QSB-質量系統(tǒng)基礎

QualitySystemsBasics質量系統(tǒng)基礎KeyStrategies關鍵戰(zhàn)略QUALITYSYSTEMSBASICS質量系統(tǒng)基礎

·

Introductions/OpeningComments.

導言/開場注釋·

Whyarewehere?

我們?yōu)槭裁丛谶@里？-6-Panel

6-面板-TopFocus

最應關注點

·

GMVideo(BoysofSummer/Paradigm)

GM錄像（夏季男孩/范例）·

QualitySystemsBasics

質量系統(tǒng)基礎-FastResponse

快速反應-ControlofNon-ConformingProduct

不合格品控制-Risk(RPN)Reduction

RPN的降低-StandardOperatorTraining

操作工標準化培訓-StandardizedWork

標準操作-LayeredAudits

分層審核-ErrorProofingVerification

防錯（即值）認證-C.A.R.E.

C.A.R.E-LessonsLearned

經驗教訓

·

DevelopEnhancedQualitySystem

開發(fā)強化質量系統(tǒng)·

DocumentChanges

文檔變化·

PresentChanges

現(xiàn)有改變

·

EstablishNextSteps

建立下一步驟-AssignFollow-upIssues

分配后續(xù)事項-IdentifyFollow-upDates

識別后續(xù)日期

·

Adjourn

休會QUALITYSYSTEMSBASICS（Continued)質量系統(tǒng)基礎（續(xù)）

Name

姓名Organization

組織CurrentPosition

現(xiàn)任職務Introductions介紹Let’sGetToKnowOneAnother!讓我們相互認識一下吧Whyarewehere?

我們?yōu)槭裁丛谶@里？Profit-CostofQualityEquation

質量的利潤成本等式QualityOrganization質量組織Cost成本Profit利潤MarketPrice市場價格0Price價格0CostCompanyinneedofQSB需要QSB的公司Cost成本Profit利潤CostofQuality質量成本CostofQuality(examples).質量成本（案例）

Scrap

廢料Repair

維修Rework

返工Containment

遏制AddedOperations&Operators

增加的操作和操作工

PremiumFreight

額外運費LossofBusiness,etc.

商業(yè)損失等0SuppliersofTheYear當年供應商SupplierPerformanceDistribution供應商績效分布Poor差ExitStrategy退出戰(zhàn)略TopFocus最應關注Exec.Champions執(zhí)行冠軍5%Maintain/Improve維持/提高90%Excellent優(yōu)5%

NewBusiness新業(yè)務UseactualSupplierBidListfromWWPPCLWebSite.使用從WWPPCL網站得到的現(xiàn)行的供應商投標表InsertSupplierslatestQuality6-PanelfromGMWWPPCLWebSite從GMWWPPCL網站填寫供應商最近的質量6-面板表Whyarewehere?

我們?yōu)槭裁丛谶@里？TointroducethesuppliertoQualitySystemsBasicsandtoidentifyopportunitiesforimprovementandsupportforGMexpectations.(QS-9000isthefoundation,theseQSBtoolsareasupplement)

為了向供應商介紹質量系統(tǒng)基礎，以及識別出能夠提高和支持GM（對產品）期望的機會（QS-9000是基礎，而QSB工具是補充）。Toestablishavision

ofwhatcanbeaccomplishedthroughutilizationofQSBtechniques.

為了建立應用QSB技術后所形成的遠景。ToobtainsuppliermanagementsupportofQSBtrainingactivity.

為了得到供應商有關QSB培訓活動的管理方面的支持。ConducttrainingofQualitySystemsBasicsKeyInitiatives.

對QSB的關鍵初始點進行培訓。?

FastResponse快速反應

FirstReactiontoanIssue對問題進行第一時間的反應?

ControlofNon-ConformingProduct(Labeling)不合格產品的控制（標簽）

Containment遏制?

Risk(RPN)Reduction風險(RPN)降低

Didweknowtheriskexisted?ErrorProofed?我們是否知道已存在的風險？錯誤被防止了么？?

StandardOperatorTraining操作工標準化培訓

Wastheoperatortrained?操作工是否已被培訓？?

StandardizedWork標準化作業(yè)

Didtheoperatorfollowstandardizedwork?操作工是否遵循了標準化作業(yè)？?

LayeredAudits分層審核

Wereleadershiplayeredauditsperformed?是否對領導層進行了分層審核??

ErrorProofingVerification防錯認證

WastheErrorProofingverified?防錯（機制）進行認證了么??

C.A.R.E.

WasC.A.R.E.inplace?(100%inspectionforhighriskitems)[e.g.Customerusedfeatures]C.A.R.E.是恰當的么？（對高風險項目是否進行了100%的檢查）[比如：客戶的習慣性特點]

?

