課堂活動#3-30分鐘分鐘 追溯各類別產品追溯各類別產品4BUILDING HONGBAOs建立紅包 Supplier供應商 Receivin

16、g進料檢驗 Assembly Coin To Envelope將硬幣裝進紅包 Assembly Note To Envelope將標簽裝進紅包 Assembly Tab To Envelope將紅包的封上 Containment 遏制 Warehouse 倉庫 Shipping發(fā)交 Customer客戶Step 5第五步第五步: Define Exit Strategy定義退出策略定義退出策略Material remains in containment until permanent corrective action is in place物料處于遏制狀態(tài)，直到永久對策實施到位Contai

17、nment could last days, weeks or years. This is all up to your ability and attitude to address the root cause遏制可以持續(xù)幾天、幾周、幾年。主要取決于找到根本原因的能力和態(tài)度Use Containment as a form of corrective action validation 把遏制當成糾正措施驗證的一種形式 result should be 0結果應該是結果應該是0Material is evaluated and categorized until a certain tr

18、igger is met 物料被評估和分類，直到特定的觸發(fā)條件被滿足 ( 0 defects for a certain time frame after corrective action )在糾正措施實施后，特定的時間段內應該是在糾正措施實施后，特定的時間段內應該是0缺陷缺陷CLASS ACTIVITY #4 30min Blind課堂活動課堂活動#4 30分鐘分鐘-盲（帶上眼罩裝配）盲（帶上眼罩裝配）4BUILDING HONGBAOs建立紅包 Supplier供應商 Receiving接受 Assembly Coin To Envelope將硬幣裝進紅包 Assembly Note T

19、o Envelope將標簽裝進紅包 Assembly Tab To Envelope將紅包的封上 Warehouse 倉庫 Shipping 發(fā)交 Customer客戶Basic Containment Process Flow基本的遏制流程基本的遏制流程Review - Containment Improvement ProcessSuggested Steps回顧回顧-遏制改善流程建議步驟遏制改善流程建議步驟Define the Area Set up定義區(qū)域設定Work with supplier to identify the area and outline a plan.和供應商一

20、起識別區(qū)域并總結出一個計劃Include the Key Elements包括關鍵要素Perform the physical rearrangement In the containment area with the appropriate people在遏制區(qū)域，有合適的人員Review the methods 回顧方法Work with the people to define the practices that match with Customer needs and Company existing methods和人員一起定義與顧客需求相匹配的實踐以及公司的退出方法Analy

21、ze the Material Capture plans and methods分析物料獲取計劃和方法 This is best done with a Material Control type person.最好由物料控制人員來做DefineTools - TrainingDoTrack and MonitorHow To Actualize - Example Containment Area Layout如何實踐如何實踐-遏制區(qū)域布局的案例遏制區(qū)域布局的案例Good Parts ONLY!“GP 11 / GP 12” GP 11 / GP 12標準標準 Final Inspecti

22、on of all axles off all line assembled at DRK在在DRK的所有離線橋的終檢的所有離線橋的終檢4 lanes includes final bill out inspected racks have “stickers”四個通道-？-檢查工位器具的標簽Criteria are immediate customer issues準則是及時的客戶問題Customer Attachment points客戶附帶的問題Findings Documented 問題點記錄Audit is conducted in “Real Time” final inspect

23、ion findings are treated as customer issues開展實時審核-最終檢查的問題點視為在顧客處發(fā)生的問題Team leaders are called to final audit station escalation plan followed團隊領導實施最終崗位審核-升級計劃的執(zhí)行Indicator Chart 指標圖表指標圖表Acton ItemResp. and DateStatusPrediction & dateCommentsMarking Strategies標識策略標識策略4Simple To Do容易做4Quick Unless S

24、ituation Dictates Differently快，除非有特殊要求4Visual可視4Documented Location 標記位置 4Location Visible In Installed Position*裝配后位置可視41 Design / Color per Inspection Campaign每次檢查活動1種設計/顏色4Sensitive to Past Inspections 與以往的檢查易于區(qū)別4Weather Resistant Product Life for Safety Issues不因天氣發(fā)生變化-產品生命周期內有安全要求的4Pens, Pricks,

25、 Nicks, Stickers 筆、？、？、標簽Containment Improvement Process Check Status遏制改善流程遏制改善流程-檢查狀態(tài)檢查狀態(tài) Expectation期望Visual科室: Simple method to see evolution of Containment簡單的方法能夠看到遏制的變化- Area Set up 區(qū)域設定區(qū)域設定 Distinct location 單獨的區(qū)域 Lighting, Equipment 燈光、設備 Designated Material Locations 指定的物料區(qū)域 Post and record

