16.Qualitycontrol質(zhì)量控制11Step2步驟

2Step3步驟

3Step4步驟

4Step5步驟

5Step6步驟

6Step7步驟

7Step1步驟

1Identificationandanalysisofcurrentconditions確認(rèn)和分析當(dāng)前條件Restorationofbasicsconditions恢復(fù)基本條件Analysisofthecausesofchronicproblems分析長(zhǎng)期損失的原因Reductionandeliminationofcausesofchroniclosses減少和消除導(dǎo)致長(zhǎng)期損失的原因Establishentofconditionsforzerodefects建立零缺陷條件Improvementofmethodsofconditionsforzerodefects改善零缺陷條件的方法Maintenanceofconditionsforzerodefects維護(hù)零缺陷條件ManMachineMaterialMethodSTEP7步驟7Selecttopic選擇主題STEP1步驟1Understandsituationandsettargets了解形勢(shì)并設(shè)定目標(biāo)STEP2步驟2Planactivities計(jì)劃活動(dòng)STEP3步驟3Analyzecauses分析原因STEP4步驟4Considerandimplementcountermeasures考慮并實(shí)施對(duì)策STEP5步驟5Checkresults檢查結(jié)果STEP6步驟6Standardizeandestablishcontrol建立標(biāo)準(zhǔn)化的控制STEP7步驟7STEP6步驟6Investigationofcurrentconditions調(diào)查當(dāng)前條件STEP1步驟1Restorationoftheabnormalconditions恢復(fù)異常條件STEP2步驟2Factoranalysisofchroniclosses分析導(dǎo)致長(zhǎng)期損失的因素STEP3步驟3Reduceandeliminateallcausesofchroniclosses減少和消除導(dǎo)致長(zhǎng)期損失的所有原因STEP4步驟4Establishmentofproperconditionsforzerodefects

建立零缺陷的合適條件STEP5步驟5Maintenanceofproperconditionsforzerodefects維護(hù)零缺陷的合適條件Improvementofmaintenancemethodsofconditionsforzerodefects改善零缺陷條件的方法Machine機(jī)器Man人員Material材料Method方法Qualitymaintenance7steps維護(hù)質(zhì)量的七個(gè)步驟Problemsolving7steps解決問(wèn)題的七個(gè)步驟16.Qualitycontrol質(zhì)量控制11Step2Step1步驟1Step2步驟2Step3步驟3Step4步驟4Step5步驟5Step6步驟6Step7步驟7Definitionofcurrentconditions

確定當(dāng)前條件Firstrestoringoftheabnormalconditions首次恢復(fù)異常條件Cause-and-effectanalysisofchronicdefects長(zhǎng)期缺陷的因果分析Attackagainstthemaincausesofchronicdefects克服長(zhǎng)期缺陷的主要原因Definitionofzeroscrapcondition確定零報(bào)廢的條件Checkconditionsforzeroscraps檢查零報(bào)廢條件Improvementofzeroscrapconditions改善零報(bào)廢條件Qualitymaintenance質(zhì)量維護(hù)Proactive前瞻性Reactive反應(yīng)性Preventive預(yù)防性2Step1Step2Step3Step4Step3Level1等級(jí)1Level2等級(jí)2Level3等級(jí)3Level4等級(jí)4Level5等級(jí)5Level6等級(jí)6Level7等級(jí)7Thesevenlevelsofqualitymaintenance質(zhì)量維護(hù)的七個(gè)等級(jí)1.Defectidentificationandclassification

缺陷識(shí)別和分類(lèi)2.CompleteQAmatrix

完成QA矩陣3.TheprocessofQcomponentsdeterminationhavebeencompleted.已完成質(zhì)量零部件確定過(guò)程

4.Morethan50$ofqualityproblemshavebeensolved.

已解決50%以上的質(zhì)量問(wèn)題5.Morethan80%ofqualityproblemshavebeensolved.

已解決80%以上的質(zhì)量問(wèn)題6.Qualitycontrolparametersaresetfortheentireprocesstoguaranteequality100%attheprocess.

設(shè)定整個(gè)過(guò)程的質(zhì)量控制參數(shù)，以確保工序上100%的質(zhì)量。

7.Wellestablishedqualitycontrol

建立良好的質(zhì)量控制12345Expansionanddevelopment延伸和發(fā)展呢3Level1Level2Level3Level4L41. Defectidentificationandclassification

缺陷識(shí)別和分類(lèi) *1stQAmatrix*第一個(gè)QA矩陣 *MeasurementofCp,Cpk*Cp，Cpk測(cè)量2.CompleteQAmatrix

完成QA矩陣 *QAmatrixwith4Manalysis*含4M分析的QA矩陣3.TheprocessofQcomponentdeterminationhasbeencompletedformodelareas /machines.

已完成示范區(qū)/樣機(jī)的質(zhì)量零部件確定過(guò)程 *Sufficientzerodefectconditionshavebeenestablishedforthemodelprocesses.*已為示范過(guò)程建立了足夠的零缺陷條件。4.Morethan50%ofqualityproblemshavebeensolved.

已解決50%以上的質(zhì)量問(wèn)題5.Morethan80%ofqualityproblemshavebeensolved.

已解決80%以上的質(zhì)量問(wèn)題6.Qualitycontrolparametersaresetfortheentireprocesstoguaranteequality100% attheprocess.Everyqualityissuesareundercontrol.