LessonsLearned經驗教訓

KEYSTRATEGIES關鍵戰(zhàn)略

Capitalizeonoursuccesses,minimizemistakes使我們的成功增值，使我們的錯誤最小化Yeah,but....是的，但是

Wehaveconstraintsfromthelargersystem!!

我們在更大的系統(tǒng)中會遇到障礙!! Wedon’thavetime!!

我們沒有時間!! Wedon’tknowhow!!

我們不知道如何做!! Wedon’thavethetools!!

我們沒有工具!!(Weallmakeexcusesandsay,ICan’t)（我們所有的人都在制造借口，說：我不能）Quote:“Thosewhosaywecan’t,shouldgetoutofthewayofthosewhoaregettingitdone.”引用：“說‘做不了’的人應該閃開，讓那些能夠做的人來”

JoelBarker

BusinessofParadigms

Ican’t…我不能…

butWEcan!!

但是我們能!!“GMCan’tdoitalone,andwecan’texpectourSupplierstodoitaloneeither”“GM不會單獨行動，我們也不能期望供應商單獨行動Suppliers供應商WorkingTogetherToProvideHigherQualityforourCustomer一起努力以高質量回報我們的客戶通用汽車?

FastResponse快速反應?

ControlofNon-Conforming不合格品控制

Product(Labeling)產品（標簽）?

Risk(RPN)Reduction風險（RPN）降低?

StandardOperatorTraining操作工標準化培訓?

StandardizedWork標準化作業(yè)?

LayeredAudits分層審核?

ErrorProofingVerification防錯驗證?

C.A.R.E.?

LessonsLearned經驗教訓KEYSTRATEGIES關鍵戰(zhàn)略

NoMajorDisruptions無重要中斷

NoPRR’S無PRR’S+0PPM’S0PPM’S=WorldClassQuality

世界級的質量2001vs.2002J.D.PowerIQS22001vs.2002J.D.PowerIQS2Problemsper100VehiclesbyManufacturerProblemsper100VehiclesbyManufacturerPowertrainSummaryPowertrainSummaryLegend圖例20012002*TotalPowertrainincludesEngineandAutomaticTransmission全部動力總成包括發(fā)動機和自動變速器*TotalPowertrainincludesEngineandAutomaticTransmissionEngine發(fā)動機18.713.413.015.210.116.216.111.110.59.202468101214161820FordDCHondaGMPTToyotaProblemsPer100VehiclesAutoTransmission自動變速器6.12.25.95.43.95.95.15.03.63.202468101214161820FordToyotaDCHondaGMPTProblemsPer100VehiclesPassengerCarPowertrain*客車動力總成24.819.318.412.219.122.121.014.814.313.6051015202530FordDCHondaToyotaGMPTProblemsPer100Vehicles生產商每百輛車中動力總成問題概攬2001vs.2002J.D.PowerIQS22001vs.2002J.D.PowerIQS2Problemsper100VehiclesbyManufacturerProblemsper100VehiclesbyManufacturerPowertrainSummaryPowertrainSummaryLegend圖例20012002*TotalPowertrainincludesEngineandAutomaticTransmission

全部動力總成包括發(fā)動機和自動變速器Engine

發(fā)動機20.921.717.614.219.618.616.210.60510152025DCFordGMPTToyotaProblemsPer100VehiclesAutoTransmission自動變速器15.99.37.47.013.29.78.15.40510152025DCFordGMPTToyotaPassengerCarAutomaticTransmissions10.86.24.94.54.44.43.62.92.60246810124L30-EML44L60-EM304T80-EMH14T65-EMN73T40MD94T40-EMN44T65-EMN34T65-EM154T45-EMN5LightDutyTruckPowertrain*輕卡動力總成36.831.124.921.232.828.324.316.00510152025303540DCFordGMPTToyota生產商每百輛車中動力總成問題概攬我們與他人討論得到的占到45%EducatorsTellUsWeLearn&Understand教育專家告訴我們如何學習并理解10%ofwhatwehear15%ofwhatwesee20%ofwhatwebothsee&hear40%ofwhatwediscuss

withothers80%ofwhatweexperience

directlyorpractice90%ofwhatweattempttoteachothers我們聽到的占10%我們看到的占15%我們既看到又聽到的占20%我們試圖教育別人的時候所得知識占90%我們通過直接經驗或實踐得到的占80%FASTRESPONSEPROCESS快速反應過程PURPOSE:

目的：Toimmediatelyaddressqualityfailures.迅速確定質量缺陷SCOPE:范圍：Theseproceduresapplytoallmanufacturing.

