QSBSGM

QSB

OverviewSGM

質(zhì)量系統(tǒng)基礎(chǔ)概述1SGM

ConfidentialSDE

Module

2011.042023最新整理收集do

somethingQSBProfit

-

Cost

of

Equation利潤-成本等式降低成本Cost

downScrap,

Repair,Rework,

Containment,Added

Operations

&

Operators,Premium

Freight,

Loss

of

Business,etc.廢料、維修、返工、遏制、

增加的操作和操作工、

額外運(yùn)費(fèi)、

商業(yè)損失等2SGM

ConfidentialSDE

Module

2011.04QSBProfit

-

Cost

of

Equation利潤-成本等式原材料、能源、勞動力等整車OEM廠、市場降低成本Cost

down3SGM

ConfidentialSDE

Module

2011.04QSBSupplier

Performance

Distribution供應(yīng)商績效分布0Suppliers

of

The

Year年度優(yōu)秀供應(yīng)商Poor差Top

Focus高關(guān)注Exec.

Champions最高管理者牽頭5%Maintain/Improve維持/提高NewBusinessExcellent優(yōu)5%新業(yè)務(wù)90%Workshop研討改進(jìn)Exit

Strategy退出戰(zhàn)略4SGM

ConfidentialSDE

Module

2011.04QSB快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

RiskReduction異物控制

Contamination

Control供應(yīng)鏈管理

SupplyChain

Management變更管理 Managing

Change引領(lǐng)至世界級質(zhì)量Leadto

world

class

quality無重大質(zhì)量問題No

MajorDisruptions無PR/RsNo

PR/Rs0PPM+

0

PPMWorld

Class

Quality=世界級質(zhì)量Quality

Systems

Basics質(zhì)量系統(tǒng)基礎(chǔ)5SGM

ConfidentialSDE

Module

2011.04QSBQuality

Systems

Basics質(zhì)量系統(tǒng)基礎(chǔ)質(zhì)量、過程問題Quality、Process

Issues快速響應(yīng)Fast

Response不合格產(chǎn)品的控制Control

ofNon-ConformingProduct驗(yàn)證崗位Verification

Station標(biāo)準(zhǔn)化操作Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)Standardized

Operator

Training變更管理Managing

Change分層審核Layered

Process

Audits供應(yīng)鏈管理Supply

Chain

ManagementSGM

Confidential6SDE

Module

2011.04防錯驗(yàn)證Error

Proofing

Verification風(fēng)險(xiǎn)降低RPN

Risk

Reduction異物控制Contamination

ControlQSBQSB實(shí)施關(guān)鍵點(diǎn)Key

pointsofQSBWorkshopImplementation?

抓住高報(bào)廢率，高返工等存在較大成本改善的區(qū)域Focus

on

high

cost-lost

field

,such

as

scrap,

rework,

etc..?

結(jié)合實(shí)物質(zhì)量控制方法（產(chǎn)品審核、焊接模塊、尺寸控制、注塑工藝等）Connect

with

product

quality

control

modules?

通過分層審核保障過程有效性，通過PDCA保持制造/裝配的完整性.Keep

manufacture/assemble

effect

based

on

L.P.A.

Keep

integralitythrough

PDCA?

通過快速響應(yīng)平臺促進(jìn)溝通Improve

communicate

based

on

F.R.M.?

強(qiáng)化ISO/TS

16949質(zhì)量體系Enhance

ISO/TS

16949systemQuality

Systems

Basics質(zhì)量系統(tǒng)基礎(chǔ)7SGM

ConfidentialSDE

Module

2011.04QSBQuality

Systems

Basics質(zhì)量系統(tǒng)基礎(chǔ)有效的組織Effect

Organization8SGM

ConfidentialSDE

Module

2011.04QSBQuality

Systems

Basics質(zhì)量系統(tǒng)基礎(chǔ)QSB成果QSB

Achievements9SGM

ConfidentialSDE

Module

2011.04QSBKey

Strategies關(guān)鍵策略快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

Risk

Reduction異物控制

Contamination

Control供應(yīng)鏈管理

Supply

Chain

Management變更管理

Managing

Change10SGM

ConfidentialSDE

Module

2011.04QSB用于迅速處理質(zhì)量問題的系統(tǒng)層面強(qiáng)制性的方法Systematic

and

compelling

way

forRapidReaction

to

QualityIssues? 工廠有高層領(lǐng)導(dǎo)參與的晨會嗎？(高層支持)Leadership

involved?? 會議是否對近期重大質(zhì)量問題的解決狀態(tài)進(jìn)行確認(rèn)？(及時(shí)跟進(jìn))Open

issue

closed

intime?? 會后相關(guān)責(zé)任人或團(tuán)隊(duì)是否對專項(xiàng)質(zhì)量問題進(jìn)行研討？(有效解決)Findroot