設(shè)定整個(gè)過(guò)程的質(zhì)量控制參數(shù)，以確保工序上100%的質(zhì)量。所有質(zhì)量問(wèn)題均在可控范圍內(nèi)。7.Wellestablishedqualitycontrol

建立良好的質(zhì)量控制 FeedbacksystemtoEPMandEEM

早期產(chǎn)品管理和早期設(shè)備管理反饋系統(tǒng)ThesevenlevelsofQualitymaintenance質(zhì)量維護(hù)的七個(gè)等級(jí)41. Defectidentificationand5Reactive反應(yīng)性Preventive預(yù)防性

Proactive前瞻性

ControlledbyresultsCp,Cpk由結(jié)果Cp、Cpk控制Controlledbycausesforknowncausalqualityparameters由已知的因果質(zhì)量參數(shù)的原因控制Identificationof0defectconditionControlbycausesSPCofcausalqualityparameters確定零缺陷條件由因果質(zhì)量參數(shù)的原因SPC控制Approaches方法5ReactivePreventiveProactiveCo66.Resultsofthecontrols控制結(jié)果

1.Chosingtheproblemtosolve選擇要解決的問(wèn)題

Collectingdata.Choosingthecharacteristictoattack.Settingtargets(valueandexpiration)收集數(shù)據(jù)。選擇需要克服的特征。設(shè)定目標(biāo)（價(jià)值和終結(jié)）Decidingwhattodo.Definingthescheduleandassigntheresponsibility決定要執(zhí)行的內(nèi)容。確定安排表并分配責(zé)任。Verifyingthecurrentvalueofthecharacteristics.Rankingthepossiblecauses.Decidingaboutargumentstofaceup.驗(yàn)證特性的當(dāng)前值。將可能的原因分級(jí)。決定爭(zhēng)論的結(jié)果。2.Understandingthesituationandthetargets了解形勢(shì)和目標(biāo)

3.ActivityPlan活動(dòng)計(jì)劃5.Consideringandimplantingthesolution考慮和貫徹解決方案4.CauseAnalysis原因分析

Consideringthesolutions:suggestingideasforthesolutions,arguingabouthowtoimplantthem.Implantingthesolutions:planninghowtoimplantthepoints.Implantingthesolutions.考慮解決方案：提出解決方案的想法，討論如何貫徹。貫徹解決方案：計(jì)劃如何貫徹解決方案。貫徹解決方案。Verifyingtheresultsofthemeans.Comparingtheresultswiththetarget.Identifyingthetangibleandnon-tangiblebenefits驗(yàn)證方式結(jié)果，將結(jié)果與目標(biāo)進(jìn)行對(duì)比。識(shí)別有形和無(wú)形效益。7.Standardizingandestablishingthecontrol.Standardizing:establishingnewstandardsandrevisingtheoldones.Decidingthecontrolmethods,establishingthecontrol.Makingresponsiblepeoplefamiliarwithnewmethods.Trainingresponsiblepeopleandmakingsurethatbenefitsarekept.標(biāo)準(zhǔn)化：建立新標(biāo)準(zhǔn)，修改舊標(biāo)準(zhǔn)。決定控制方法，建立控制系統(tǒng)。使負(fù)責(zé)人員熟悉新方法。對(duì)負(fù)責(zé)人員進(jìn)行培訓(xùn)，確保維持效益。Step1步驟1Step2步驟2Step3步驟3Step4步驟4Step5步驟5Step6步驟6Step7步驟7AAABCqualityproblems

質(zhì)量問(wèn)題66.Resultsofthecontrols控制結(jié)果7Level1等級(jí)1Level2等級(jí)2Level3等級(jí)3Level4等級(jí)4Level5等級(jí)5Level6等級(jí)6Level7等級(jí)7Thesevenlevelsofqualitycontrol質(zhì)量控制的七個(gè)等級(jí)1.Creationofbasicknowledge創(chuàng)建基本知識(shí)

2.Extensiveuseofthesemethodsandtools廣泛應(yīng)用這些方法和工具

3.Applicationofintermediatemethodsandtools應(yīng)用中級(jí)方法和工具4.Challengetousemoreadvancedandsophisticatedmethodsandtools挑戰(zhàn)性的使用更為高級(jí)和復(fù)雜的方法和工具

5.Frominductive(analytical)approachestodeductive(design)approaches從歸納（分析）方法到演繹（設(shè)計(jì)）方法

6.Continuoussearchingforopportunitiestoimprovequalityusingmoreandmoresophisticatedmethodsandtools從歸納（分析）方法到演繹（設(shè)計(jì)）方法