這些程序應用于全部生產過程FASTRESPONSE快速反應RESPONSIBILITY:

職責：ThePlantManagerorQualityManagerareresponsibleforimplementationandexecutionofthisprocedure.工廠經理和質量經理對該程序的應用和執(zhí)行負責REQUIREMENTS:要求：Eachday,thequalityfunctionshallidentifysignificantqualityconcerns(fromthelast24hours)tobereviewedatthatday’sleadershipmeeting.Inputshouldincludecustomerconcerns,supplierconcerns,linestops,teardown,CARE(Buy-off),Dockaudits,auditissuesandotherinternalqualityconcerns.每天（相關人員）都應通過質量等式識別出重要質量關注點（最近24小時之內的），以備領導層日常會議進行回顧之用。輸入應該包括客戶關注點、供應商關注點、生產線停工、拆卸、CARE（確認）、出貨檢查、審核事項和其它內部質量關注點。FASTRESPONSE快速反應REQUIREMENTS(continued):要求（繼續(xù)）Atthatday’sleadershipmeeting,siteleadershipshallreviewsignificantqualityconcernsanddesignatetherespectiveowner(s)toreportoutatthefollowingday’sleadershipmeeting.OwnerreportoutshallbeginwiththeFastResponsetrackingsheetandshallincludetheupdated:在領導層日常會議上，現(xiàn)場領導應該對重要質量關注點進行評估，并委派相關人員在第二天的領導層會議上進行匯報。各匯報人的報告應該以快速反應跟蹤表作為開始，并包括如下更新的內容：ProblemSolvingForm問題解決表FMEA失效模式與后果分析ControlPlan控制計劃StandardizedWork(method&sequence)標準化作業(yè)（方法與順序）LayeredAudit分層審核WorkforceNotification對工作人員通知Manufacturingsiteleadershipmaydisplayavisualqualitystatus(e.g.similartosafety’sgreencross).生產現(xiàn)場領導應該展示直觀的質量狀態(tài)圖（比如：跟安全綠十字相似的圖）RECORDS:記錄Recordsshallbemaintainedperlocalprocedures.記錄應該就地保存FASTRESPONSE快速反應NoQualityDisruptions無質量中斷InternalQualityDisruption(definedlocally)內部質量中斷（現(xiàn)場定義）CustomerQualityDisruption(eg.PRR,Pull,Spill)客戶質量中斷（比如：PRR、拉力、溢出等）GMPTFLINTV-6DailyQualityChart每日質量表LEGEND:圖例Month月份Year年份January一月2002World'sBestPowertrains31292830212223242526271213141516171819202345678910111Green綠色Yellow黃色Red紅色GQP-029a世界上最好的動力總成FASTRESPONSETRACKING

(Example)快速反應追蹤（案例）EXITCRITERIA退出標準OverallStatus狀態(tài)總攬IssueNumber問題號IssueDescription問題描述DateOpened發(fā)現(xiàn)日期UnitI.D.#單位I.D#Owner責任人NextDate后續(xù)日期(ofOwnerReportouttoStaff)Containment遏制PFMEA/CPErrorProofing防錯StandardWork標準化作業(yè)LayeredAudit分層審核DateClosed關閉日期Y1Engineoutoftime10/10/00N/AMcGrath11/29/00GGYGYG2Burrsonfrontfaceofblock10/10/00N/AMcIntosh-SmithGGN/AN/AG10/11/00R3Injectorharnessplacement10/10/00N/AMcGrath11/29/00GGRGGY4Reversedthrustbearing10/11/00N/AMcGrath11/29/00GGYGGG5Proudoilgalleryplug10/12/00N/AMcIntosh-SmithGGGN/AG10/13/00Y6Looseoilpumppulleybolts10/16/00N/AMcGrath11/30/00GGGN/AYG7Unfinishedcylinderbores10/16/00N/AMcIntosh-SmithGGN/AGN/A10/17/00Y8MissingUpperBearingShells11/20/00N/AMcGrath11/30/00GGGYGR9Paintdotsfoundonloose&mis-builtparts11/21/20N/AMcGrath11/30/00GN/AN/ARROpenR10Loose7mmboltonfrontcover11/26/00N/AMcGrath12/4/00RRR??ROpenEXITCRITERIASTATUSKEYRRequiredbutnotinitiated需要，但沒有開始YInitiatedbutnotcomplete已開始，但沒有完成GComplete完成N/ANotApplicable不能實施GQP-029b責任人匯報日期FastResponse快速反應