26、results張貼和記錄結果 Boundary Samples限度樣件- Methods and Practices方法和實踐方法和實踐 How to sort如何挑選 Marking strategy標識策略 Material Quarantine, Capture and return 物料的隔離、獲取和回收 Data Collection數據收集 Corrective action monitoring糾正措施的監(jiān)控 Exit Criteria退出準則XXGreenYellowRedXContainment Process Improvement Summary遏制流程改善遏制流程改善-

27、總結總結Purpose:Provide a focused effort to isolate the customer from discrepant products especially when the normal process is know to be weak通過努力，將不合格產品隔離，防止流到客戶-特別是過程很差。Process流程:Definition and implementation of a formal process to定義和實施一個正式的流程:Conduct redundant inspection指導額外的檢驗Collect data and infor

28、mation收集數據和信息 Perform Data driven corrective actions 基于數據制定糾正措施Product產品產品:Thorough Customer Isolation and Improved Process完全防止流入到客戶，并改善流程 Key Points關鍵點關鍵點: Stop the flow of discrepant parts停止不合格品的流程. Define containment (Sort Rework Dispose) 定義遏制（分類-返工-處置） Collect data and drive corrective actions基于

29、數據制定糾正措施 Clean the Pipeline清理途徑Material identification plan (parts and containers).物料識別計劃（產品和器具）Scope: Location and return of questionable stock.范圍：位置及可疑庫存的召回 Requirements要求要求:Dedicated well laid out area 專用的，有很好布局的區(qū)域Properly defined and controlled methods合適的定義和控制方法 Advanced Topic - Launch Containme

30、nt高級話題高級話題-發(fā)起遏制發(fā)起遏制Known Past Common Defects知道過去共性的問題Potential New Defects ( From Gate Reviews )潛在的新問題（門回顧）Version / Qty / In process Inspection Checks版本/質量/過程檢驗Customer Critical Requirements客戶關鍵的要求Engineering Issues工程問題Manufacturing Issues制造問題Prove Out The Process 驗證過程驗證過程Protect The Customer While

31、 Manufacturing Stabilizes過程穩(wěn)定，過程穩(wěn)定，保護客戶保護客戶PREVENTION預防 2010 Dana Limited. This presentation contains copyrighted and confidential information of Dana Holding Corporation and/or its subsidiaries. Those having access to this work may not copy it, use it, or disclose the information contained within i

32、t without written authorization of Dana Holding Corporation. Unauthorized use may result in prosecution.Quality Gates質量門質量門Isolating the Next Process from fault defects.將不合格品隔離，防止流入到下道工序4Quality gate issues are generally selected from the Fast Response Board or issues that are small in severity but

33、high in occurrence.設定質量門依據快速反設定質量門依據快速反應看板或者不嚴重但是發(fā)生頻次很高的問題應看板或者不嚴重但是發(fā)生頻次很高的問題4Quality gates are an inspection placed at a key point in the production line to drive defects back to their source and prevent them from going forward.質量質量門是對生產線關鍵點的檢查，從而使不合格控制在源頭，防止其向下流動門是對生產線關鍵點的檢查，從而使不合格控制在源頭，防止其向下流動4Th

34、e quality gate is followed by a verification station (usually the end of line inspection / containment) to ensure the gate is working by measuring how many make it past the inspection gate.質量門有一個驗證工序（經常在線尾檢查質量門有一個驗證工序（經常在線尾檢查/遏制），通過測量的數量確保質量門在工作遏制），通過測量的數量確保質量門在工作4The idea is to address the quality

35、issue as close to the source as possible and not add value to a defective part. Likewise, if defects are driven back from a mid point in the line the chances of getting a defect to the end of the line are dramatically decreased.質量門是使質量問題盡可能的接近源頭，對不合質量門是使質量問題盡可能的接近源頭，對不合格品不增值。此外，如果不合格品在生產線的中部被發(fā)現，那么流到

36、先為的概率就格品不增值。此外，如果不合格品在生產線的中部被發(fā)現，那么流到先為的概率就會大大地降低會大大地降低4Typically the top 5 defects from that line are put on the gate.通過生產線前五位通過生產線前五位典型的問題來設置質量門典型的問題來設置質量門What are Quality Gates質量門是什么質量門是什么? Quality gates can be used to improve the visibility of quality in the production process as well as being us