7.ContinuouschallengetowardIPS持續(xù)挑戰(zhàn)理想生產(chǎn)系統(tǒng)12345Expansionanddevelopment延伸和發(fā)展7Level1Level2Level3Level4L8ThesevenlevelsofQC質(zhì)量控制的七個(gè)等級(jí)1.CreationofbasicknowledgetoattackeasilyattackablebutprofitablequalityproblemsbyusingthebasicQCmethodsandtools使用基本質(zhì)量控制方法和工具創(chuàng)建基本知識(shí)，該基本知識(shí)易于克服可克服的但可營(yíng)利的質(zhì)量問(wèn)題2.Extensiveuseofthesemethodsandtoolsfortheentireplantqualityproblems(morethan50%ofthepeople)將這些方法和工具廣泛用于整個(gè)工廠的質(zhì)量問(wèn)題（50%以上的人）。3.Applicationsofintermediatemethodsandtoolstoattackmoredifficult,chroniclebutstillattackablequalityproblems使用中級(jí)方法和工具克服更為困難、更為久遠(yuǎn)、但仍然可克服的質(zhì)量問(wèn)題。4.ChallengetousemoreadvancedandsophisticatedmethodsandtoolstoattackmostdifficultandcomplicatedQCproblems(involvementofmorethan80%ofthepeople)使用更為高級(jí)、更為復(fù)雜的方法和工具克服更為困難、更為復(fù)雜的質(zhì)量控制問(wèn)題（包含80%以上的人）。5.Frominductive(analytical)approachestodeductive(design)approaches從歸納（分析）方法到演繹（設(shè)計(jì)）方法6.Continuoussearchingforopportunitiestoimprovequalityusingmoreandmoresophisticatedmethodsandtools.Fullyengagedinqualitycontrolatalllevels.Thebestqualityamongcompetitors.100%qualityassurance.使用越來(lái)越復(fù)雜的方法和工具持續(xù)尋找提高質(zhì)量的機(jī)會(huì)。在所有等級(jí)上均全身心投入質(zhì)量控制中。在競(jìng)爭(zhēng)者中保持最佳質(zhì)量。100%質(zhì)量保證。7.ContinuouschallengetowardIPS.持續(xù)挑戰(zhàn)理想生產(chǎn)系統(tǒng)8ThesevenlevelsofQC質(zhì)量控制的七個(gè)9AAVeryimportantissues非常重要的問(wèn)題AImportantissues重要的問(wèn)題BConcernedissues關(guān)心的問(wèn)題CPreferablywantedissues最好要關(guān)注的問(wèn)題ClassificationofAA,A,BandCqualityissuesAA、A、B和C級(jí)質(zhì)量問(wèn)題的分類(lèi)9AAVeryimportantissuesAImpor10QC(Reactive)質(zhì)量控制（反應(yīng)性）1.5G2.5W+1H,5Why7WCMtools七種世界級(jí)制造工具4.10QCViewpoints十種質(zhì)量控制觀點(diǎn)5.ReactiveQAmatrix反應(yīng)性QA矩陣6.Managementofclams索賠管理7.4Manalysis4M分析8.7QCtools七種質(zhì)量控制工具9.7stepsofQCproblemsolving解決質(zhì)量控制問(wèn)題的七個(gè)步驟10.SQC

標(biāo)準(zhǔn)質(zhì)量控制10QC(Reactive)1.5G2.5W+111QC(Reactive)質(zhì)量控制（反應(yīng)性）1.5G2.5W+1H,5Why3.7WCMtools

七種世界級(jí)制造工具4.The10QCviewpoints

十種質(zhì)量控制觀點(diǎn)5.ReactiveQAmatrix

反應(yīng)性QA矩陣6.Managementofclaimscomingfrommanufacturing

生產(chǎn)制造索賠管理7.4Manalysisandcountermeasures

4M分析和對(duì)策 *HERCA *SOP

*標(biāo)準(zhǔn)操作程序 *QCofthein-comingmaterials

*來(lái)料質(zhì)量控制 *ProcesscapabilityCp,Cpk

*工序能力Cp，Cpk11QC(Reactive)質(zhì)量控制（反應(yīng)性）12QCofincomingmaterials(8stages)

來(lái)料質(zhì)量控制（8個(gè)階段）Supplier

供應(yīng)商Customer

客戶Stage階段Productiondepartment生產(chǎn)部門(mén)Inspectiondepartment

檢驗(yàn)部門(mén)Inspectiondepartment

檢驗(yàn)部門(mén)Productiondepartment

生產(chǎn)部門(mén)1---100%inspection100%檢驗(yàn)2--100%inspection100%檢驗(yàn)3-100%inspection100%檢驗(yàn)100%inspection100%檢驗(yàn)4-100%inspection100%檢驗(yàn)Samplinginspectionorcheckinspection抽樣檢驗(yàn)或復(fù)核檢驗(yàn)5100%inspection100%檢驗(yàn)Samplinginspection抽樣檢驗(yàn)Samplinginspectionorcheckinspection抽樣檢驗(yàn)或復(fù)核檢驗(yàn)6Processcontrol過(guò)程控制Samplinginspection抽樣檢驗(yàn)Checkinspectionornoinspection復(fù)核檢驗(yàn)或無(wú)檢驗(yàn)7Processcontrol過(guò)程控制Checkinspection復(fù)核檢驗(yàn)Checkinspectionornoinspection復(fù)核檢驗(yàn)或無(wú)檢驗(yàn)8Processcontrol過(guò)程控制Noinspection無(wú)檢驗(yàn)Noinspection無(wú)檢驗(yàn)Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))12QCofincomingmaterials(8138.7QCtools[cause-and-effectdiagrams,paretodiagrams,graphs,checksheets,histograms,scatterdiagrams,controlcharts]七種質(zhì)量控制工具[因果關(guān)系圖、排列圖、曲線圖、檢查表、柱狀圖、散點(diǎn)圖、控制圖表]9.7stepsofQCproblemsolving[Selecttopic,understandsituationandset targets,planactivities,analyzecauses,considerandimplement countermeasures,checkresults,standardizeandestablishcontrol)解決質(zhì)量控制問(wèn)題的七個(gè)步驟[選擇主題、認(rèn)清形勢(shì)和設(shè)定目標(biāo)、計(jì)劃活動(dòng)、分析原因、考慮和執(zhí)行對(duì)策、檢查結(jié)果、建立控制并將其標(biāo)準(zhǔn)化]10.SQCforproductcharacteristics(resultorientedSQC)產(chǎn)品特性的標(biāo)準(zhǔn)質(zhì)量控制（結(jié)果導(dǎo)向標(biāo)準(zhǔn)質(zhì)量控制）Step1–4of7stepsofqualitymaintenance