cause?? 已關(guān)閉問題是否及時(shí)總結(jié)并經(jīng)驗(yàn)推廣？（舉一反三）Lesson

learned?11SGM

ConfidentialSDE

Module

2011.041.

快速響應(yīng)Fast

ResponseQSB1.

快速響應(yīng)Fast

Response關(guān)鍵步驟Key

Steps1.收集當(dāng)天重要的質(zhì)量問題Daily

Problem

Collection2.

召開快速響應(yīng)會議Daily

Fast

Response

Meeting4.狀態(tài)跟蹤Status

Tracking3.解決問題Problem

Solving5

.經(jīng)驗(yàn)教訓(xùn)Lesson

learned12SGM

ConfidentialSDE

Module

2011.04QSB1.

快速響應(yīng)Fast

Response分供方的問題Supplier

concerns客戶關(guān)注的問題(PRR’s,客戶抱怨，客戶電話等)Customer

concerns

(PRR’s,

Liaison關(guān)鍵步驟-1：收集當(dāng)天重要的質(zhì)量問題Key

Steps

–

Daily

Problem

Collection-驗(yàn)證崗位*發(fā)現(xiàn)的問題Verification

Station

Findings-過程分層審核*中發(fā)現(xiàn)的問題Layered

Process

Audit

issues-停線問題Line

stops

and

Teardown

issues-其他的內(nèi)部質(zhì)量問題(出貨審核,

產(chǎn)品遏制行動等)Other

internal

Quality

concerns

(DockAudits,

containment

activity)-一次下線合格率數(shù)據(jù)FTQ，F(xiàn)irst

Time

QualityIssues,

Customer

Calls)SGM

Confidential13SDE

Module

2011.04QSB1.

快速響應(yīng)Fast

Response?是一個交流會，不是一個問題解決會議A

communications

meeting,

nota

problem

solving

meeting.?Engineering,

Maintenance,etc…?責(zé)任人提前將問題相關(guān)措施公布在快速響應(yīng)板上Issues

shall

be

added

to

theFast

Response

board

prior

to

the

meeting

by

the

owner.-負(fù)責(zé)人應(yīng)確保其負(fù)責(zé)的重要問題及時(shí)得到解決，并且符合所有問題解決標(biāo)準(zhǔn)和退出條件。Owner

responsible

forcompletion

of

all

exit

criteria.-

對于未明確的問題，指定責(zé)任人Designate

a

leader

(owner)

foreach

concern/issue

if

one

hasnot

been

already

assigned.?至少每天召開一次，有些廠可能要每班召開一次Meetings

are

held

daily

at

a

minimum,

although

some

organizations

may

choose

tohold

meetings

on

each

shift.時(shí)間Timing形式Way責(zé)任Responsibility關(guān)鍵步驟-2

：召開快速響應(yīng)會議Key

Steps

-

Daily

Fast

Response

Meeting?是一個10-20分鐘的站立會議，在生產(chǎn)現(xiàn)場召開2011.04Itshould

be

a

10

-

20

minute

stSaGndMupCmonefeidtinengthiaelld

on

the

shop

floor.14SDE

ModuleQSB1.

快速響應(yīng)Fast

Response

負(fù)責(zé)人

生產(chǎn)部門1生產(chǎn)部門2生產(chǎn)部門3相關(guān)的開發(fā)工程

師/供應(yīng)商質(zhì)量/供應(yīng)商4過程是否正確?工具/刀具是否正確零件是否正確零件質(zhì)量?是是是否工藝更改是否解決問題？產(chǎn)品更改是否需要?極端復(fù)雜問題否不確定是否需要開發(fā)支持?負(fù)責(zé)人車輛組裝工藝5設(shè)計(jì)開發(fā)6統(tǒng)計(jì)工程7關(guān)鍵步驟-3

：解決問題Key

Steps

-

3：

Problem

Solving15SGM

ConfidentialSDE

Module

2011.04QSB關(guān)鍵步驟-4

：狀態(tài)跟蹤Key

Steps-4：

Status

Tracking1.