QualitySystemsBasics

KeyStrategies質量系統(tǒng)基礎關鍵戰(zhàn)略ApplicabilitytoAIAG

QS9000ManualAIAGGS9000手冊的適用性ApplicabilitytoAIAG

APQPManualFastResponse快速反應

Firstreactiontoanissue.對問題的第一反應

FastResponseteachesthesuppliertoimmediatelyaddressqualityfailuresandprovidesasimpleeffectivetooltoorganizeandreporttheseissuesinavisualformat.Thismethodologyutilizesinputstoidentifyconcernseachdayfromtheprior24hours,assignsresponsibilityandprovidesavisualtrackingsystem.FastResponseappliestoelement4.14.2ofQS9000whichcallsforthe

effectivehandlingofcustomercomplaintsandreportsofproductnonconformitiesIntheAIAGAPQPmanualsection1.0PlanandDefineProgram,theinputsfortheplanincludesthevoiceofthecustomer.Thisencompassescomplaints,recommendations,dataandinformationfrominternalandexternalcustomers.Additionallyotheritemswhichcanassistinidentifyingcustomerconcernsare:ThingsGoneWrong(TGW)reports,Warrantyreports,capabilityindicators,Supplierplantinternalqualityreports,Problemresolutionreports,customerplantreturnsandrejections,andfieldreturnproductanalysis.AIAGAPQP手冊的適用性快速反應可以使供應商迅速確定質量缺陷，可以為解決這些問題提供一種簡單有效的工具，并以直觀的模式報告這些問題。這種方法的思想就是：每天使用輸入數據（24小時內的）來識別關注點，分配職責并提供直觀的追蹤系統(tǒng)?？焖俜磻m用于QS9000的4.14.2要素，而QS9000可以對客戶抱怨進行有效處理，并能夠報告產品的不符合性情況。在AIAGAPQP手冊1節(jié)計劃與定義項目中，計劃的輸入包括客戶意見，這包含內部和外部客戶的抱怨、建議、數據和信息。此外其它可能有助于識別客戶關注點的項目是：事件錯誤報告、保證報告、能力指示器、供應商工廠內部質量報告、問題解決報告、客戶工廠返回件、拒收件以及現(xiàn)場返回產品分析等CONTROLOFNON-CONFORMINGPRODUCT不合格品的控制PURPOSE:目的：Establishbaserequirementstoensurethatproductthatdoesnotconformtospecifiedrequirementsispreventedfromunintendeduseorinstallation.建立基本要求，以確保那些不能滿足特別要求的產品不被無意使用或安裝。SCOPE:范圍：Thisprocedureappliestoallmanufacturing.該程序應用于所有生產過程。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制RESPONSIBILITY:職責：TheManufacturingPlantManagerisresponsibleforimplementationandexecutionofthisprocedure.生產工廠經理負責該程序的應用和實施。TheManufacturingQualityManagerisresponsibleforsupportingtheimplementationofthisprocedure生產質量經理負責支持該程序的應用。REQUIREMENTS:要求：ManufacturingsitesshalluseVisualManagement-Stoplight.生產現(xiàn)場應該實行可視化管理—停止信號燈Nonconformingproductshouldbesegregated.Areasofsegregation(e.g.scrapbins,reworktables,reworkproductfloat,spillcontainmentareas)shouldbefootprintedorotherwiseclearlyidentified.不合格品應該分離開，分離區(qū)域應該標出范圍軌跡或有清晰的標示。UseDepartmentContainmentWorksheettofilloutandidentifytheareasineachdepartmentwhichwillneedtobecheckedfornon-conformingproductintheeventcontainmentactivityisinitiated.填寫部門遏制表單，標示出每個需要對不合格品進行檢驗的部門的遏制區(qū)域以啟動遏制行動CONTROLOFNON-CONFORMINGPRODUCT不合格品控制REQUIREMENTS(continued):要求（繼續(xù)）：Forproductcontainmentissues(I.e.whennonconformingproductisbeyondadepartment’sscopeofcontrol),DepartmentContainmentWorksheetsshallbecompletedforeachdepartmentcontainingsuspectproduct(thiswillensureestablishmentofaneffectivebreakpoint).對產品遏制事件（比如當不合格品超出部門控制區(qū)域時），部門遏制表單應該由包含可疑產品的各部門完成（這將確保建立有效中斷點）。Forproductcontainmentissues,allproductcontainersshallbeidentifiedinadherencetoaboveprocess.Tomaintainaneffectivebreakpoint,allconformingproductcontainersafterbreakpointshallbeidentifiedwithagreenmark(useofothercolors,exceptredandyellow,isacceptabletoindicateverificationofmultiplefeatures).Suspectandnonconformingproductshallbeidentifiedwithayelloworredpaintmarkwhenfeasible.對于產品遏制事件，所有產品容器(包裝）應該根據以上程序進行識別。為了保持有效的中斷點，所有中斷點以后的合格產品都應該以綠色進行標示（除紅、黃外，其它顏色也可以用來標示多特性的驗證情況）。在可行的情況下，可疑品和不合格品應該用黃色或紅色來標示。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制REQUIREMENTS(continued):要求（繼續(xù)）：Forproductcontainmentissues,breakpointmaintenanceshallbeverified(via100%inspectionforcontainmentidentification)foradurationspecifiedbythesiteQualityManagerordesignate.對于產品遏制事件，應該對現(xiàn)場質量經理或委派人員指定的對中斷點的維護期進行驗證（通過對遏制識別進行100%檢查來進行）。Productwhichhasbeenremovedfromtheconformingproductprocessflow(e.g.productincontainmentareas,rework/repairareas)shouldbereintroducedintotheprocessstreamatorpriortothepointofremovaltoensureallControlPlaninspectionandtestsareadheredto.從合格產品流中移除的產品（比如：遏制區(qū)域、返工/維修區(qū)域的產品）應該在移除點或之前重新引入到過程流中，以確保所有對控制計劃進行檢查和測試。Themanufacturingsiteshallclearlydefinetheprocess&authorityforreleasingproductoutofrework,repairandcontainmentareas.生產現(xiàn)場應該對返工、維修和遏制區(qū)域產品的分發(fā)過程和權限進行清晰的定義。Forproductcontainmentissues,localleadershipshallreviewtheresultsofthecontainmentuponcompletion.對于產品遏制事件，相關領導應該對遏制行動的完成情況進行評估。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產品的標簽內容應該基于現(xiàn)場人員的判斷力TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產品的標簽內容應該基于現(xiàn)場人員的判斷力TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產品的標簽內容應該基于現(xiàn)場人員的判斷力PLT001SUSPECTDONOTUSE可疑產品