質(zhì)量問(wèn)題七個(gè)步驟中的步驟1-4Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))138.7QCtools[cause-and-e14QC(Preventive)質(zhì)量控制（預(yù)防性）PreventiveQAmatrix預(yù)防性QA矩陣2.SQC

標(biāo)準(zhǔn)質(zhì)量控制3.Step5,6of7stepsofqualityMaintenance質(zhì)量維護(hù)七個(gè)步驟中的步驟5和6

Visualization可視化5.HERCA6.Errorproofing,Foolproofing防錯(cuò)、防誤VisualSOP可視化標(biāo)準(zhǔn)操作程序8.QCofin-comingmaterials來(lái)料質(zhì)量控制9.QAnetworkQA網(wǎng)絡(luò)10.Claimstrendanalysi索賠趨勢(shì)分析Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))14QC(Preventive)PreventiveQA15QC(Preventive)

質(zhì)量控制（預(yù)防性）1.PreventiveQAmatrix

預(yù)防性QA矩陣2.SQCforcauses(Processcontrol)

原因標(biāo)準(zhǔn)質(zhì)量控制（過(guò)程控制）3.Step5,6of7stepsofqualitymaintenance

質(zhì)量維護(hù)七個(gè)步驟中的步驟5和6 -Xmatrix,QMmatrix,P

PAX矩陣，QM矩陣，PPA -Fivequestionsforzerodefects

零缺陷的五個(gè)問(wèn)題 - Minimalcheckingtimeforzerodefectsconditions

零缺陷條件的最少檢查時(shí)間4.Visualizationofprocessingpoint

處理點(diǎn)的可視化5.HERCA–TWTTP

HERCA—教育員工的方法6.Errorproofing,foolproofing

防誤、防錯(cuò)7.VisualSOPcombinedwithQgate

可視化標(biāo)準(zhǔn)操作程序與質(zhì)量門(mén)相結(jié)合8.QCofin-comingmaterials

來(lái)料質(zhì)量控制9.QAnetwork

QA網(wǎng)絡(luò)10.Claimstrendanalysis

索賠趨勢(shì)分析Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))15QC(Preventive)質(zhì)量控制（預(yù)防性）Qua16ERRORANALYSIS錯(cuò)誤分析

MATERIAL材料

MACHINE機(jī)器

METHOD方法

MAN

人員

TWTTP

教育員工的方法

ACTION

行動(dòng)

HUMANERRORSROOTCAUSE

人為失誤根本原因CERTIFICATIONTWTTP

證明TWTTP

MONITORING

監(jiān)督

EXTENSION/STANDARDIZATION

延伸/標(biāo)準(zhǔn)化PROCESSWEAKNESS工藝缺陷Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))16ERRORANALYSISMATERIAL材料MAC17QC(Proactive)質(zhì)量控制（前瞻性）1.Step7步驟72.New7QCtools

七種質(zhì)量控制新工具3.Useofvarioustools使用各種工具4.ProactiveQAMatrix

前瞻性QA矩陣5.QFD

質(zhì)量功能部署6.DRsystem

DR系統(tǒng)7.Reliabilityengineering

FTA,FMEA可靠性工程，F(xiàn)TA，F(xiàn)MEA8.DOE+ANOVA9.DF(X)10.RobustDesign穩(wěn)健設(shè)計(jì)Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))17QC(Proactive)1.Step7步驟718QC(Proactive)質(zhì)量控制（前瞻性）1.Step7of7stepsofqualitymaintenance:Easycheckingfor maintenanceandzerodefectsconditions,質(zhì)量維護(hù)七個(gè)步驟中的步驟7：簡(jiǎn)單檢查維護(hù)和零缺陷條件 HERCA–TWTTP–Identificationatoneofthreephases(perception,judgmentandaction)anditspropercountermeasureHERCA—TWTTP—在三個(gè)階段（感知、判斷和行動(dòng)）中的一個(gè)階段進(jìn)行識(shí)別及其合適的對(duì)策2.Thenew7QCtools[relationsdiagrams,systematicdiagrams,matrixdiagrams,affinitydiagrams,arrowdiagrams,processdecisionprogramcharts,matrixdataanalysis]七種質(zhì)量控制新工具（關(guān)系圖、系統(tǒng)圖、矩陣圖、分類(lèi)圖、矢量圖、過(guò)程決定計(jì)劃流程圖、矩陣數(shù)據(jù)分析）3.Useofvarioustoolsofstatisticalanalysessuchasregressionanalysis,multi-variantanalysis,etc.使用各種系統(tǒng)分析工具，如：回歸分析、多元分析等。4.ProactiveQAmatrix前瞻性QA矩陣5.QFD,processQFD質(zhì)量功能部署、過(guò)程質(zhì)量功能部署6.DRsystem,DRBFD(DRbasedonfailuremodes)DR系統(tǒng)，DRBFD（基于故障模式的DR）7.Reliabilityengineering,FTA,FMEA,processFMEA,FMECA可靠性工程、FTA、故障模式和影響分析、過(guò)程故障模式和影響分析、FMECA8.DOE+ANOVA, Factorialdesign,Orthogonalarray, Parameterdesign, Tolerancedesign

因子設(shè)計(jì)、正交陣列、參數(shù)設(shè)計(jì)、公差設(shè)計(jì)9.DF(X)10.Robustdesign,Taguchimethods

穩(wěn)健設(shè)計(jì)，田口法Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))18QC(Proactive)質(zhì)量控制（前瞻性）Quali19QC(Proactive)質(zhì)量控制（前瞻性）1.Step7

步驟72.New7QCtools七種質(zhì)量控制新工具3.Useofvarioustools使用各種工具4.ProactiveQAMatrix前瞻性QA矩陣5.QFD