快速響應(yīng)Fast

ResponseY16SGM

ConfidentialSDE

Module

2011.041QSB1.

快速響應(yīng)Fast

ResponseNo

Quality

DisruptionsInternal

Quality

Disruption

(defined

locally)Customer

Quality

Disruption

(eg.

PRR,

Pull,

Spill)Daily

Quality

ChartLEGEND:MonthYearJanuary2004312928

302122

24232526271213141516171819202345678910111GreenYellowRedLeadership

shall

display

a

visualQuality

status.可使用任何形式的目視方法:

如日歷,

圖表,關(guān)鍵步驟-4

：狀態(tài)跟蹤Key

Steps-4：

Status

Tracking管理層必須通過目視的方式來展示質(zhì)量狀態(tài)Any

typeof

visual

management

can

be

used:

calendar,

chart,

etc…SGM

Confidential7SDE

Module

2011.04QSB1.

快速響應(yīng)Fast

Response關(guān)鍵步驟-5

：經(jīng)驗(yàn)教訓(xùn)Key

Steps

-

5：

Lesson

learned? 識別出哪些類似的產(chǎn)品或過程可能或已經(jīng)發(fā)生同樣的失效模式。Identify

similar

products

and

processes

which

can

potentially

have

or

produce

the

same

failuremode.? 將問題解決報(bào)告發(fā)送到其他有類似潛在問題的部門/工廠。在整個組織內(nèi)貫徹實(shí)施解決方案。Implement

the

solution

across

the

organization? 更新相關(guān)的文件：Update

the

necessary

documentation:*PFMEA

潛在過程失效模式分析*Control

Plan控制計(jì)劃*Error

Proofing

Verification*

防錯驗(yàn)證*Standardized

WorkInstructions*

標(biāo)準(zhǔn)化操作指導(dǎo)書*Operator

Instructions*

操作員指導(dǎo)書*LessonsLearned*

經(jīng)驗(yàn)教訓(xùn)? 通過過程分層審核*

來驗(yàn)證系統(tǒng)是否始終如一的在運(yùn)作。Implement

Layered

Process

Audits*

to

verify

the

system

is

working

consistently.18SGM

ConfidentialSDE

Module

2011.04QSB1.

快速響應(yīng)Fast

Response建立質(zhì)量問題（過去24小時(shí)內(nèi)）快速反映渠道Build

to

gather

fast

significant

issues

from

the

past

24

hours.領(lǐng)導(dǎo)層參與快反會議，督促問題的及時(shí)跟進(jìn)和解決Leadership

joinFast

Response

Meeting

to

push

problem-solving培養(yǎng)問題解決隊(duì)伍，關(guān)鍵在于找到根本原因Build

problem-resolving

team.

Focus

onfinding

root

cause.通過分層審核

及時(shí)驗(yàn)證措施的有效落實(shí)Verifyaction

plan

based

on

L.P.A.

in

time已關(guān)閉問題及時(shí)舉一反三，防止問題的再發(fā)生。Lesson

learned

in

time19SGM

ConfidentialSDE

Module

2011.04QSBKey

Strategies關(guān)鍵策略快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

Risk

Reduction異物控制

Contamination

Control供應(yīng)鏈管理

Supply

Chain

Management變更管理

Managing

Change20SGM

ConfidentialSDE

Module

2011.04QSB2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT防止不合格產(chǎn)品被無意使用或安裝的標(biāo)準(zhǔn)化系統(tǒng)Standardized

System

Of

Preventing

Unintended

Use

Or

Installation

Of

All

Nonconforming

Product不同狀態(tài)的產(chǎn)品是否清晰可辨？Product

status

clear？篩選是否覆蓋整個物流鏈？Overcome

total

logistical

chain?是否及時(shí)通知相關(guān)方？Notice

correlative

customer?21SGM

ConfidentialSDE

Module

2011.04QSB2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCTXXXXX汽車飾件統(tǒng)有限公司品系報(bào)廢Scrap系統(tǒng)有限公司物品名稱物品名稱物品名稱物品代碼物品代碼物品代碼日期: 檢驗(yàn)員:統(tǒng)一的標(biāo)識（標(biāo)簽）和隔離區(qū)域Consistent

