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1、Company Confidential First Time Quality PPM TIME 2 First Time Quality Training Module Training Objectives 培訓目標 : To Understand 理解 What First Time Quality Is 什么是一次下線合格率 ? Why It Is Important 一次下線合格率的重要性 Why We Need to Measure It 為什么需要對一次下線合格率進行測量 ? How to C

2、alculate It 如何計算 ? What the FTQ Deployment Process is 怎樣進行 FTQ? What the Basic Quality Tools Are 基本質(zhì)量工具是什么 ? How to Apply the Quality Tools 怎樣運用基本質(zhì)量工具 ? What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 每個工廠應該監(jiān)控和匯報什么 ? 3 First Time Quality Training Module

3、 What is First Time Quality? 什么是一次下線合格率 ? First Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted 一次下線合格率是測量制造過程中不合格品數(shù) 與總產(chǎn)品數(shù)的比值 . REJECTS 4 First Time Quality Training Module Why is FTQ important? 一次下線合格率的重要性 Beca

4、use if we dont make good parts the first time, we have to inspect in quality 因為如果我們第一次沒有生產(chǎn)出好的產(chǎn)品 ,我們就必須進行檢驗 . We know inspection is at best 85% effective 我們知道檢驗最多只 有 85%的有效性 . Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因而 ,如果任何時候一次下線合 格率大于 0,我

5、們都需要依賴檢驗來保護客戶 . To reduce manufacturing costs 降低制造成本 To eliminate waste through the value stream and meet customer requirements (take time) 通過價值流和滿足客戶要求來消除浪費 . 5 Catch Defects Filter Inspection misses some defects 檢驗會遺漏一些缺陷 Defects not caught 漏網(wǎng)缺陷 Voice of the Customer 客戶的聲音 Problem問題 D D

6、The Role of Inspection D Inspection is like a filter 檢驗好比一個篩子 6 1 2 Catch & Count defects 抓住并計算缺陷 React to ALARM LIMITS 超過警戒線的反應 Follow Reaction Plan 執(zhí)行反應計劃 Voice of the Customer客戶的聲音 The Role of First Time Quality Process Reaction Plan ZERO Defects Forward 7 Analyze Data分析數(shù)據(jù) Understand Defe

7、cts and Decide the Order of Priority: 理解缺陷并決定優(yōu)先次序 Assign problems to Cross-Functional Group: 向跨功能小組提出問題 Select and Plan the Improvement: 1.Right Information 2.Right Cause 3.Right Timing 選擇并計劃改善問題 正確的信息 正確的原因 正確的時間選擇 Fix the Biggest Problems First: 首先找到最大的問題所在

8、1 2 A B C D Problems 1 2 1 2 Responsible Team Works Problems 相關團隊負責解決問題 DEFECT 1. ---------------------- 2. ---------------------- 3. ---------------------- Hour Glass The Role of First Time Quality Process 4 3 2 3 2 2 1 1 1 1 8 Inspection Exercise THE NECESSITY OF TRAINING FARMHANDS FOR FIRST

9、 CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH THE FAMILY TRADITION

10、 OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT. Count the Number of Fs contained in the paragraph below (60sec) 數(shù)一下下面總共出現(xiàn)了幾個“ F”（ 60秒） 9 Inspection Exercise THE NECESSITY OF TRAINING

11、 FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH

12、THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT. Total of 36 Fs 10 First Time Quality Training Module Why does FTQ need to be measured? 為什么需要測量 FTQ Main Reason

13、s 主要原因 : It is the first signal that a process is out of control 它是過程失控最先發(fā)出的信號 It allows us to respond to problems internally before they reach our customers 它使我們能夠在問題到達客戶之前先在內(nèi)部作出反應 . It measures improvement from corrective actions implemented 通過執(zhí)行糾正措施后來衡量問題改善的情況

14、. If we dont fix our quality problems internally, we will never be able to fix our external customer issues 如果我們不能在 內(nèi)部找到質(zhì)量問題 ,我們就不能確定外部客戶的問題 . 11 First Time Quality Training Module How is First Time Quality calculated? 如何計算 FTQ FTQ is reported in parts per million (PPM) defective FTQ反映每一百萬個產(chǎn)品中的

15、缺陷產(chǎn) 品數(shù) . It can be measured at any step in the manufacturing process where parts are rejected 可以 在有拒收產(chǎn)生的制造過程的任何一步測量 FTQ. It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 通過以不合格品數(shù)除以總數(shù)來計算 . The total number of pieces attempted includes all go