質(zhì)量功能部署6.DRsystem

DR系統(tǒng)7.ReliabilityengineeringFTA,

FMEA可靠性工程，F(xiàn)TA，F(xiàn)MEA

8.DOE+ANOVA9.DF(X)10.RobustDesign穩(wěn)健設(shè)計(jì)Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))19QC(Proactive)1.Step7步驟20QC(Proactive)

質(zhì)量控制（前瞻性）1.Step7of7stepsofqualitymaintenance:Easycheckingfor maintenanceandzerodefectsconditions,質(zhì)量維護(hù)七個(gè)步驟中的步驟7：簡(jiǎn)單檢查維護(hù)和零缺陷條件,2.Thenew7QCtools[relationsdiagrams,systematicdiagrams,matrixdiagrams,affinitydiagrams,arrowdiagrams,processdecisionprogramcharts,matrixdataanalysis]七種質(zhì)量控制新工具（關(guān)系圖、系統(tǒng)圖、矩陣圖、分類(lèi)圖、矢量圖、過(guò)程決定計(jì)劃流程圖、矩陣數(shù)據(jù)分析）3.Useofvarioustoolsofstatisticalanalysessuchasregressionanalysis,multi-variantanalysis,etc.使用各種系統(tǒng)分析工具，如：回歸分析、多元分析等。4.ProactiveQAmatrix前瞻性QA矩陣5.QFD,processQFD質(zhì)量功能部署、過(guò)程質(zhì)量功能部署6.DRsystem,DRBFD(DRbasedonfailuremodes)DR系統(tǒng)，DRBFD（基于故障模式的DR）7.Reliabilityengineering,FTA,FMEA,processFMEA,FMECA可靠性工程、FTA、故障模式和影響分析、過(guò)程故障模式和影響分析、FMECA

8.DOE+ANOVA, Factorialdesign

因子設(shè)計(jì) Orthogonalarray

正交陣列 Parameterdesign

參數(shù)設(shè)計(jì) Tolerancedesign

公差設(shè)計(jì)9.DF(X)10.Robustdesign,Taguchimethods

穩(wěn)健設(shè)計(jì)，田口法Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))20QC(Proactive)質(zhì)量控制（前瞻性）Qua21CriteriatoEvaluateAchievementLevel–QualityControl

評(píng)估實(shí)現(xiàn)等級(jí)的標(biāo)準(zhǔn)—質(zhì)量控制(6)QualityControlEvaluationLevels

質(zhì)量控制評(píng)估等級(jí)

0.[Noaction]NoproperQualityControlispracticed.Basedoninspectionthegoodandrejectsaresortedout.NomeasurementofCp,Cpk.[無(wú)行動(dòng)]未實(shí)行合適的質(zhì)量控制。通過(guò)檢驗(yàn)，將合格與不合格的產(chǎn)品分開(kāi)。未測(cè)量Cp，Cpk。 1.[Overallview,4Manalysis,measurementofCp,Cpk]QAmatrixdeveloped–analyzingexternal(customer)qualityissuesandinternallyidentifieddefects.Quantityandcostimpactofqualitydefectsareclearlyidentified.Managingdefectsandemergencydefectpreventionworkordersystem.BasedonQAmatrix,modelprocessesforQualityControlhavebeenchosen,and4Manalysisatcriticalprocessareasisappliedproperly.Formachinerelatedqualityproblems,Step1~Step4ofQMhavebeenimplemented.Step1–7ofQC7stepsappliedtothefollowings:[全貌圖、4M分析、Cp和Cpk測(cè)量]發(fā)展QA矩陣—分析外部（客戶）質(zhì)量問(wèn)題并識(shí)別內(nèi)部缺陷。明確定義質(zhì)量缺陷的數(shù)量和成本影響。管理缺陷和緊急缺陷預(yù)防工作指令系統(tǒng)。根據(jù)QA矩陣選擇了質(zhì)量控制示范過(guò)程。將4M分析合理運(yùn)用于關(guān)鍵過(guò)程區(qū)域。對(duì)于有質(zhì)量問(wèn)題的機(jī)器，執(zhí)行了質(zhì)量管理步驟1-4。將質(zhì)量控制步驟1-7應(yīng)用于以下方面： materials:inputcontrol

材料：輸入控制 method:SOP

方法：標(biāo)準(zhǔn)操作程序 Man:Errorproofing,foolproofing,training

人員：防誤、防錯(cuò)、培訓(xùn) TheresultsimproveQualityControlgivingbenefits.Cp,Cpkaremeasured.結(jié)果為提高了質(zhì)量控制，產(chǎn)生了效益。測(cè)量Cp和Cpk。Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))21CriteriatoEvaluateAchieve22

2.[Establishmentofconditionsforzerodefectsformodelareas]Step5ofQMtothemodelprocesses.Fivequestionsforzerodefectsareraisedatthecriticalprocessingpointtoidentifyrootcausesofqualityproblems.Conditionsforzerodefectsareknownformorethan40percentofthequalityproblemsandoperatingstandardsarewellestablishedforthem.[建立示范區(qū)零缺陷條件]質(zhì)量管理步驟5用于示范過(guò)程。在關(guān)鍵處理點(diǎn)提出零缺陷的五個(gè)問(wèn)題，以識(shí)別質(zhì)量問(wèn)題的根本原因。將零缺陷條件應(yīng)用于40%以上的質(zhì)量問(wèn)題，并為其建立良好的操作步驟。