不能使用OKFORUSE可以使用REQ’DFORSCRAPPRODUCT/CONTAINERS(scrapbinspaintedreddonotrequireatag)

對廢品/容器的要求(漆成紅色的廢品箱不需要標簽）REQUIREDFORSUSPECT,REWORK,REINSPECTPRODUCT/CONTAINERS對可疑品、返工品和復查品/容器的要求ANYCOLORTAGFORCONFORMINGPRODUCTISACCEPTABLE(exceptredoryellow)對于合格品，任何顏色的標示都是可以的（紅色、黃色除外）REDorYELLOWNONCONFORMINGPRODUCTTAGSSHALLBEUSEDTOIDENTIFYNONCONFORMINGPRODUCT/CONTAINERS.CONFORMINGPRODUCTIDENTIFICATIONWILLBEACCOMPLISHEDTHROUGHAVARIETYOFMETHODS(e.g.IDENTIFICATIONPLATES,SHIPPINGLABELS,PRODUCTCOLORCODING,TAGS).ANYCOLORIDENTIFICATIONISACCEPTABLEFORCONFORMINGPRODUCT(EXCEPTREDORYELLOW)-GREENISPREFERRED.紅色或黃色不合格品標簽應該被用來標示不合格產品或容器。合格品的標示應該通過不同的方法來完成（比如：標示盤、發(fā)貨標簽、產品顏色代碼、標簽等）。任何顏色的標示都可以用來標示合格品（紅、黃色除外）—綠色是首選色。6/28/00SCRAP廢料PLT002PLT003ControlOfNonconformingProduct(Labeling)不合格品控制（標簽）

RISKREDUCTIONPROCESS風險降低過程PURPOSE:目的:ToreducetheriskofallproductionprocessesbyclosingtheRPNgaptotheIdealState.通過填平RPN與理想狀態(tài)之間的差距，以降低所有生產過程的風險SCOPE:范圍：Thisprocedureappliestoallmanufacturing.該程序適用于所有生產過程POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質量缺陷RPN降低過程Part1:(Proactive)RESPONSIBILITY:職責：ThesiteManufacturingEngineerisresponsibletodrivethePFMEAprocess,facilitatemulti-disciplinaryteamsandtocoordinateRPNreductionactivities.現(xiàn)場生產工程師負責：驅動PFMEA過程，推進多功能型團隊和管理RPN降低活動。DEFINITIONS:定義：PFMEA:PotentialFailureModeandEffectsAnalysis

潛在失效模式與后果分析RPN:(RiskPriorityNumber)isanindicatorofriskbasedonPFMEASeverity,OccurrenceandDetectionrankings.（風險順序數）是一個風險指示器，該風險基于PFMEA嚴重性、發(fā)生的概率

和缺陷程度。IDEALTocalculatetheIdealState#,sumtotalallRPNnumbers,whereas:STATE:RPN’sunder40=actualRPNnumberandRPN’sover40=40