identification

(tagging)

and

Segregation

AreasXXXXX汽車飾件暫停使用HoldXXXX汽車飾件系統(tǒng)有限公司合格品Pass遏制和重新安排Containment

AndReintroduction與顧客交流Communication

withCustomerSGM

Confidential22SDE

Module

2011.04QSB統(tǒng)一的標(biāo)識Consistent

identification

(tagging)可疑品不可使用SUSPECT

DONOT

USE合格品可以使用OK

FOR

USE涂成紅色的報(bào)廢箱可不用標(biāo)簽SCRAP

BINSPAINTED

REDDO

NOT

REQUIRE

A

TAG標(biāo)簽必須顯示最后的工位，以保證重新導(dǎo)入生產(chǎn)時(shí)回到正確工位TAG

MUST

SHOW

LASTOPERATION.TO

ASSUREPROPER

REINTRODUCTION綠色或其他顏色（紅色和黃色除外）.的標(biāo)簽表示是可接受的

合格產(chǎn)品ANY

COLOR

(except

red

oryellow)

FOR

CONFORMINGPRODUCT

IS

ACCEPTABLE廢品SCRAP標(biāo)簽內(nèi)容TAG

CONTENTIN

THIS

SECTIONIS

AT

LOCALDISCRETIONPLT003PLT002標(biāo)簽內(nèi)容TAG

CONTENTIN

THIS

SECTIONIS

AT

LOCALDISCRETION(例)(Example)2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT標(biāo)簽內(nèi)容

TAG

CONTENTIN

THISSECTION23SGM

ConfidentialSDE

Module

2011.04IS

AT

LOCALDISCRETIONPLT001QSB隔離區(qū)域Segregation

Areas所有可疑產(chǎn)品和不合格產(chǎn)品必須被隔離。（尤其中班和晚班發(fā)現(xiàn)的）All

nonconforming

andsuspect

product

shall

be

segregated.隔離區(qū)域必須劃線區(qū)分或明顯標(biāo)識。Segregation

areas

shallbe

footprintedorotherwise

identified.例如：Example:-

廢料箱Scrap

bins-

返工臺Rework

Tables-

遏制區(qū)域Containment

areas-

不合格產(chǎn)品存放區(qū)Nonconforming

material

hold

areas2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT24SGM

ConfidentialSDE

Module

2011.04QSB遏制Containment遏制措施必須確認(rèn)斷點(diǎn):Containment

shall

verify

breakpoint:-

對于遏制范圍內(nèi)的產(chǎn)品100％檢查using100%

Inspection-

持續(xù)時(shí)間由現(xiàn)場領(lǐng)導(dǎo)層決定for

a

duration

specified

by

site

leadership2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT混淆和弄錯斷點(diǎn)是你所能犯的最大錯誤。Violating

the

BREAKPOINT

is

the

biggestmistake

youcan

make.25SGM

ConfidentialSDE

Module

2011.04PRODUCT

CONTAINMENT

SCOPEIDENTIFY

ALLAREAS

WHERE

SUSPECT

PRODUCT

COULDBE

LOCATEDLOCATION可能存在的數(shù)量區(qū)域確認(rèn)人可疑品發(fā)現(xiàn)數(shù)量確認(rèn)責(zé)任人Receiving

收貨區(qū)500P.S.500P.

SmithLaboratory

實(shí)驗(yàn)室6K.C.6T.

BrownWIP

Storage

Areas

在制品放置區(qū)1000P.S.1000P.

SmithOutside

Processing

-

(Plating)外加工1000C.J.1000C.

JonesScrap

Bins

報(bào)廢品區(qū)42K.C.42C.

JonesRework

Areas

返工區(qū)0B.T.0C.

JonesShippingDock

發(fā)貨區(qū)0K.C.0C.

JonesHeat

Treater

熱處理中0P.S.0C.

JonesAt

Customer

顧客端0B.T.0C.

JonesIn

Transit

運(yùn)輸中0B.T.0C.

JonesService

Parts

Operations

售后部門0P.S.0C.