Forequipmentrelatedqualityproblems,Step1–4ofQMtoAAmachineshavebeenimplemented.Cp,Cpkaremeasured.對(duì)于有質(zhì)量問(wèn)題的設(shè)備，已對(duì)AA級(jí)的機(jī)器執(zhí)行了質(zhì)量管理的步驟1-4。測(cè)量Cp和Cpk。 Fornonequipmentrelatedqualityproblems,Step1–7ofQChavebeenimplemented:對(duì)于無(wú)質(zhì)量問(wèn)題的設(shè)備，執(zhí)行了質(zhì)量控制的步驟1-7： ForMaterials,materialinputcontroliswellestablished.關(guān)于材料，建立了良好的材料輸入控制系統(tǒng) ForMethods,SOPiswellestablishedtoguaranteequalityattheprocesses.關(guān)于方法，建立良好的標(biāo)準(zhǔn)操作程序，以確保工序質(zhì)量。 ForMan(humanerrors),TWTTPisextensivelyapplied,foolprooforerrorproofingdevicesarewellinstalled.Forthelackofknowledgeandskills,propereducationandtrainingaredone.對(duì)于人員（人為失誤），廣泛應(yīng)用了TWTTP，且安裝了防誤或防錯(cuò)裝置。對(duì)于缺乏知識(shí)和技能的員工，進(jìn)行了合適的教育和培訓(xùn)。

CriteriatoEvaluateAchievementLevel–QualityControl

評(píng)估實(shí)現(xiàn)等級(jí)的標(biāo)準(zhǔn)—質(zhì)量控制Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))22 2.[Establishmentofcondit23

3.[Establishmentofconditionsforzerodefects,applicationofPPAfordifficultandchronicproblems]Forequipmentrelatedqualityproblems,Step1–5ofQMhavebeenimplemented.PPAisappliedatthecriticalprocessingpointstodetermineunknowncausesofqualityproblems.Forequipmentrelatedqualityproblems,X-matrixandQM-matrixaremadetoestablishoperatingstandards.Theapproachismovingfrompreventivetoproactive.[建立零缺陷條件，將PPA應(yīng)用于困難且長(zhǎng)期的問(wèn)題]對(duì)于有質(zhì)量問(wèn)題的設(shè)備，執(zhí)行了質(zhì)量管理步驟1-5。在關(guān)鍵處理點(diǎn)使用PPA，以確定質(zhì)量問(wèn)題的未知原因。對(duì)于有質(zhì)量問(wèn)題的設(shè)備，創(chuàng)建QM矩陣，以便建立操作標(biāo)準(zhǔn)。方法從預(yù)防性轉(zhuǎn)移到了前瞻性上。 Fornonequipmentrelatedqualityproblems,Step1–Step7ofQChasbeenimplemented:

對(duì)于無(wú)質(zhì)量問(wèn)題的設(shè)備，執(zhí)行了質(zhì)量控制的步驟1-7： ForMaterials,materialinputcontroliswellestablished.

關(guān)于材料，建立良好的材料輸入控制系統(tǒng)。 ForMethods,SOPiswellestablishedtoguaranteequalityattheprocesses.

關(guān)于方法，建立良好的標(biāo)準(zhǔn)操作程序，以確保工序質(zhì)量。 ForMan(humanerrors),foolproofing,errorproofingdevicesarewellinstalled.Foolproofdevicesareextensivelyusedincaseofabsent-mindedness,forgetfulness,carelessness,inattention,etc.

對(duì)于人員（人為失誤），安裝了防誤或防錯(cuò)裝置。防誤裝置廣泛應(yīng)用于心不在焉、健忘、粗心、疏忽等情況中。 Conditionsforzerodefectsareknownformorethan70percentofthequalityproblemsandoperatingstandardsarewellestablishedforthem.將零缺陷條件應(yīng)用于70%以上的質(zhì)量問(wèn)題，并為其建立良好的操作步驟。CriteriatoEvaluateAchievementLevel–QualityControl

評(píng)估實(shí)現(xiàn)等級(jí)的標(biāo)準(zhǔn)—質(zhì)量控制Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))23 3.[Establishmentofcondit244.[Applicationofmoreadvancedmethods]Step6ofQMformodelprocesses.Toidentifyqualityfactors,DOEand/orTaguchiMethodsareappliedtothosequalityproblemswhichprovedtobedifficulttoanalyzeevenbyPPA.Analysisofvariance(ANOVA)isappliedtoidentifythecontributionrateofeachfactor.Formajorqualityfactors,controlchartsareusedtocontrolqualitynotbyresultsbutbycauses.Step5forAAclassprocesses.Step1~Step4forAclassmachines.Theapproachismovingfrompreventivetoproactive. [應(yīng)用更為高級(jí)的方法]質(zhì)量管理步驟6用于示范過(guò)程。為識(shí)別質(zhì)量因素，將DOE和/或田口法應(yīng)用于那些甚至用PPA都難以分析的質(zhì)量問(wèn)題。用方差分析（ANOVA）法確定每種因素的貢獻(xiàn)率。對(duì)于主要質(zhì)量因素，用原因控制圖取代結(jié)果控制圖來(lái)控制質(zhì)量。步驟5用于AA級(jí)過(guò)程。步驟1-4用于A級(jí)機(jī)器。方法正從預(yù)防性轉(zhuǎn)移至前瞻性。Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))244.[Applicationofmoreadv25

