美资企业内训资料(PPT)

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1.6TOOL?100PPMQUALITYPROCESSOS&D*SequentialInspectionMainProcessControlTimeCheckQualityAuditReviewMeeting123456PerfectCheckSystemCultivatingTeamSkillImplement6TOOL*OS&D:Over,Shortage&Defect100PPM第一页，共二十八页。

12.6TOOL-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-up100PPM第二页，共二十八页。

22.6TOOL-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&TransportationReturnDataReplacementfordefectiveparts100PPM第三页，共二十八页。

3Self-inspectionCheck-listPreparedByCheckedByApprovedByMACHINE/MODELBUYERORIGINDATEREVISEDDATEPROCESSNAMEDRAWINGPARTSPECIFICATIONSELF-INSPECTIONMETHODREVISIONNO100PPM第四页，共二十八页。

4*OS&DStickers1.SUPPLIERDEFECT2.WORKMANSHIPDEFECT100PPM第五页，共二十八页。

5OS&DReportPreparedByCheckedByApprovedByProductionLine:DATE://S/NoPartNamePartNoDefectDescriptionVendorProd.QCWorkmanshipProd.QCTotalDefectStatusVendorNameQCSupervisorManagerPRODRemarks第六页，共二十八页。

6Pro-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-ing100PPM第七页，共二十八页。

7*SequentialinspectionGuideITEMPROCESSNAMESequentialinspectionguide100PPM第八页，共二十八页。

8*SequentialinspectionSticker100PPM第九页，共二十八页。

9Individualresult-SequentialinspectionNONameLINE:MONTH:PreparedByCheckedByApprovedBy12345678910111213141516171819202122232425262728293031PtPtPtPtPtPtPtPtPt第十页，共二十八页。

10RepairRecordNOFaultSHOP/:DATE://PreparedByCheckedByApprovedByCauseActionTakenItemQtyConcernedOperationTOTALPROD.QTY%REPAIRRemarks100PPM第十一页，共二十八页。

114.6TOOL-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-Engineering100PPM第十二页，共二十八页。

12*SignBoardMAJORPROCESSSPECIFICPROCESSCRITICALPROCESS550MM145MM100PPM第十三页，共二十八页。

13MainProcessControlSheetProductionQ’tyDefectiveQ’tyDefectiveRateDate12345678910111213141516171819202122232425262728293031TotalDefectRate(ppm)1,0002,000SHOPPROCESSNAMECATEGORYOPERATOROPENINGDATESUPERVISORTARGET100PPM第十四页，共二十八页。

145.6TOOL-4/TimeCheckToassurecomponentqualitywhichareprocessedinhouse,checkmaincontrolpointregularlyTimeCheckImageFlowChartActivity-Checkqualityperiodicallyandtakeaction-Initialinspection:.Assureinitialsettingcondition-Intermediateinspection:Check4Mvariation.Correctspecificationvariationof4Matmidofproductionday-Finalinspection:AssurethequalityoffinishedproductDecidecheckpointTakesampleCheckKeepsampleRecordingInitialIntermediateFinalEverytwohourOKNGStopproduction&checkearlyLotRecheckall(100%)Changeworkingcondition&repair-Isolaterejectedlot-Stopthedefectiveinputtothenextprocess-Decidelimitlevelandsegregate-Repairordisposal-Findoutdefectcause-Establishpermanentsolutionwithconcerneddept.100PPM第十五页，共二十八页。

15TIMECHECKSHEETCHECKEDBY(SUPERVISOR):APPROVEDBY(MANAGER):LINEPROCESSNAMEDURATION(//)~(//)CYCLEEVERY()HROPERATOR’SNAMESUPERVISOR’SNAMENoCheckitemsSignaturebysupervisorMON(/)TUE(/)WED(/)THU(/)FRI(/)SAT(/)09:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:0009:00~11:0011:00~01:0002:00~04:0004:00~06:00Specs100PPM第十六页，共二十八页。

16*TimeCheckProcessBoardTIMECHECKPROCESS550MM145MMTIMECHECKBOARDTimeCheckSheet09:00~11:0011:00~01:0002:00~04:0004:00~06:00LINE:________ITEM:_________OPERATORSUPERVISOR100PPM第十七页，共二十八页。