JonesQSB重新安排Reintroduction從正常的工藝過程中取走的產(chǎn)品重新回到生產(chǎn)線時(shí)，返回點(diǎn)必須在取出工位或之前。

Product

removed

from

the

approved

process

flow

shallbe

reintroduced

into

the

processstream

at

or

prior

to

the

point

of

removal.對于退出返工、返修和遏制區(qū)域的產(chǎn)品，必須明確建立放行流程與授權(quán)。Process&

authority

for

releasing

product

out

of

rework,

repair

andcontainment

areasshall

be

defined.2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT26SGM

ConfidentialSDE

Module

2011.04QSB與顧客交流Communication

with

Customer不合格警報(bào)和遏制程序必須建立時(shí)間順序，任務(wù)和溝通方式以滿足顧客要求，確?？勺匪菪?。A

nonconformance

alert

and

containment

procedure

shall

establish

the

timeline,

tasksand

communications

necessary

tomeet

customer

requirements

and

insure

the

traceability.質(zhì)量問題通知Quality

issuenotificationN開始遏制行動，決定可疑品數(shù)量，開始快速反應(yīng)*程序Initiate

containmentactions,

determinesuspect

population,begin

FastResponse*.關(guān)注的問題是否已被確認(rèn)發(fā)生或可疑庫存已被發(fā)出?Concern

withcertification

or

wassuspect

stockshipped?開始發(fā)運(yùn)經(jīng)驗(yàn)證的產(chǎn)品.Begin

shippingcertified

stock.制定和執(zhí)行外部遏制和驗(yàn)證計(jì)劃.Develop

&

implement

externalcontainment

and

certification

plans.開始發(fā)運(yùn)經(jīng)驗(yàn)證的產(chǎn)品.Begin

shipping

certified

stock.繼續(xù)快速反應(yīng)*程序直到關(guān)閉問題.Continue

FastResponse*

&Close

Issue.聯(lián)系外部顧客，實(shí)施產(chǎn)品追溯Contact

external

customer.(例)(Example)Y2.

不合格品控制27SGM

ConfidentialSDE

Module

2011.04CONTROL

OF

NONCONFORMING

PRODUCTQSB2.

不合格品控制CONTROL

OF

NONCONFORMING

PRODUCT利用統(tǒng)一的標(biāo)識(標(biāo)簽)以清楚地識別，在標(biāo)識明確的區(qū)域進(jìn)行隔離(狀態(tài)明確)Clearly

identified

using

consistent

identification

(tagging).

Segregated

in

well-identified

areas通過遏制工作表加以遏制（全過程篩選）Contained

through

the

use

of

a

containment

worksheet放行時(shí)，應(yīng)按規(guī)定程序進(jìn)行并有授權(quán)（獨(dú)立執(zhí)行）Released

using

a

defined

process

and

authority在取出點(diǎn)或之前重新回到過程流中（防止漏加工）Reintroduced

into

the

process

stream

at

or

prior

to

the

point

of

removal領(lǐng)導(dǎo)層必須對產(chǎn)品遏制問題進(jìn)行審核（確保追溯性）Product

containment

issues

shall

be

reviewedby

Leadership28SGM

ConfidentialSDE

Module

2011.04QSBKey

Strategies關(guān)鍵策略快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

Risk

Reduction異物控制

Contamination

Control供應(yīng)鏈管理

Supply

Chain

Management變更管理

Managing

Change29SGM

ConfidentialSDE

Module

2011.04QSB在

線

控

制

和

驗(yàn)

證In-Process

Control

&Verification為什么需要驗(yàn)證崗位？Why

need

verification

stations

？哪些區(qū)域應(yīng)該設(shè)立驗(yàn)證崗位？Where

verification

stations placed?如何設(shè)立驗(yàn)證崗位？How

to

build

verification

stations?3.

驗(yàn)證崗位Verification

Stations絕不Do

not一件缺陷零件！A

defect!30SGM

ConfidentialSDE

Module

2011.04QSB為什么需要驗(yàn)證崗位？Why

need

verification

stations此策略避免你的客戶接受不合格產(chǎn)品、偏差零件和標(biāo)簽錯誤的零件Isolate

our

customersfromdisqualification,

bias,

andwrong

tag

parts? 驗(yàn)證崗位提供了一個通過報(bào)警系統(tǒng)來處理顧客關(guān)注的優(yōu)先級問題的方法，也對頻發(fā)的低嚴(yán)重度的不符合項(xiàng)提醒注意。Provide

a

means

through

an

alarm

system

to

address

highest

priority

customerconcernsand

the

frequent,

low

severity

non-conformances? 改善一次合格率（FTQ）并提高過程能力（迅速識別特殊原因變差、系統(tǒng)地減少普通原因變差）Improve

first

time

quality

(FTQ)

and

process

capability

(promptly

identifying

specialcause

variation

and

systematicallyreducingcommon

cause

variation)? 警示操作員過程有變化，提供信息以采取快速糾正措施Alert

operators

of

changes

in

the

process

and

provide

information

for

rapidcorrective

action?