37、ed to measure and monitor quality in real time at strategic points.質量門用于提升生產過程的質量可視化，同時也用于在關鍵點實時的測量和監(jiān)控質量 Quality gates are designed to facilitate the detection, discussion and resolution of Issues and problems through a collaborative effort to improve the quality of products.設計質量門，通過團隊的努力，促進質量問題的探測、

38、討論和解決，從而提升產品質量 Its more then just in process inspection不僅僅是過程檢驗Why Use Them?為什么要使用質量門為什么要使用質量門 Model of accountability and responsibility for productionProcesses.對生產過程的責任模式 The ability to detect and rectify problems early on.提前發(fā)現和糾正問題的能力 Predetermined expectations of acceptable levels ofQuality.質量可接

39、受水平的預期 Documentation and monitoring of issues and actionsthroughout the production cycle.問題的記錄/監(jiān)控，生產周期的行動 The creation of a store of corporate knowledge.企業(yè)知識商店的建立Benefits of Implementing實施后的受益實施后的受益Assessment Framework評估框架 “statistical risk”統計風險Is a Quality Gate Necessary?質量門是否是必要的？質量門是否是必要的？Quality

40、 Gates質量門質量門How are they set up?如何設置如何設置4The gate should be as close to the defect occurrence as possible and situated such that the inspector can record data.質量門應該盡可質量門應該盡可能的和問題發(fā)生的地方接近，同時方便檢查人員記錄數據能的和問題發(fā)生的地方接近，同時方便檢查人員記錄數據4For each defect an alarm limit is calculated based on the occurrence of the

41、defect.針對每個缺陷，基于問題發(fā)生的頻次計算警戒線針對每個缺陷，基于問題發(fā)生的頻次計算警戒線4A data recording sheet and immediate response sheet are given to the gate inspector. 給質量門的檢查人員一個數據記錄表和反應表給質量門的檢查人員一個數據記錄表和反應表4A verification station is identified or created after the gate towards the end of the production line to measure how well th

42、e gate worked. 在生產線線尾設定驗證的崗位，測量質量門的有效性在生產線線尾設定驗證的崗位，測量質量門的有效性4The inspector at the verification station must be equipped to record any defects that they may find.在驗證崗位應該配備檢查人員，記錄他在驗證崗位應該配備檢查人員，記錄他們發(fā)現的任何問題們發(fā)現的任何問題 6 Components6個方面: Placement 位置 Where will it be located?位置設定在哪？ Quality Measures 質量測量 W

43、hat will we check and how?測量什么，怎么測量？ Roles角色 Who will check and who will be notified?誰檢查，通知誰？ Tolerance限度What level is acceptable?什么樣的水平是可以接受的 Actions 行動Response to findings? ESCALATION 問題的反應？升級 Evaluation評估Review and trend analysis 回顧，趨勢分析6 Items To Consider During Setup設置質量門要考慮的設置質量門要考慮的6個方面?zhèn)€方面Qua

44、lity Gate Documents質量門的文件質量門的文件Quality Gate Documents質量門的文件質量門的文件Example of a Quality Gate Board:質量門看板的例子質量門看板的例子Trend charts for each defect每個問題的趨勢圖每個問題的趨勢圖Enter and Exit charts for each defect每個問題進每個問題進/表圖表表圖表The immediate response sheets for each shift.每每個班次快速反應表個班次快速反應表Corrective Actions for eac

45、h issue.每個問題的糾正每個問題的糾正措施措施Quality Gate Board質量門看板質量門看板Quality Gate Board質量門看板質量門看板Data Collection Sheet 數據收集表數據收集表Immediate Response Sheet 快速反應表快速反應表CLASS ACTIVITY #5 30min課堂活動課堂活動#5-30分鐘分鐘4BUILDING HONGBAOs 建立紅包 Receiving進料檢驗 Painting噴漆 Gate門 sembly Coin To Envelope將硬幣裝進紅包 Assembly Note To Envelope

46、將標簽裝進紅包 Assembly Tab To Envelope將紅包的封上 Containment 遏制 Warehouse 倉庫 Shipping發(fā)交 Customer客戶Quality Gates質量門質量門Process - How do they work?過程過程-如何運行如何運行When the alarm limit for that defect is reached at the gate, the inspector immediately calls the appropriate person to take action. This could be a line

47、supervisor, a process engineer, a quality engineer, superintendent etc 質量門的缺陷達到警戒線，檢查人員立質量門的缺陷達到警戒線，檢查人員立即通知相關人員采取措施。人員可能是線長，工藝工程師，質量工程師，更高級別的人員等等即通知相關人員采取措施。人員可能是線長，工藝工程師，質量工程師，更高級別的人員等等The inspector notes who they called and the time.檢查人員通知相關人員和時間檢查人員通知相關人員和時間The person that is called is responsib

