Containment遏制Isolatingthecustomerfromdefects.將不合格產(chǎn)品隔離，防止流到客戶Containment遏制

Purpose–Process–Product目的-流程-產(chǎn)品Purpose目的:Provideafocusedefforttoisolatethecustomerfromdiscrepantproducts–especiallywhenthenormalprocessisknowntobeweak通過(guò)努力，將不合格產(chǎn)品隔離，防止流到客戶-特別是過(guò)程很弱時(shí)。Process流程:Definitionandimplementationofaformalprocessto:定義和實(shí)施一個(gè)正式的流程Conductredundantinspection指導(dǎo)額外的檢驗(yàn)Collectdataandinformation收集數(shù)據(jù)和信息PerformDatadrivencorrectiveactions基于數(shù)據(jù)制定糾正措施Product產(chǎn)品:Customersisolatedfrombadpartsresultingingreatercustomersatisfactionandmorebusinessforthesupplier防止不合格品流到客戶，從而使客戶更滿意，為供應(yīng)商帶來(lái)更多的業(yè)務(wù)

(Pathwayto0PPM通往0PPM的路徑)CLASSACTIVITY#1–30minInitialDefect

課堂活動(dòng)#1–30分鐘最初的缺陷BUILDINGHONGBAOs建立紅包Supplier供應(yīng)商Receiving進(jìn)料檢驗(yàn)AssemblyCoinToEnvelope將硬幣裝進(jìn)紅包AssemblyNoteToEnvelope將標(biāo)簽裝進(jìn)紅包AssemblyTabToEnvelope將紅包封上Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶Step1第一步:

StoptheFlowofBadParts停止不合格品流動(dòng)Lookforthespecificdefect找具體的缺陷Differentiatethe“good”fromthe“suspect”將合格產(chǎn)品和可疑產(chǎn)品區(qū)分開(kāi)。Establishunderstandableproductstandards建立易理解的產(chǎn)品標(biāo)準(zhǔn)Begindatacollection開(kāi)展數(shù)據(jù)收集Beginsortingorinspection開(kāi)展分類(lèi)和檢查IdentifyandHOLDanyquestionableparts識(shí)別并隔離任何可疑產(chǎn)品

ProperContainmentProcessInputs正常的遏制流程的輸入Action行動(dòng):AssureacomprehensiveandproperlyManagedContainmentActivityisdefined,organizedandcapableofbeingimplementedwithin4hoursifrequired確保全面的、合適的遏制管理活動(dòng)被定義，組織，如果需要的話在4小時(shí)內(nèi)實(shí)施Properlydesignatedarea合適的指定的區(qū)域Distinctlocation清晰的位置ProperLighting,equipmentandmaterialflowspace合適的燈光、設(shè)備和物料流動(dòng)空間DesignatedMaterialLocations制定的物料位置VerifiedGoodProducts被驗(yàn)證是合格產(chǎn)品VerifiedBadProduct被驗(yàn)證是不合格產(chǎn)品Q(chēng)uestionable(productsawaitingmanagement/customerdisposition)可疑產(chǎn)品（等待管理層或者是客戶處置的產(chǎn)品）Productstobesorted產(chǎn)品分類(lèi)Properwallspacetopostandrecordresults張貼和記錄結(jié)果合適的位置AdequateSpaceforProceduresandBoundarySamples有放置程序和限度樣件的充足的空間WellDefinedmethods很好的方法Howtosortandhandlematerials如何挑選和處置物料DefinedPartandContainerMarkingstrategy定義產(chǎn)品和器具的標(biāo)識(shí)策略DefinedMaterialQuarantine,Captureandreturnmethods定義物料隔離、獲取和回收的方法。DataCollectionandreportingprocess數(shù)據(jù)收集和報(bào)告流程Correctiveactionmonitoringmethods糾正措施的監(jiān)控方法DefinedCriteriatosupportContainmentExit定義支持遏制解除的準(zhǔn)則CLASSACTIVITY#1.1–30minDefectControl