5.[Theprocessiswellstabilizedandunderfullprocesscontrol.]Controlchartsareusedtocontrolqualitybycauses.[良好穩(wěn)定過(guò)程，并全面處于過(guò)程控制范圍內(nèi)]使用原因控制圖控制質(zhì)量。 Forequipmentrelatedqualityproblems:對(duì)于有質(zhì)量問(wèn)題的設(shè)備： Step7ofQMformodelprocesses.質(zhì)量管理步驟7用于示范過(guò)程。 Step6–Step7ofQMtoAAhavebeencorrectlyimplemented.已將質(zhì)量管理步驟6-7正確用于AA級(jí)過(guò)程。 Step5forAclassprocesses.步驟5用于A級(jí)過(guò)程。 Analysisofvariance(ANOVA)isappliedtoidentifythecontributionrateofeachfactor.將方差分析（ANOVA）法用于識(shí)別每種因素的貢獻(xiàn)率。 Formajorqualityfactors,controlchartsareusedtocontrolqualitynotbyresultsbutbycauses.對(duì)于主要質(zhì)量因素，用原因控制圖取代結(jié)果控制圖來(lái)控制質(zhì)量。 Theapproachisproactive.Theprocessiswellstabilizedandunderfullprocesscontrol.FeedbacktoEPMandEEM.InvolvementofQCpeopleatthedesignstageofthenewroductandthenewequipment.該方法是前瞻性的。過(guò)程得到了良好穩(wěn)定，并全面處于過(guò)程控制范圍內(nèi)。早期產(chǎn)品管理和早期設(shè)備管理反饋信息。質(zhì)量控制人員參與新產(chǎn)品和新設(shè)備的設(shè)計(jì)階段。CriteriatoEvaluateAchievementLevel–QualityControl

評(píng)估實(shí)現(xiàn)等級(jí)的標(biāo)準(zhǔn)—質(zhì)量控制Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))Qualitycontrol質(zhì)量控制培訓(xùn)教材(PPT25頁(yè))25 5.[Theprocessiswellst266.Qualitycontrol質(zhì)量控制2626Step2步驟

2Step3步驟

3Step4步驟

4Step5步驟

5Step6步驟

6Step7步驟

7Step1步驟

1Identificationandanalysisofcurrentconditions確認(rèn)和分析當(dāng)前條件Restorationofbasicsconditions恢復(fù)基本條件Analysisofthecausesofchronicproblems分析長(zhǎng)期損失的原因Reductionandeliminationofcausesofchroniclosses減少和消除導(dǎo)致長(zhǎng)期損失的原因Establishentofconditionsforzerodefects建立零缺陷條件Improvementofmethodsofconditionsforzerodefects改善零缺陷條件的方法Maintenanceofconditionsforzerodefects維護(hù)零缺陷條件ManMachineMaterialMethodSTEP7步驟7Selecttopic選擇主題STEP1步驟1Understandsituationandsettargets了解形勢(shì)并設(shè)定目標(biāo)STEP2步驟2Planactivities計(jì)劃活動(dòng)STEP3步驟3Analyzecauses分析原因STEP4步驟4Considerandimplementcountermeasures考慮并實(shí)施對(duì)策STEP5步驟5Checkresults檢查結(jié)果STEP6步驟6Standardizeandestablishcontrol建立標(biāo)準(zhǔn)化的控制STEP7步驟7STEP6步驟6Investigationofcurrentconditions調(diào)查當(dāng)前條件STEP1步驟1Restorationoftheabnormalconditions恢復(fù)異常條件STEP2步驟2Factoranalysisofchroniclosses分析導(dǎo)致長(zhǎng)期損失的因素STEP3步驟3Reduceandeliminateallcausesofchroniclosses減少和消除導(dǎo)致長(zhǎng)期損失的所有原因STEP4步驟4Establishmentofproperconditionsforzerodefects

建立零缺陷的合適條件STEP5步驟5Maintenanceofproperconditionsforzerodefects維護(hù)零缺陷的合適條件Improvementofmaintenancemethodsofconditionsforzerodefects改善零缺陷條件的方法Machine機(jī)器Man人員Material材料Method方法Qualitymaintenance7steps維護(hù)質(zhì)量的七個(gè)步驟Problemsolving7steps解決問(wèn)題的七個(gè)步驟16.Qualitycontrol質(zhì)量控制11Step27Step1步驟1Step2步驟2Step3步驟3Step4步驟4Step5步驟5Step6步驟6Step7步驟7Definitionofcurrentconditions

確定當(dāng)前條件Firstrestoringoftheabnormalconditions首次恢復(fù)異常條件Cause-and-effectanalysisofchronicdefects長(zhǎng)期缺陷的因果分析Attackagainstthemaincausesofchronicdefects克服長(zhǎng)期缺陷的主要原因Definitionofzeroscrapcondition確定零報(bào)廢的條件Checkconditionsforzeroscraps檢查零報(bào)廢條件Improvementofzeroscrapconditions改善零報(bào)廢條件Qualitymaintenance質(zhì)量維護(hù)Proactive前瞻性Reactive反應(yīng)性Preventive預(yù)防性2Step1Step2Step3Step4Step28Level1等級(jí)1Level2等級(jí)2Level3等級(jí)3Level4等級(jí)4Level5等級(jí)5Level6等級(jí)6Level7等級(jí)7Thesevenlevelsofqualitymaintenance質(zhì)量維護(hù)的七個(gè)等級(jí)1.Defectidentificationandclassification

缺陷識(shí)別和分類(lèi)2.CompleteQAmatrix

完成QA矩陣3.TheprocessofQcomponentsdeterminationhavebeencompleted.已完成質(zhì)量零部件確定過(guò)程

4.Morethan50$ofqualityproblemshavebeensolved.

已解決50%以上的質(zhì)量問(wèn)題5.Morethan80%ofqualityproblemshavebeensolved.

已解決80%以上的質(zhì)量問(wèn)題6.Qualitycontrolparametersaresetfortheentireprocesstoguaranteequality100%attheprocess.