48、le for taking immediate action to resolve the issue. They are empowered with the ability to call anyone to their aid up to and including senior management.被通知的人員負責立即采取行動來解決問題。他們被授權可以通知任何被通知的人員負責立即采取行動來解決問題。他們被授權可以通知任何人來幫組，包括高級管理人員。人來幫組，包括高級管理人員。The action can be adjustment of process parameters, sor

49、ting raw product, retraining operators, etc 行動可能是調整過程參數，挑選原材料，對操作者再培訓等等行動可能是調整過程參數，挑選原材料，對操作者再培訓等等The person taking action notes the time when product coming to the gate will be clean.采取行動的人注意，當產品進入質量門后清零。采取行動的人注意，當產品進入質量門后清零。When the clean point is reached the tally of defects towards the alarm lim

50、it resumes and the process starts again.當清零后，問題的數量再次達到警戒線，流程重新開始。當清零后，問題的數量再次達到警戒線，流程重新開始。At the gate several metrics are posted to show the current trend for the gate defects.在質量門，張貼幾種衡量指標來顯示當前質量門問題的趨勢。在質量門，張貼幾種衡量指標來顯示當前質量門問題的趨勢。Metrics include指標包含指標包含: - First time through for those defects on the

51、 gate. 質量門問題的一次通過合格率。質量門問題的一次通過合格率。 - Quality Calendar detailing by day if their have been any concerns at the customer or internally with the product line.質量日歷描述每天顧客出的質量問質量日歷描述每天顧客出的質量問題和生產線內部的質量問題題和生產線內部的質量問題 - A chart of the top 5 or 10 defects for that production line.生產線前五位或前十位生產線前五位或前十位問題圖表問題圖

52、表 - A chart indicating how many defects entered the gate and how many exited the gate. (qty at gate & qty at verification station)描述進入質量門的問題描述進入質量門的問題數量和出質量門問題數量的圖表（質量門的質量數量和出質量門問題數量的圖表（質量門的質量&驗證工序的質量）驗證工序的質量） - A copy of the last review that management did of the gate.有一份最后一次管理有一份最后一次管理層對質量

53、所做的工作的回顧層對質量所做的工作的回顧 - A copy of the corrective action from the issue champion.有一份主要問題的糾正有一份主要問題的糾正措施措施How do you measure their effectiveness? 如何測量他們的有效性如何測量他們的有效性Enter / Exit chart入入/出圖表出圖表Quality Calendar質量日歷質量日歷Top 5 Defects Chart前五位問題的圖表前五位問題的圖表First Time Through chart一次通過合格率圖表一次通過合格率圖表Key Metri

54、cs posted on the gate張貼在質量門的關鍵衡量指標張貼在質量門的關鍵衡量指標2. Daily the supervisor, quality engineer, and shift superintendent meet to review the defects found at the gate. The goal of the meeting is to ensure that the actions taken were effective and timely.每日主管、質量工程師，當班的主管開每日主管、質量工程師，當班的主管開會，一起回顧質量門產生的不合格。會議的

55、目的是確認措施的有效性和及時性會，一起回顧質量門產生的不合格。會議的目的是確認措施的有效性和及時性Questions asked during the review include回顧期間需要詢問的問題包括回顧期間需要詢問的問題包括: - Where the actions listed for this defect effective at resolving the issue or keeping it from getting to the gate? 解決問題或防止不合格流到質量門的措施解決問題或防止不合格流到質量門的措施有效性有效性 - Did the person who wa

56、s called respond quick enough to the issue? (15min max is the rule of thumb)被通知來快速解決問題的人員是否勝任？（最多被通知來快速解決問題的人員是否勝任？（最多15分鐘分鐘是經驗法則）是經驗法則） - Are we calling the appropriate people to help us fix the issue?我們是否通知了我們是否通知了合適的人員來幫組我們解決問題合適的人員來幫組我們解決問題 - Do we need to elevate any of the issues to get better

57、 results?我們是否需要提出我們是否需要提出任何問題，從而讓結果更好任何問題，從而讓結果更好How do you measure theireffectiveness? (continued)如何測量他們的有效性（繼續(xù)）如何測量他們的有效性（繼續(xù)）3. Daily or weekly depending on the need, management meets with all the issue champions, the supervisors, quality engineers etc. The meeting is held at the gate to ensure operator visibility.每日或每周的會議根據需要，管理層和主管、質量每日或每周的會議根據需要，管理層和主管、質量