課堂活動(dòng)#1.1-30分鐘不合格的控制BUILDINGHONGBAOs建立紅包Supplier供應(yīng)商Receiving進(jìn)料檢驗(yàn)AssemblyCoinToEnvelope將硬幣裝進(jìn)紅包AssemblyNoteToEnvelope將標(biāo)簽裝進(jìn)紅包AssemblyTabToEnvelope將紅包的封上Containment遏制

Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶ExplanationofContainment

遏制的解釋Explainingeffectivecontainment解釋一個(gè)有效的遏制

ContainedStateContainmentProcess遏制的流程Expectationsofeffectivecontainment–Phases期望的有效遏制-階段StoptheFlow停止流動(dòng)InstallFilter安裝過(guò)濾ProtectCustomer保護(hù)客戶CollectData&Improve收集數(shù)據(jù)改進(jìn)Data數(shù)據(jù)DailyMeeting日常會(huì)議TrackResults跟中結(jié)果CleanPipeline清理途徑RetrieveSuspect召回可以產(chǎn)品ReleaseGood放行合格產(chǎn)品KeyPoints關(guān)鍵點(diǎn)Stoptheflowofdiscrepantparts.停止不合格品的流動(dòng)Definethecontainmentactions(Sort–Rework–Dispose).定義遏制行動(dòng)（挑選-返工-處置）Collectdataanddrivecorrectiveactions收集數(shù)據(jù)，制定糾正措施CleanthePipeline清理途徑Definethematerialidentificationplan(partsandcontainers).定義物料識(shí)別計(jì)劃（產(chǎn)品和器具）Establishthescopeofexposurewithlocationandreturnofquestionablestock.建立工廠的范圍，召回有問(wèn)題的庫(kù)存Step2第二步:

DefineContainmentActions定義遏制行動(dòng)CLASSACTIVITY#2–30min(LogSheet)

課堂活動(dòng)#2-30分鐘（記錄表）

BUILDINGHONGBAOs建立紅包Supplier供應(yīng)商Receiving進(jìn)料檢驗(yàn)AssemblyCoinToEnvelope將硬幣裝進(jìn)紅包AssemblyNoteToEnvelope將標(biāo)簽裝進(jìn)紅包AssemblyTabToEnvelope將紅包的封上Containment遏制

Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶Step3第三步步:DefineMaterialIdentificationPlan定義物物料識(shí)識(shí)別計(jì)計(jì)劃Clearandeasilyidentifiable(Parts&Containers)清晰的的，易易于識(shí)識(shí)別的的（產(chǎn)產(chǎn)品&器具））Identifiespartsindifferentcategories識(shí)別不不同類(lèi)類(lèi)別下下的產(chǎn)產(chǎn)品OKPartsthathavebeensorted已經(jīng)分分類(lèi)的的合格格產(chǎn)品品SuspectPartsthatrequiresorting需要分分類(lèi)的的可疑疑產(chǎn)品品KnownBadParts已識(shí)別別的不不合格格產(chǎn)品品Q(chēng)uestionableparts––awaitingdisposition有問(wèn)題題的產(chǎn)產(chǎn)品-需要處處置Step4第四步步:Scope&LocationofQuestionableStock問(wèn)題產(chǎn)品的的范圍圍&位置WorkwithMaterialControlPeople和物料料控制制人員員一起起Identifythepartsandcreateaninventory識(shí)別零零件和和建立立庫(kù)存存Adjustinventory/feedback調(diào)整庫(kù)庫(kù)存/反饋Retrievethepartsthatneedcontainment召回需需要遏遏制的的零件件SpecialCustomers––LikeServiceParts特殊的的客戶戶-備件Speciallocationslikesecondaryprocessors特殊的的位置置-二級(jí)加加工Step4第四步步:DefineContainment/MaterialReturnPlan定義遏遏制/物料召召回計(jì)計(jì)劃Suspectmaterialcanenter可疑物物料能能夠進(jìn)進(jìn)入Materialisevaluatedandcategorized物料被被評(píng)估估和分分類(lèi)Propertymarkedgoodmaterialcanexittofinishedgoods標(biāo)識(shí)為為合格格物料料能夠夠到最最終的的成品品Properlymarkedbadmaterialcanexittodisposal標(biāo)識(shí)為為不合合格物物料進(jìn)進(jìn)入到到處置置Uncertainmaterialisheld不確定定的物物料隔隔離CLASSACTIVITY#3–30minTraceMultiple課堂活活動(dòng)#3-30分鐘追追溯各各類(lèi)別別產(chǎn)品品BUILDINGHONGBAOs建立紅紅包Supplier供應(yīng)商商Receiving進(jìn)料檢檢驗(yàn)AssemblyCoinToEnvelope將硬幣幣裝進(jìn)進(jìn)紅包包AssemblyNoteToEnvelope將標(biāo)簽簽裝進(jìn)進(jìn)紅包包AssemblyTabToEnvelope將紅包包的封封上Containment遏制Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶Step5第五步步:DefineExitStrategy定義退退出策策略Materialremainsincontainmentuntilpermanentcorrectiveactionisinplace物料處處于遏遏制狀狀態(tài)，，直到到永久久對(duì)策策實(shí)施施到位位Containmentcouldlastdays,weeksoryears.Thisisalluptoyourabilityandattitudetoaddresstherootcause遏制可可以持持續(xù)幾幾天、、幾周周、幾幾年。。主要要取決決于找找到根根本原原因的的能力力和態(tài)態(tài)度UseContainmentasaformofcorrectiveactionvalidation––把遏制制當(dāng)成成糾正正措施施驗(yàn)證證的一一種形形式resultshouldbe0結(jié)果應(yīng)應(yīng)該是是0Materialisevaluatedandcategorizeduntilacertaintriggerismet物料被被評(píng)估估和分分類(lèi)，，直到到特定定的觸觸發(fā)條條件被被滿足足(0defectsforacertaintimeframeaftercorrectiveaction)在糾正正措施施實(shí)施施后，，特定定的時(shí)時(shí)間段段內(nèi)應(yīng)應(yīng)該是是0缺陷CLASSACTIVITY#4–30min––Blind課堂活活動(dòng)#4––30分鐘-盲（帶帶上眼眼罩裝裝配））BUILDINGHONGBAOs建立紅紅包Supplier供應(yīng)商商Receiving接受AssemblyCoinToEnvelope將硬幣幣裝進(jìn)進(jìn)紅包包AssemblyNoteToEnvelope將標(biāo)簽簽裝進(jìn)進(jìn)紅包包AssemblyTabToEnvelope將紅包包的封封上Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶BasicContainmentProcessFlow基本的的遏制制流程程Review-ContainmentImprovementProcessSuggestedSteps回顧-遏制改改善流流程建建議步步驟DefinetheAreaSetup定義區(qū)區(qū)域設(shè)設(shè)定Workwithsuppliertoidentifytheareaandoutlineaplan.和供應(yīng)應(yīng)商一一起識(shí)識(shí)別區(qū)區(qū)域并并總結(jié)結(jié)出一一個(gè)計(jì)計(jì)劃IncludetheKeyElements包括關(guān)關(guān)鍵要要素PerformthephysicalrearrangementInthecontainmentareawiththeappropriatepeople在遏制制區(qū)域域，有有合適適的人人員Reviewthemethods回顧方方法WorkwiththepeopletodefinethepracticesthatmatchwithCustomerneedsandCompanyexistingmethods和人員員一起起定義義與顧顧客需需求相相匹配配的實(shí)實(shí)踐以以及公公司的的退出出方法法AnalyzetheMaterialCaptureplansandmethods分析物物料獲獲取計(jì)計(jì)劃和和方法法ThisisbestdonewithaMaterialControltypeperson.