用來計算理想狀態(tài)的編號，對所有RPN數求和，但是應注意：RPN低于40時以實際RPN數計，高于40時以40計。GAP:DifferencebetweenthetotalsumofRPNandIdealState（實際）RPN總數和理想狀態(tài)間的差距。Part1:

(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質量缺陷RPN降低過程REQUIREMENTS:要求：PFMEA’sshallbecompletedforallmanufacturingprocessesasrequiredbyQS-9000.所有生產過程的PFMEA都應該按照QS9000的要求完成。TheRPNreductionprocessshallbeimplementedforthesemanufacturingprocesses.應該針對這些生產過程實施RPN降低過程。Severity,OccurrenceandDetectionrankingchartsshallbeusedincompletingthePFMEA.在完成PFMEA時，應該使用嚴重性、發(fā)生的概率和缺陷程度分級圖表。TheRPNReductionFlowDiagramshallbeadheredtointhecategorizationofrisk,establishmentofatop5list,anddevelopmentofimprovementactions.RPN降低流程圖應該遵守風險的分類原則，建立RPN的前五位名單并開發(fā)出改進行動（計劃）。Part1:(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質量缺陷RPN降低過程REQUIREMENTS(continued):要求（繼續(xù)）：TheRPNreductiontrackingchartsshouldbeupdatedmonthlytoreflectthecurrentRPNactualandidealstatenumbers.RPN降低追蹤表應該每月更新，以反應RPN的實際狀況和理想狀態(tài)。RPNreductiontrackingchartsshallbereviewedbymanufacturingsiteleadershipatafrequencydefinedlocally.根據實際情況，生產現(xiàn)場領導應該定期對RPN降低追蹤表進行回顧。Part1:(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質量缺陷RPN降低過程

*Thissection(Part1)dealtwithpotentialrisks;Thenextsection(Part2),addressespastqualityfailures(customerandinternal).Asstatedinpart1weshouldhaveanactionplantoreducethetop5RPNnumbersandasyouwillseeinpart2weshouldalsohaveanactionplantoErrorProofallpastqualityfailures.

該節(jié)（第1部分）處理潛在風險問題；后面一節(jié)（第2部分）確定以往的質量缺陷（客戶的和內部的）。就像第1部分所述，我們應該針對降低前5位的RPN來制定計劃；在第2部分，你將會看到：對于所有以往質量缺陷的防錯問題，我們也應該制訂行動計劃。Comment:注釋：Severity

嚴重性Part1:(Proactive)Occurrence

發(fā)生概率Part1:(Proactive)Detection

檢測Part1:(Proactive)RPNREDUCTION

RPN降低PFMEA'SPROCESSPFMEA過程LISTALLRPN'S列出所有PRNPARETO'SOFRPN'SRPN的排列RPNLESSTHAN40RPNBETWEEN

40-100RPNOVER100

FOREACHBUSINESSUNITORPRODUCTFAMILY針對每一個業(yè)務單位或產品類別PERIODICREVIEWSTO

ASSURENOCHANGESTOP”5"LIST前5個列表ACTIONPLANS行動計劃TRACKPROGRESS追蹤程序MANAGEMENTREVIEWS管理回顧PRIORITYACTIONPLANDEVELOPEDBYNATURALOWNER

Part1:(Proactive)RPN小于40RPN介于40-100之間RPN大于100定期回顧以確保不發(fā)生變化由相關責任人開發(fā)優(yōu)先行動計劃RPNRANGECHARTRPN范圍表

Part1:(Proactive)Part1:(Proactive)TOP5RPN

前5位RPNPart1:(Proactive)REQUIREMENTS(continued):要求（繼續(xù)）：Multi-disciplinaryteam(s)asidentifiedinRPNReduction

Responsibilityshallalsoidentifyandpareto

past

quality

failures(customerandinternal).應該確認相應的多功能型團隊在RPN降低的過程中的相應職責，并排列出過去的質量缺陷（客戶的和內部的）Team(s)shalllisttopfailuresanddesignatetruePFMEADetectionRatingforeachRPN.團隊應該列出最嚴重的缺陷并對每一個RPN分配準確的PFMEA檢測等級。Team(s)shalldevelopanactionplantoErrorProoftopfailures(whereE/Pisnotfeasible,aplantoimprovedetectionshallbeestablished).團隊應該制訂出行動計劃以便對最嚴重的缺陷防錯（在E/P不可行時，應該建立計劃以改善檢測工作）RISKREDUCTIONPROCESSERRORPROOFINGPASTQUALITYFAILURES風險降低過程過去質量缺陷的防錯