補(bǔ)充經(jīng)核準(zhǔn)的控制計(jì)劃Complement

approved

control

plan3.

驗(yàn)證崗位Verification

Stations31SGM

ConfidentialSDE

Module

2011.04QSB在哪里設(shè)立驗(yàn)證崗位Where

Are

VerificationStations

Placed??

存在以下狀況的任何過程或作業(yè)點(diǎn)：Pointsin

the

processoroperation

where

there

exists:高風(fēng)險(xiǎn)/High

riskPR&R（顧客抱怨）/Customer

complain高嚴(yán)重度（安全）

/High

severity高頻次

/High

Occurrence–

低過程能力

(Ppk,

Cpk,FTQ)：任何

Cpk

或

Ppk低于1.33

的工序必須

100%

檢驗(yàn)/

low

capability (Ppk,Cpk,

FTQ)

Anyoperation

with

aCpk

orPpkbelow

1.33requires

100%

inspection?

在問題發(fā)現(xiàn)點(diǎn)（Pointof

Cause)

的不同部門或在截然不同的過程之間Between

departments

ordistinct

processes

at

point

ofcause.3.

驗(yàn)證崗位Verification

Stations32SGM

ConfidentialSDE

Module

2011.04QSB如何設(shè)立驗(yàn)證崗位How

to

build

VerificationStations?? 針對新項(xiàng)目，通過GP-12驗(yàn)證崗位采取100%檢查方式控制過程風(fēng)險(xiǎn)。For

new

part,

set

up

GP-12

for

100%

check? 針對單一簡單問題，在相應(yīng)后道工序中增加確認(rèn)動作。For

Single

simple

issue, add

verification

action

in

following

station? 針對最終產(chǎn)品，采取抽檢的方式，由獨(dú)立人員執(zhí)行AUDIT，領(lǐng)導(dǎo)層評審責(zé)任部門的整改行動For

finished

product,

independent

do

product

audit

and

leadership

review theowner’s

action.? 針對復(fù)雜問題，設(shè)立獨(dú)立的驗(yàn)證崗位，對相應(yīng)缺陷進(jìn)行100%檢查，直到長期有效措施生效。For

complex

problem,

verification

station

set

up

for

100%

check

until

long-termactionOP

103.

驗(yàn)證崗位Verification

StationsOP

30OP

50AUDITGP-12OP

4033SGM

ConfidentialSDE

Module

2011.04OP

20VSQSB3.

驗(yàn)證崗位Verification

Stations驗(yàn)證崗位內(nèi)容Verification

Stations

Content問題解決

–

驅(qū)動在過程中解決問題ProblemSolving

–

Driving

fixes

intostation缺陷件進(jìn)入驗(yàn)證崗位Defects

Entering

VS缺陷流出驗(yàn)證崗位Defects

LeavingVSStation

產(chǎn)品檢驗(yàn)

排列缺陷優(yōu)先次序

警報(bào)升級程序

立即響應(yīng)

領(lǐng)導(dǎo)層召開每班會議

會議指定負(fù)責(zé)人

Pareto

分析

顧客

PR&R抱怨

顧客夜班口頭抱怨。

Q-終檢l/GP-12/CS-1/CS-2

一次合格率

FTQ

&

廢品趨勢圖

（隨時(shí)間）34SGM

ConfidentialSDE

Module

2011.04QSB3.