176.6TOOL-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.第十八页，共二十八页。

187.6TOOL-6/ReviewMeetingWemustnaturalizeourselvestopreventdefectinput&improvementofsuchdefectsthroughsystematicreview.DailyMeetingWeeklyMeetingMonthlyMeeting-Describeprocess&partsdefectwithactualmaterial-Conductedbysupervisorwithalloperators-Dodaily-Weeklymeetingtomakecounter-measure(OS&D,LineRejection)-Supervisor&Manager-Onceperweek-Reviewmonthlytarget&result,establishnextmonthplan-Supervisor&AllManagers-Oncepermonth100PPM第十九页，共二十八页。

19QualityReviewReportLINEDATE//PreparedbyAPPROVALPreparedbyCheckedbyHODLQCStatus1.Rejectionrate(/)~(/)ProdQ’tyRejQ’tyPPMAPCusedAPCrejPPMrej2.Worst5items(Customer/Line)12345Problem&CauseCountermeasureDateResp.SignAPCSHOP第二十页，共二十八页。

20REJECTIONSTATUSMONTH12345678910111213141516171819202122232425262728293031TotalProductionQ’tyAPCusedQtyRejectionQ’tyAPCRej.RateDateRate(Unit:PPM)50100150200300APCrej.QtyShopRejectionRateAPCTARGET第二十一页，共二十八页。

21MonthlyLineRejectionRate2004REJECTIONRATE(PPM)JANFEBMARAPRMAYJUNJULAUGSEPOCTNOVDEC50100150200ProdQ’tyAPCusedRej.Q’tyAPCRej.RateAPCrej.ShopRej.RateAPCTARGET第二十二页，共二十八页。

221-16SigmaConceptσlevelPPM63.4523346210366,8072308,537ProcessDefectsCapabilityOpportunitySweetFruits(PerfectDesign)Bulkoffruits(Optimization)Lowerfruits(7QCtools)Groundfruits(Straightviewpt)第二十三页，共二十八页。

231-16SigmaConcept-I3SigmaLevelCompany6SigmaLevelCompany10~15%ofsalesisfailurecostHaving66,807defectsperMillionDependsonthedetectionofdefectsBelievesthathighQualityisexpensiveDoesn’tfollowsystematicapproachBenchmarkingagainstcompetingcompaniesBelieves99%isgoodenoughDefinesCTQ’sinternally5%ofsalesisfailurecost3.4defectsperMillionFocusonprocessnottoproduceDefectsBelievesthathighQualitycreateslowcostUsesD-M-A-I-CKnowhowBenchmarkingtobetheBestintheWorldBelieves99%isunacceptable.DefinesCTQ’sfromcustomerpointofview第二十四页，共二十八页。

241-16SigmaConcept-II3SigmaLevelCompany6SigmaLevelCompany54,000wrongdrugprescriptions/yearUnsafedrinkingwater2hrs/monthNotelephoneservicefor27min/week5Shortorlonglandingsattheheatheroairportinaday.1,350incorrectsurgicaloperations/week.54,000lostarticlesofmailloss/hr.1wrongdrugprescriptionin25years.Unsafedrinkingwaterfor16years.Notelephoneservicefor6secfor100years1shortorlonglandingsatHeatheroairportin10years.1incorrectsurgicaloperationfor20years.35lostarticlesofmail/year.第二十五页，共二十八页。

251-26SigmaConcept(Aspectoftools)StepsToolsDefinitionMeasurementAnalysisImprovementControlProcessMappingLogicTreeParetoAnalysisQFD,FMEAGageR&RRationalsubgroupingsProcessCapabilityHypothesisTestingRegressionGraphanalysisDOE(DesignofExperimentDirectImprovements13)SPC第二十六页，共二十八页。

261-3UnderstandingBasicconceptsofStatistics“Z“isthemeasureofprocesscapabilityZ=3Z=61σμ2σ3σLSLUSL1σμ2σ3σLSLUSL4σ5σ6σThereareequalnoOfS.DonbothsidesSoforZ=3,thetoleranceBandisdividedinto6S.DForZ=6,thetoleranceBandisDividedinto12S.DAsnumberofS.DincreasesThecurvenarrowsdown&soProcesscapabilityincreases&Thusdefectdecreases.Cp>2.0Cpk>1.5第二十七页，共二十八页。

27内容(nèiróng)总结1.6TOOL。*I&P:Incentive&Penalty。Tofilteralltherejectiononthelinebyinspectingpre-processedworktotally(100%)。LINE:MONTH:。63.4第二十八页，共二十八页。