設(shè)定整個(gè)過(guò)程的質(zhì)量控制參數(shù)，以確保工序上100%的質(zhì)量。

7.Wellestablishedqualitycontrol

建立良好的質(zhì)量控制12345Expansionanddevelopment延伸和發(fā)展呢3Level1Level2Level3Level4L291. Defectidentificationandclassification

缺陷識(shí)別和分類(lèi) *1stQAmatrix*第一個(gè)QA矩陣 *MeasurementofCp,Cpk*Cp，Cpk測(cè)量2.CompleteQAmatrix

完成QA矩陣 *QAmatrixwith4Manalysis*含4M分析的QA矩陣3.TheprocessofQcomponentdeterminationhasbeencompletedformodelareas /machines.

已完成示范區(qū)/樣機(jī)的質(zhì)量零部件確定過(guò)程 *Sufficientzerodefectconditionshavebeenestablishedforthemodelprocesses.*已為示范過(guò)程建立了足夠的零缺陷條件。4.Morethan50%ofqualityproblemshavebeensolved.

已解決50%以上的質(zhì)量問(wèn)題5.Morethan80%ofqualityproblemshavebeensolved.

已解決80%以上的質(zhì)量問(wèn)題6.Qualitycontrolparametersaresetfortheentireprocesstoguaranteequality100% attheprocess.Everyqualityissuesareundercontrol.

設(shè)定整個(gè)過(guò)程的質(zhì)量控制參數(shù)，以確保工序上100%的質(zhì)量。所有質(zhì)量問(wèn)題均在可控范圍內(nèi)。7.Wellestablishedqualitycontrol

建立良好的質(zhì)量控制 FeedbacksystemtoEPMandEEM

早期產(chǎn)品管理和早期設(shè)備管理反饋系統(tǒng)ThesevenlevelsofQualitymaintenance質(zhì)量維護(hù)的七個(gè)等級(jí)41. Defectidentificationand30Reactive反應(yīng)性Preventive預(yù)防性

Proactive前瞻性

ControlledbyresultsCp,Cpk由結(jié)果Cp、Cpk控制Controlledbycausesforknowncausalqualityparameters由已知的因果質(zhì)量參數(shù)的原因控制Identificationof0defectconditionControlbycausesSPCofcausalqualityparameters確定零缺陷條件由因果質(zhì)量參數(shù)的原因SPC控制Approaches方法5ReactivePreventiveProactiveCo316.Resultsofthecontrols控制結(jié)果

1.Chosingtheproblemtosolve選擇要解決的問(wèn)題

Collectingdata.Choosingthecharacteristictoattack.Settingtargets(valueandexpiration)收集數(shù)據(jù)。選擇需要克服的特征。設(shè)定目標(biāo)（價(jià)值和終結(jié)）Decidingwhattodo.Definingthescheduleandassigntheresponsibility決定要執(zhí)行的內(nèi)容。確定安排表并分配責(zé)任。Verifyingthecurrentvalueofthecharacteristics.Rankingthepossiblecauses.Decidingaboutargumentstofaceup.驗(yàn)證特性的當(dāng)前值。將可能的原因分級(jí)。決定爭(zhēng)論的結(jié)果。2.Understandingthesituationandthetargets了解形勢(shì)和目標(biāo)

3.ActivityPlan活動(dòng)計(jì)劃5.Consideringandimplantingthesolution考慮和貫徹解決方案4.CauseAnalysis原因分析

Consideringthesolutions:suggestingideasforthesolutions,arguingabouthowtoimplantthem.Implantingthesolutions:planninghowtoimplantthepoints.Implantingthesolutions.考慮解決方案：提出解決方案的想法，討論如何貫徹。貫徹解決方案：計(jì)劃如何貫徹解決方案。貫徹解決方案。Verifyingtheresultsofthemeans.Comparingtheresultswiththetarget.Identifyingthetangibleandnon-tangiblebenefits驗(yàn)證方式結(jié)果，將結(jié)果與目標(biāo)進(jìn)行對(duì)比。識(shí)別有形和無(wú)形效益。7.Standardizingandestablishingthecontrol.Standardizing:establishingnewstandardsandrevisingtheoldones.Decidingthecontrolmethods,establishingthecontrol.Makingresponsiblepeoplefamiliarwithnewmethods.Trainingresponsiblepeopleandmakingsurethatbenefitsarekept.標(biāo)準(zhǔn)化：建立新標(biāo)準(zhǔn)，修改舊標(biāo)準(zhǔn)。決定控制方法，建立控制系統(tǒng)。使負(fù)責(zé)人員熟悉新方法。對(duì)負(fù)責(zé)人員進(jìn)行培訓(xùn)，確保維持效益。Step1步驟1Step2步驟2Step3步驟3Step4步驟4Step5步驟5Step6步驟6Step7步驟7AAABCqualityproblems

質(zhì)量問(wèn)題66.Resultsofthecontrols控制結(jié)果32Level1等級(jí)1Level2等級(jí)2Level3等級(jí)3Level4等級(jí)4Level5等級(jí)5Level6等級(jí)6Level7等級(jí)7Thesevenlevelsofqualitycontrol質(zhì)量控制的七個(gè)等級(jí)1.Creationofbasicknowledge創(chuàng)建基本知識(shí)

2.Extensiveuseofthesemethodsandtools廣泛應(yīng)用這些方法和工具

3.Applicationofintermediatemethodsandtools應(yīng)用中級(jí)方法和工具4.Challengetousemoreadvancedandsophisticatedmethodsandtools挑戰(zhàn)性的使用更為高級(jí)和復(fù)雜的方法和