最好由由物料料控制制人員員來(lái)做做DefineTools-TrainingDoTrackandMonitorHowToActualize-ExampleContainmentAreaLayout如何實(shí)實(shí)踐-遏制區(qū)區(qū)域布布局的的案例例GoodPartsONLY!!!!“GP11/GP12””GP11/GP12標(biāo)準(zhǔn)–FinalInspectionofallaxlesoffalllineassembledatDRK在DRK的所有有離線線橋的的終檢檢4lanes––includesfinalbillout–inspectedrackshave““stickers”四個(gè)通道-？-檢查工位器器具的標(biāo)簽簽Criteriaareimmediatecustomerissues準(zhǔn)則是及時(shí)時(shí)的客戶問(wèn)問(wèn)題CustomerAttachmentpoints客戶附帶的的問(wèn)題FindingsDocumented問(wèn)題點(diǎn)記錄錄Auditisconductedin“RealTime””–finalinspectionfindingsaretreatedascustomerissues開(kāi)展實(shí)時(shí)審審核-最終檢查的的問(wèn)題點(diǎn)視視為在顧客客處發(fā)生的的問(wèn)題Teamleadersarecalledtofinalauditstation–escalationplanfollowed團(tuán)隊(duì)領(lǐng)導(dǎo)實(shí)實(shí)施最終崗崗位審核-升級(jí)計(jì)劃的的執(zhí)行IndicatorChart指標(biāo)圖表MarkingStrategies標(biāo)識(shí)策略SimpleToDo容易做QuickUnlessSituationDictatesDifferently快，除非有有特殊要求求Visual可視DocumentedLocation標(biāo)記位置LocationVisibleInInstalledPosition*裝配后位置置可視1Design/ColorperInspectionCampaign每次檢查活活動(dòng)1種設(shè)計(jì)/顏色SensitivetoPastInspections與以往的檢檢查易于區(qū)區(qū)別WeatherResistant–ProductLifeforSafetyIssues不因天氣發(fā)發(fā)生變化-產(chǎn)品生命周周期內(nèi)有安安全要求的的Pens,Pricks,Nicks,Stickers筆、？、？？、標(biāo)簽ContainmentImprovementProcess––CheckStatus遏制改善流流程-檢查狀態(tài)Expectation期望Visual科室:SimplemethodtoseeevolutionofContainment簡(jiǎn)單的方法法能夠看到到遏制的變變化-AreaSetup區(qū)域設(shè)定Distinctlocation單獨(dú)的區(qū)域域Lighting,Equipment燈光、設(shè)備備DesignatedMaterialLocations指定的物料料區(qū)域Postandrecordresults張貼和記錄錄結(jié)果BoundarySamples限度樣件-MethodsandPractices方法和實(shí)踐踐Howtosort如何挑選Markingstrategy標(biāo)識(shí)策略MaterialQuarantine,Captureandreturn物料的隔離離、獲取和和回收DataCollection數(shù)據(jù)收集Correctiveactionmonitoring糾正措施的的監(jiān)控ExitCriteria退出準(zhǔn)則XXGreenYellowRedXContainmentProcessImprovement––Summary遏制流程改改善-總結(jié)Purpose:Provideafocusedefforttoisolatethecustomerfromdiscrepantproducts–especiallywhenthenormalprocessisknowtobeweak通過(guò)努力，，將不合格格產(chǎn)品隔離離，防止流流到客戶-特別是過(guò)程程很差。