Part2:(Reactive)REQUIREMENTS(continued):要求（繼續(xù)）：ErrorproofingshallbeverifiedpertheErrorProofingVerificationProcess.每一個防錯驗證過程都應該得到驗證Team(s)shallmonitorqualityperformancefortopfailurestoensurenoreoccurrence.對于嚴重的缺陷，團隊應該監(jiān)視其質量（改善）情況以確保不再發(fā)生類似情況Manufacturingsiteleadershipshallscheduleregularprogressreviews.生產現(xiàn)場的領導應該針對規(guī)則的過程回顧制訂計劃RECORDS:記錄：Recordsshallbemaintainedperlocalprocedures.記錄應該隨地保存RISKREDUCTIONPROCESSERRORPROOFINGPASTQUALITYFAILURES風險降低過程過去質量缺陷的防錯

Part2:(Reactive)Part2:(Reactive)12MonthParetoofCustomerConcerns(Example)Risk(RPN)Reduction

降低風險（RPN）STANDARDIZEDOPERATORTRAINING操作工標準化培訓PURPOSE目標:

Todefinestandardoperatortrainingrequirement.說明操作工標準化培訓要求。SCOPE范圍:Thisprocedureappliestoallmanufacturingsites.Itappliestoalloperatorsnewtoanoperationandtooperatorrefreshertraining.該程序適用于所有的生產點，適用于所有新操作工培訓和操作工復習進修培訓。STANDARDIZEDOPERATORTRAINING操作工標準化培訓RESPONSIBILITY職責:TheProductionManagerisresponsibleforimplementationofthisprocedure.TheManufacturingsiteQualitySystemsandPersonnelstaffsareresponsibletosupportimplementationofthisprocedure.生產經理負責執(zhí)行這一程序。生產點質量系統(tǒng)和人事部門職員負責支持這一程序的執(zhí)行。REQUIREMENTS要求:Thefollowingrepresentstheminimumcontentrequirementsforoperatortrainingandshallbeusedintrainingalloperatorsnewtoanoperationandforoperatorrefreshertraining.Operatortrainingrecordsshallbeupdated(seeattachedform)foreachoperatornewtoanoperation.以下是操作工培訓的最低內容要求，應在所有的新操作工培訓和操作工復習進修培訓中使用。一有新到崗的操作工，操作工培訓記錄都應更新（見附表）。Thetrainershallreturnwithintheshift(e.g.withintheoperatorsfirst8hoursofproduction)toverifytheoperatorisadheringtostandardizedworkandtoverifytheproductqualityagain.Thetrainershallreturninapproximately1daytoverifythesameagain.培訓人員應在班次內（例如，在操作工生產的第一個8小時內）回訪，再次確認操作工遵守標準化工作，并檢驗產品質量。培訓人員應在1日內再次回訪確認相同內容。STANDARDIZEDOPERATORTRAINING操作工標準化培訓REQUIREMENTS(continued)要求（續(xù)）:Thetrainershouldnotifythedownstreamoperationsofpotentialdefects.培訓人員應事先將潛在缺陷通知后續(xù)操作點。Operatortrainingshallbetrackedonthe“TrainedOperatorTracking”sheet(attached).Thesheetdefinesminimumcontent,electronictrackingattheoperationisacceptable.The“TrainedOperatorTracking”sheetshallbepostedattheoperationandverifiedthroughprocessverification.Schedulingofrefreshertrainingforassignedoperatorsisatlocalsitediscretion.操作工培訓將以“已培訓操作工跟蹤表”（附）進行跟蹤。該表定義了最低要求，操作過程的電子跟蹤也可接受?！耙雅嘤柌僮鞴じ櫛怼睉獜堎N于操作點，并在過程驗證時進行核對。指派操作工的復習進修培訓進度由本地生產點自行決定。Supplementalemployeesshallnotperformthejobunlesstheyhavebeentrainedwithinthelastthreemonths.候補員工不得參與操作，除非最近三個月內接受過培訓。STANDARDIZEDOPERATORTRAINING操作工標準化培訓RECORDS記錄:Recordsshallbemaintainedperlocalprocedures.記錄應由本地程序進行保存。StandardizedOperation-TrainingRecord標準化操作——培訓記錄

(Example)（示例）Application

應用：:Thefollowingshallbecompletedwithanynewoperator(foranygivenoperation).