驗(yàn)證崗位Verification

Stations問題上升ProblemEscalation3Team

LeaderSupervisor(Group

Leader)Superintendent

/ShiftManagerPlantManagementTeam

MemberTeam

LeaderPlantManagementSuperintendent

/ShiftManagerSupervisor(Group

Leader)Team

MemberEscalationResponse設(shè)定報(bào)警界限SET

ALARM

LIMITS逐級上報(bào)流程ESCALATIONPROCESSES立即行動響應(yīng)IMMEDIATE

ACTION

RESPONSE質(zhì)量反饋/質(zhì)量匯報(bào)QUALITY

FEEDBACK

/

FEEDFORWARD35SGM

ConfidentialSDE

Module

2011.04QSB實(shí)施100%檢驗(yàn)或其它檢驗(yàn)方式Institute

100%

inspection

or

other

inspections到達(dá)報(bào)警界線時(shí)，立即采取行動（問題上升）Take

immediate

action

whenalarm

limit

is

reached根據(jù)驗(yàn)證崗位信息，實(shí)施整改（問題解決）Implement

corrective

actions

based

on

VS

data將根本原因/整改行動增加到過程分層審核中（執(zhí)行確認(rèn)）Add

the

Root

Cause/Corrective

Action

to

the

Layered

Process

Audit管理層定期到驗(yàn)證崗位進(jìn)行巡視/并召開會議（領(lǐng)導(dǎo)重視）Conduct

regular

management

walk-through/meetings

at

the

Station3.

驗(yàn)證崗位Verification

Stations36SGM

ConfidentialSDE

Module

2011.04QSBKey

Strategies關(guān)鍵策略快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

Risk

Reduction異物控制

Contamination

Control供應(yīng)鏈管理

Supply

Chain

Management變更管理

Managing

Change37SGM

ConfidentialSDE

Module

2011.04QSB確定執(zhí)行任務(wù)的最佳方式，然后制定每個人應(yīng)遵守的標(biāo)準(zhǔn)工作流程的過程The

best

way

of

work

procedure

which

everyone

must

obey?

有效、增值的生產(chǎn)順序Efficient

and

value-added

production

sequence?

減少浪費(fèi)、解決問題和控制質(zhì)量Waste

reduction,

problem

solving

and

qualitycontrol?

檢查操作工的操作是否符合作業(yè)指導(dǎo)書的要求（例如分層審核）Auditing

operator

conformance

to

work

instructions

(Layered

Process

Audit*).?

確保操作工始終如一地執(zhí)行同樣的任務(wù)和程序Ensuring

operators

are

consistentlyperforming

the

same

tasks

and

procedures4.

標(biāo)準(zhǔn)化操作Standardized

Operations38SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations七大 過多生產(chǎn)浪費(fèi)過多加工 返工多余動作物料搬運(yùn)等待庫存周期時(shí)間LucyEthel節(jié)拍時(shí)間周期時(shí)間5”4”3”2”1”時(shí)間超負(fù)荷!!等待時(shí)間周期時(shí)間LucyEthel節(jié)拍時(shí)間5”4”3”2”1”時(shí)間不平衡Fred39SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations整潔、有序的工作環(huán)境A

clean,

well-organized

workenvironment.操作主要步驟，每一步驟所花時(shí)間What

are

theMajor

Steps,

howlong

should

it

take?詳細(xì)的動作步驟，怎樣做，為什么這樣操作。Detailed

Steps

for

What,

How,

and

Why.40SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations整潔、有序的工作環(huán)境A

clean,

well-organized

workenvironment.工作場地的組織–

7種浪費(fèi)

/

5SWorkplace

Organization---7

wastes/5S整頓素養(yǎng)整理清潔標(biāo)準(zhǔn)化41SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations操作主要步驟，每一步驟所花時(shí)間What

are

theMajor

Steps,

howlong

should

it

take?標(biāo)準(zhǔn)化操作－標(biāo)準(zhǔn)化作業(yè)指導(dǎo)書Standardized

Work(Standard

Operation

Sheet

)作業(yè)要素Work

Element要素時(shí)間ElementTime作業(yè)順序Work

Flow標(biāo)準(zhǔn)化作業(yè)指導(dǎo)書StandardOperation

Sheet作業(yè)符號Operating

Symbols42SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations操作主要步驟，每一步驟所花時(shí)間What

are

theMajor

Steps,

howlong

should

it

take?標(biāo)準(zhǔn)化操作－標(biāo)準(zhǔn)化作業(yè)指導(dǎo)書Standardized

Work(Standard

Operation

Sheet

)詳細(xì)的動作步驟，怎樣做，為什么這樣操作。Detailed

Steps

for

What,

How,

and

Why.操作工指導(dǎo)書–

作業(yè)要素表Operator

Instructions(Job

Element

Sheet)STANDARDOPERATION

SHEET

(A)J.E.S.