Process流程:Definitionandimplementationofaformalprocessto定義和實(shí)施施一個(gè)正式式的流程:Conductredundantinspection指導(dǎo)額外的的檢驗(yàn)Collectdataandinformation收集數(shù)據(jù)和和信息PerformDatadrivencorrectiveactions基于數(shù)據(jù)制制定糾正措措施Product產(chǎn)品:ThoroughCustomerIsolationandImprovedProcess完全防止流流入到客戶戶，并改善善流程KeyPoints關(guān)鍵點(diǎn):Stoptheflowofdiscrepantparts停止不合格格品的流程程.Definecontainment(Sort––Rework–Dispose)定義遏制（（分類(lèi)-返工-處置）Collectdataanddrivecorrectiveactions基于數(shù)據(jù)制制定糾正措措施CleanthePipeline清理途徑Materialidentificationplan(partsandcontainers).物料識(shí)別計(jì)計(jì)劃（產(chǎn)品品和器具））Scope:Locationandreturnofquestionablestock.范圍：位置置及可疑庫(kù)庫(kù)存的召回回Requirements要求:Dedicatedwelllaidoutarea專(zhuān)用的，有有很好布局局的區(qū)域Properlydefinedandcontrolledmethods合適的定義義和控制方方法AdvancedTopic-LaunchContainment高級(jí)話題-發(fā)起遏制KnownPastCommonDefects知道過(guò)去共共性的問(wèn)題題PotentialNewDefects(FromGateReviews)潛在的新問(wèn)問(wèn)題（門(mén)回回顧）Version/Qty/InprocessInspectionChecks版本本/質(zhì)量量/過(guò)程程檢檢驗(yàn)驗(yàn)CustomerCriticalRequirements客戶戶關(guān)關(guān)鍵鍵的的要要求求EngineeringIssues工程程問(wèn)問(wèn)題題ManufacturingIssues制造造問(wèn)問(wèn)題題ProveOutTheProcess驗(yàn)證證過(guò)過(guò)程程ProtectTheCustomerWhileManufacturingStabilizes過(guò)程程穩(wěn)穩(wěn)定定，，保保護(hù)護(hù)客客戶戶PREVENTION預(yù)防防QualityGates質(zhì)量量門(mén)門(mén)IsolatingtheNextProcessfromfaultdefects.將不不合合格格品品隔隔離離，，防防止止流流入入到到下下道道工工序序QualitygateissuesaregenerallyselectedfromtheFastResponseBoardorissuesthataresmallinseveritybuthighinoccurrence.設(shè)定定質(zhì)質(zhì)量量門(mén)門(mén)依依據(jù)據(jù)快快速速反反應(yīng)應(yīng)看看板板或或者者不不嚴(yán)嚴(yán)重重但但是是發(fā)發(fā)生生頻頻次次很很高高的的問(wèn)問(wèn)題題Qualitygatesareaninspectionplacedatakeypointintheproductionlinetodrivedefectsbacktotheirsourceandpreventthemfromgoingforward.質(zhì)量量門(mén)門(mén)是是對(duì)對(duì)生生產(chǎn)產(chǎn)線線關(guān)關(guān)鍵鍵點(diǎn)點(diǎn)的的檢檢查查，，從從而而使使不不合合格格控控制制在在源源頭頭，，防防止止其其向向下下流流動(dòng)動(dòng)Thequalitygateisfollowedbyaverificationstation(usuallytheendoflineinspection/containment)toensurethegateisworkingbymeasuringhowmanymakeitpasttheinspectiongate.質(zhì)量量門(mén)門(mén)有有一一個(gè)個(gè)驗(yàn)驗(yàn)證證工工序序（（經(jīng)經(jīng)常常在在線線尾尾檢檢查查/遏制制）），，通通過(guò)過(guò)測(cè)測(cè)量量的的數(shù)數(shù)量量確確保保質(zhì)質(zhì)量量門(mén)門(mén)在在工工作作Theideaistoaddressthequalityissueasclosetothesourceaspossibleandnotaddvaluetoadefectivepart.Likewise,ifdefectsaredrivenbackfromamidpointinthelinethechancesofgettingadefecttotheendofthelinearedramaticallydecreased.質(zhì)量量門(mén)門(mén)是是使使質(zhì)質(zhì)量量問(wèn)問(wèn)題題盡盡可可能能的的接接近近源源頭頭，，對(duì)對(duì)不不合合格格品品不不增增值值。。