（在任何給定操作點）有任何新操作工時，以下都應填寫完整。Review評定

Complete完成Standardizedwork/jobinstructions標準化作業(yè)/工作指示Qualityrecordstobefilledout(eg.Checksheets)應填寫的質量記錄（如驗收單）Part(product)function零件（產品）功能Equipmentoperations/Safety設備操作/安全Demonstratetheoperationandanswerquestions示范操作及回答問題Demonstrategagingandanswerquestions示范量具及回答問題Havenewemployeerunoperationandanswerquestions讓新員工操作及回答問題Teachpastproblems(eg.FMEA,TopProblemsList)傳授過去的問題（如FMEA，常見問題列表）Verifyfirstunitsproduced,coachasneeded檢驗首批產品，根據需要指導Returnwithintheshift,verifystdwork&productqualityagain班次內回訪，檢驗標準化操作和產品質量Returninapprox.1day,verifystdwork&productqualityagain約一日內回訪，再次檢驗Notifydownstreamoperationsofpotentialdefects將潛在缺陷通知后續(xù)操作點EmployeeSignature

員工簽名______________TrainerSignature培訓員簽名_______________OperationNameand#

操作點名稱和號碼_______________TrainedOperatorTracking已培訓操作工跟蹤(Example)（示例）OperationName/#

操作點名稱/號碼___________________DEPT.ASSIGNEDEMPLOYEE部門指派員工SUPPLEMENTALEMPLOYEE候補員工LATESTTRAININGDATEANDTRAINERINITIALS

最近培訓日期和培訓人員姓名首字母縮寫LatestJobInstructionRev.Date最近工作指示評審日期StandardOperatorTraining

操作工標準化培訓STANDARDIZEDWORK

標準化作業(yè)(Methods&Sequence)（方法和順序）PURPOSE目的:

Todevelopstandardworkmethods&sequenceforhighriskoperations.為高風險操作形成標準的作業(yè)方法和順序。SCOPE范圍:Thisprocedureappliestoallmanufacturingsites.該程序適用于所有的生產點。STANDARDIZEDWORK(Method&Sequence)

標準化作業(yè)（方法和順序）RESPONSIBILITY職責:TheManufacturingEngineeringManagerorProductionManagerareresponsibleforimplementationandexecutionofthisprocedure.生產工程經理或產品經理負責執(zhí)行和完成該程序。REQUIREMENTS要求:Siteleadershipshallidentifymulti-disciplinaryteam(s)todrivestandardizedwork.生產點領導應確定復合型小組來進行標準化作業(yè)。Multi-disciplinaryteam(s)shallidentifyandlistallassemblyoperationsandallcriticalmanufacturingoperationstoimplementstandardizedworkwithemphasisonoperationswhichexperience:復合型小組應確定并列出所有裝配定點和所有關鍵生產定點來執(zhí)行標準化作業(yè)，并突出遇到過以下問題的定點：

CustomerQualityConcerns客戶質量問題NecessityforaDefinedSequenceorMethodofwork

需要強制順序或作業(yè)方法Off-lineRework線下返工HighRPN高風險順序數EmployeeFlow-through員工流動STANDARDIZEDWORK(Method&Sequence)

標準化作業(yè)（方法和順序）REQUIREMENTS(continued)要求（續(xù)）:Multi-disciplinaryteam(s)shalldevelopstandardizedworkandstandardizedworkprocessesshallbepostedattheoperation.復合型小組應開展標準化作業(yè)，并且標準化作業(yè)過程應張貼于操作地點。ImpactedemployeesandnewemployeesshallbetrainedintheuseofStandardizedWork(StandardOperatorTraining).Impacted員工和新員工應接受培訓來進行標準化作業(yè)（標準操作工培訓）。StandardizedworkshallbeverifiedthroughLayeredAuditsforanyoperationwhichshippedanon-conformancewithinthelast12monthsduetoafailuretoadheretostandardizedwork.在任何過去12個月中因未遵循標準化作業(yè)而發(fā)運過不合格品的生產點，標準化作業(yè)都應通過分層審核來檢驗。Multi-disciplinaryteam(s)shallcontinuouslydevelop/improvestandardizedworkbasedonongoingqualityperformance.復合型小組應基于現(xiàn)時質量表現(xiàn)不斷開展/改進標準化作業(yè)。STANDARDIZEDWORK(Method&Sequence)

標準化作業(yè)

（方法和順序）StandardizedWork

標準化作業(yè)

LAYEREDAUDITS

分層審核PURPOSE目的:

Toverifycompliancetothedocumentedmanufacturing/assemblyprocess,resultinginmoredisciplinedprocessesandimprovedoverallquality.檢驗是否符合文字記錄的生產/裝配過程，以求更多的規(guī)范過程和改進整體質量。SCOPE范圍:Thisprocedureappliestoallmanufacturing.該程序適用于所有生產。LAYEREDAUDITS分層審核RESPONSIBILITY職責:TheManufacturingPlantManagerisresponsibleforimplementat