-

1J.E.S.

-

2J.E.S.

-

3J.E.S.

-

4J.E.S.

–

5Job

ElementSheetJ.E.S.

-

1J.E.S.

-

2J.E.S.

-

3J.E.S.

–

4Job

ElementSheetJ.E.S.

-

1J.E.S.

-

2J.E.S.

-

3J.E.S.

-

4J.E.S.

-

5J.E.S.

-

6J.E.S.

–

7Job

ElementSheetSTANDARDOPERATION

SHEET

(B)STANDARDOPERATION

SHEET

(C)43SGM

ConfidentialSDE

Module

2011.04QSB4.

標(biāo)準(zhǔn)化操作Standardized

Operations詳細(xì)的動作步驟，怎樣做，為什么這樣操作。Detailed

Steps

for

What,

How,

and

Why.操作工指導(dǎo)書–

作業(yè)要素表作業(yè)要素表Job

Element

Sheet主要步驟Major

Step關(guān)鍵點(diǎn)Key

Point原因ReasonOperator

Instructions(Job

Element

Sheet)44SGM

ConfidentialSDE

Module

2011.04QSB利用系統(tǒng)的方法來開展和保持車間現(xiàn)場管理（5S）Utilize

a

systematic

approach

to

implement

and

maintain

Workplace

Organization標(biāo)準(zhǔn)化操作指導(dǎo)書應(yīng)具有可操作性，采納工人的意見（全員參與）Develop

and

implement

Standardized

Work

Instructions

using

multi-disciplinary

teams.所有的操作工位均應(yīng)張貼標(biāo)準(zhǔn)化操作指導(dǎo)書（目視化）Post

Standardized

Work

Instructions

at

all

operations發(fā)生重大質(zhì)量或安全事故的工位應(yīng)張貼警示

（風(fēng)險(xiǎn)警示）Station

where

happen

major

quality/safe

issues

post

“Quality/Safe

alert”當(dāng)過程/產(chǎn)品更改時(shí)，通過分層審核確認(rèn)更新的操作指導(dǎo)書（及時(shí)確認(rèn)）Verify

update

operator

instructions

bylayered

process

Audit

as

processes/parts

change.4.

標(biāo)準(zhǔn)化操作Standardized

Operations45SGM

ConfidentialSDE

Module

2011.04QSBKey

Strategies關(guān)鍵策略快速響應(yīng)

Fast

Response不合格產(chǎn)品的控制

Control

of

Non-Conforming

Product驗(yàn)證崗位

Verification

Station標(biāo)準(zhǔn)化操作

Standardized

Operations標(biāo)準(zhǔn)化的操作工培訓(xùn)

Standardized

Operator

Training防錯驗(yàn)證

Error

Proofing

Verification分層審核

Layered

Process

Audits風(fēng)險(xiǎn)降低

RPN

Risk

Reduction異物控制

Contamination

Control供應(yīng)鏈管理

Supply

Chain

Management變更管理

Managing

Change46SGM

ConfidentialSDE

Module

2011.04QSB培訓(xùn)、監(jiān)控和評估操作工的系統(tǒng)方法Systematic

procedure

to

train,

monitor

andevaluate

operators?

確保每個人都接受相同的培訓(xùn)Assuresall

operators

have

adequate

and

similar

training?

確保每個人都始終以相同的方式來完成相同的工作Assuresunqualified

operators

receive

training

prior

to

operating

equipment?

確保有書面的培訓(xùn)流程來保證所有的操作員都知道如何完成工作Writtentrainingproceduretoassurealloperatorstoknowhowtowork?

減少操作中的偏差和不合格項(xiàng)Reduces

sort,

rework

and

containment

activities5.

標(biāo)準(zhǔn)化的操作工培訓(xùn)Standardized

Operator

Training47SGM

ConfidentialSDE

Module

2011.04QSB操作工培訓(xùn)四步法THE

4STEPS

OF

OPERATOR

TRAINING5.

標(biāo)準(zhǔn)化的操作工培訓(xùn)Standardized

Operator

Training第四步 跟蹤Major

Step

4：

Follow-up第三步 試操作Major

Step

3：

Try-out

performance第二步

示范操作Major

Step

2：

Demonstration第一步

成員準(zhǔn)備Major

Step

1：

Prepare

teammember48SGM

ConfidentialSDE

Module

2011.04E

M