此此外外，，如如果果不不合合格格品品在在生生產(chǎn)產(chǎn)線線的的中中部部被被發(fā)發(fā)現(xiàn)現(xiàn)，，那那么么流流到到先先為為的的概概率率就就會(huì)會(huì)大大大大地地降降低低Typicallythetop5defectsfromthatlineareputonthegate.通過(guò)過(guò)生生產(chǎn)產(chǎn)線線前前五五位位典典型型的的問(wèn)問(wèn)題題來(lái)來(lái)設(shè)設(shè)置置質(zhì)質(zhì)量量門(mén)門(mén)WhatareQualityGates質(zhì)量量門(mén)門(mén)是是什什么么??Qualitygatescanbeusedtoimprovethevisibilityofqualityintheproductionprocessaswellasbeingusedtomeasureandmonitorqualityinrealtimeatstrategicpoints.質(zhì)量量門(mén)門(mén)用用于于提提升升生生產(chǎn)產(chǎn)過(guò)過(guò)程程的的質(zhì)質(zhì)量量可可視視化化，，同同時(shí)時(shí)也也用用于于在在關(guān)關(guān)鍵鍵點(diǎn)點(diǎn)實(shí)實(shí)時(shí)時(shí)的的測(cè)測(cè)量量和和監(jiān)監(jiān)控控質(zhì)質(zhì)量量?Qualitygatesaredesignedtofacilitatethedetection,discussionandresolutionofIssuesandproblemsthroughacollaborativeefforttoimprovethequalityofproducts.設(shè)計(jì)計(jì)質(zhì)質(zhì)量量門(mén)門(mén)，，通通過(guò)過(guò)團(tuán)團(tuán)隊(duì)隊(duì)的的努努力力，，促促進(jìn)進(jìn)質(zhì)質(zhì)量量問(wèn)問(wèn)題題的的探探測(cè)測(cè)、、討討論論和和解解決決，，從從而而提提升升產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量Itsmorethenjustinprocessinspection不僅僅僅僅是是過(guò)過(guò)程程檢檢驗(yàn)驗(yàn)WhyUseThem?為什什么么要要使使用用質(zhì)質(zhì)量量門(mén)門(mén)?ModelofaccountabilityandresponsibilityforproductionProcesses.對(duì)生生產(chǎn)產(chǎn)過(guò)過(guò)程程的的責(zé)責(zé)任任模模式式?Theabilitytodetectandrectifyproblemsearlyon.提前發(fā)現(xiàn)和糾糾正問(wèn)題的能能力?PredeterminedexpectationsofacceptablelevelsofQuality.質(zhì)量可接受水水平的預(yù)期?Documentationandmonitoringofissuesandactionsthroughouttheproductioncycle.問(wèn)題的記錄/監(jiān)控，生產(chǎn)周周期的行動(dòng)?Thecreationofastoreofcorporateknowledge.企業(yè)知識(shí)商店店的建立BenefitsofImplementing實(shí)施后的受益益AssessmentFramework評(píng)估框架“statisticalrisk”統(tǒng)計(jì)風(fēng)險(xiǎn)IsaQualityGateNecessary?質(zhì)量門(mén)是否是是必要的？QualityGates質(zhì)量門(mén)Howaretheysetup?如何設(shè)置Thegateshouldbeasclosetothedefectoccurrenceaspossibleandsituatedsuchthattheinspectorcanrecorddata.質(zhì)量門(mén)應(yīng)該盡盡可能的和問(wèn)問(wèn)題發(fā)生的地地方接近，同同時(shí)方便檢查查人員記錄數(shù)數(shù)據(jù)Foreachdefectanalarmlimitiscalculatedbasedontheoccurrenceofthedefect.針對(duì)每個(gè)缺陷陷，基于問(wèn)題題發(fā)生的頻次次計(jì)算警戒線線Adatarecordingsheetandimmediateresponsesheetaregiventothegateinspector.給質(zhì)量門(mén)的檢檢查人員一個(gè)個(gè)數(shù)據(jù)記錄表表和反應(yīng)表Averificationstationisidentifiedorcreatedafterthegatetowardstheendoftheproductionlinetomeasurehowwellthegateworked.在生產(chǎn)線線尾尾設(shè)定驗(yàn)證的的崗位，測(cè)量量質(zhì)量門(mén)的有有效性Theinspectorattheverificationstationmustbeequippedtorecordanydefectsthattheymayfind.在驗(yàn)證崗位應(yīng)應(yīng)該配備檢查查人員，記錄錄他們發(fā)現(xiàn)的的任何問(wèn)題?6Components6個(gè)方面:–Placement位置Wherewillitbelocated?位置設(shè)定在哪哪？–QualityMeasures質(zhì)量測(cè)量Whatwillwecheckandhow?測(cè)量什么，怎怎么測(cè)量？–Roles角色Whowillcheckandwhowillbenotified?誰(shuí)檢查，通知知誰(shuí)？–Tolerance限度Whatlevelisacceptable?什么樣的水平平是可以接受受的–Actions行動(dòng)Responsetofindings?ESCALATION問(wèn)題的反應(yīng)？？升級(jí)–Evaluation評(píng)估Reviewandtrendanalysis回顧，趨勢(shì)分分析6ItemsToConsiderDuringSetup設(shè)置質(zhì)量門(mén)要要考慮的6個(gè)方面QualityGateDocuments質(zhì)量門(mén)的文件件QualityGateDocuments質(zhì)量門(mén)的文件件ExampleofaQualityGateBoard:質(zhì)量門(mén)看板的的例子Trendchartsforeachdefect每個(gè)問(wèn)題的趨趨勢(shì)圖EnterandExitchartsforeachdefect每個(gè)問(wèn)題進(jìn)/表圖表Theimmediateresponsesheetsforeachshift.每個(gè)班次快速速反應(yīng)表CorrectiveActionsforeachissue.每個(gè)問(wèn)題的糾糾正措施QualityGateBoard質(zhì)量門(mén)看板QualityGateBoard質(zhì)量門(mén)看板DataCollectionSheet數(shù)據(jù)收集表ImmediateResponseSheet快速反應(yīng)表CLASSACTIVITY#5–30min課堂活動(dòng)#5-30分鐘BUILDINGHONGBAOs建立紅包Receiving進(jìn)料檢驗(yàn)Painting噴漆Gate門(mén)semblyCoinToEnvelope將硬幣裝進(jìn)紅紅包AssemblyNoteToEnvelope將標(biāo)簽裝進(jìn)紅紅包AssemblyTabToEnvelope將紅包的封上上Containment遏制Warehouse倉(cāng)庫(kù)Shipping發(fā)交Customer客戶QualityGates質(zhì)量門(mén)Process-Howdotheywork?過(guò)程-如何運(yùn)行Whenthealarmlimitforthatdefectisreachedatthegate,theinspectorimmediatelycallstheappropriatepersontotakeaction.Thiscouldbealinesupervisor,aprocessengineer,aqualityengineer,superintendentetc…質(zhì)量門(mén)的缺陷陷達(dá)到警戒線線，檢查人員員立即通知相相關(guān)人員采取取措施。人員員可能是線長(zhǎng)長(zhǎng)，工藝工程程師，質(zhì)量工工程師，更高高級(jí)別的人員員等等Theinspectornoteswhotheycalledandthetime.檢查人員通知知相關(guān)人員和和時(shí)間Thepersonthatiscalledisresponsiblefortakingimmediateactiontoresolvetheissue.Theyareempoweredwiththeabilitytocallanyonetotheiraiduptoandincludingseniormanagement.被通知的人員員負(fù)責(zé)立即采采取行動(dòng)來(lái)解解決問(wèn)題。他他們被授權(quán)可可以通知任何何人來(lái)幫組，，包括高級(jí)管管理人員。Theactioncanbeadjustmentofprocessparameters,sortingrawproduct,retrainingoperators,etc…行動(dòng)可能是調(diào)調(diào)整過(guò)程參數(shù)數(shù)，挑選原材材料，對(duì)操作作者再培訓(xùn)等等等Thepersontakingactionnotesthetimewhenproductcomingtothegatewillbeclean.采取行動(dòng)的人人注意，當(dāng)產(chǎn)產(chǎn)品進(jìn)入質(zhì)量量門(mén)后清零。。Whenthecleanpointisreachedthetallyofdefectstowardsthealarmlimitresumesandtheprocessstartsagain.當(dāng)清零后，問(wèn)問(wèn)題的數(shù)量再再次達(dá)到警戒戒線，流程重重新開(kāi)始。Atthegateseveralmetricsarepostedtoshowthecurrenttrendforthegatedefects.在質(zhì)量門(mén)，張張貼幾種衡量量指標(biāo)來(lái)顯示示當(dāng)前質(zhì)量門(mén)門(mén)問(wèn)題的趨勢(shì)勢(shì)。Metricsinclude指標(biāo)包含:-Firsttimethroughforthosedefectsonthegate.質(zhì)量門(mén)問(wèn)題的的一次通過(guò)合合格率。-QualityCalendardetailingbydayiftheirhavebeenanyconcernsatthecustomerorinternallywiththeproductline.質(zhì)量日歷描述述每天顧客出出的質(zhì)量問(wèn)題題和生產(chǎn)線內(nèi)內(nèi)部的質(zhì)量問(wèn)問(wèn)題-Achartofthetop5or10defectsforthatproductionline.生產(chǎn)線前五位位或前十位問(wèn)問(wèn)題圖表-Achartindicatinghowmanydefectsenteredthegateandhowmanyexitedthegate.(qtyatgate&qtyatverificationstation)描述進(jìn)入質(zhì)量量門(mén)的問(wèn)題數(shù)數(shù)量和出質(zhì)量量門(mén)問(wèn)題數(shù)量量的圖表（質(zhì)質(zhì)量門(mén)的質(zhì)量量&驗(yàn)證工序的質(zhì)質(zhì)量）-Acopyofthelastreviewthatmanagementdidofthegate.有一份最后一一次管理層對(duì)對(duì)質(zhì)量所做的的工作的回顧顧-Acopyofthecorrectiveactionfromtheissuechampion.有一份主要問(wèn)問(wèn)題的糾正措措施Howdoyoumeasuretheireffectiveness?如何測(cè)量他們們的有效性Enter/Exitchart入/出圖表QualityCalendar質(zhì)量日歷Top5DefectsChart前五位問(wèn)題的的圖表FirstTimeThroughchart一次通過(guò)合格格率圖表KeyMetricspostedonthegate張貼在質(zhì)量門(mén)門(mén)的關(guān)鍵衡量量指標(biāo)2.Dailythesupervisor,qualityengineer,andshiftsuperintendentmeettoreviewthedefectsfoundatthegate.Thegoalofthemeetingistoensurethattheactionstakenwereeffectiveandtimely.每日主主管、、質(zhì)量量工程程師，，當(dāng)班班的主主管開(kāi)開(kāi)會(huì)，，一起起回顧顧質(zhì)量量門(mén)產(chǎn)產(chǎn)生的的不合合格。。會(huì)議議的目目的是是確認(rèn)認(rèn)措施施的有有效性性和及及時(shí)性性Questionsaskedduringthereviewinclude回顧期期間需需要詢?cè)儐?wèn)的的問(wèn)題題包括括:-Wheretheactionslistedforthisdefecteffectiveatresolvingtheissueorkeepingitfromgettingtothegate?解決問(wèn)問(wèn)題或或防止止不合合格流流到質(zhì)質(zhì)量門(mén)門(mén)的措措施有有效性性-Didthepersonwhowascalledrespondquickenoughtotheissue?(15minmaxistheruleofthumb)被通知知來(lái)快快速解解決問(wèn)問(wèn)題的的人員員是否否勝任任？（（最多多15分鐘是是經(jīng)驗(yàn)驗(yàn)法則則）-Arewecallingtheappropriatepeopletohelpusfixtheissue?我們是是否通通知了了合適適的人人員來(lái)來(lái)幫組組我們們解決決問(wèn)題題-Doweneedtoelevateanyoftheissuestogetbetterresults?我們是是否需需要提提出任任何問(wèn)問(wèn)題，，從而而讓結(jié)結(jié)果更更好Howdoyoumeasuretheireffectiveness?(conti