16、od pieces produced plus all pieces rejected 總的產(chǎn)品數(shù)包括生產(chǎn)出來的所有合格品數(shù)和不合格品數(shù)之和 . Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不合格品數(shù)包括所有報廢和經(jīng)過返工后合 格的產(chǎn)品數(shù) . 公式 : Number of Pcs. Rejected不合格品數(shù) Total Number of Pcs. Attempte

17、d總產(chǎn)品數(shù) X 1,000,000 = FTQ PPM 12 First Time Quality Training Module How is First Time Quality calculated?如何計算 FTQ? An example at the cell level: Cell “A” has six operations A單元有 6個操作工序 Reject data is collected at operations 3 and 6 在第三和第六工序收集到不合格品數(shù)據(jù) Cell “A” produced 1040 good pieces d

18、uring the first hour of production. 第一個小時 A單元共生產(chǎn)良品 1040件 At OP.3, 28 pcs. were rejected. 第三工序發(fā)現(xiàn) 28件不合格品 At OP.6, 16 pcs. were rejected. 第六工序發(fā)現(xiàn) 16件不合格品 What is the FTQ in PPM for Cell A? A單元 FTQ的 PPM是多少 ? 28 + 16 1040 + 28 + 16 1 2 3 4 5 6 X 1,000,000 = 40590 PPM FTQ 28 16 Tally Sheet 13

19、First Time Quality Training Module What is the First Time Quality Improvement Process? 什么是 FTQ改善過程 ? FTQ process defines a common process to be used by all Delphi manufacturing plants to meet the business plan requirements and drive defect-free manufacturing FTQ是 Delphi 工廠常用的以達到商業(yè)計劃要求和 無缺陷生產(chǎn)要求的

20、一個方法 . The FTQ process defines FTQ定義 : Process Steps 流程步驟 Stakeholders 有關系的人 Deployment Chart (functional flow chart) for identifying lead functions 用于識別重要功能的布置圖表 (功能流程圖 ) Control Plan for Tracking Implementation 控制計劃和跟蹤執(zhí)行 14 IDENTIFY & COUNT DISCREPANT PARTS IMPLEMENT IMPROVEMENT 執(zhí)行改善

21、EVALUATE 評估 INSTITUTION- ALIZE LESSONS LEARNED 系統(tǒng)化經(jīng)驗教訓 TOOLS FOR IDENTIFICATION用于識別的工具 : - PROCESS CONTROL PLAN過程控制計劃 - BOUNDARY SAMPLES邊界樣品 TOOLS FOR COUNTING用于計數(shù)的工具 : - PARTS COUNTERS產(chǎn)品計數(shù)器 - TALLY SHEETS計數(shù)表 - SIZED CONTAINERS有尺寸大小的容器 TOOLS工具 : - PARETO直方圖 - CAUSE & EFFECT

22、 (FISHBONE) 原因和結(jié)果 (魚骨圖 ) - CONCENTRATION DIAGRAM集合表 - FLOW CHART流程圖 - HISTOGRAM柱狀圖 - SCATTER DIAGRAM散布圖 - CHECK SHEET檢查表 - 5 WHYS 5個為什么 EXAMPLES例子 : - CROSS-FUNCTIONAL TEAMS跨功能小組 - CHANGE BOARDS變化看板 - RPN REDUCTION降低 RPN - STATISTICAL ENGINEERING PROJECTS統(tǒng)計工程

23、方案 ACTION PLAN行動計劃 : - WHAT, WHEN, WHO事件 ,時間 ,人物 TOOL工具 : - ACTION PLAN 行動計劃 TOOLS工具 : - PFMEA過程流程圖 - PROCESS CONTROL PLAN 過程控制計劃 - LOOK-ACROSS-CHART 瀏覽表 - 5 WHYS 5個為什么 SELECT & PLAN IMPROVEMENT 選 擇和計劃改善 NEW LEVEL OF QUALITY? 新的質(zhì)量水平 DEFINE REACTION PLAN & ALARM LIMITS

24、定義反應計 劃和警戒線 RECORD DATA 記錄數(shù)據(jù) TOOLS工具 : - CONTROL CHART控制圖 ANALYZE DATA 分析數(shù)據(jù) TOOL工具 : - RUN CHART 運行圖 - GATE CHART 門圖 ALARM EXCEEDED 是否超過警戒 ? IMPLEMENT ALARM REACTION PLAN 執(zhí)行報警反應計劃 YES NO NO YES IDENTIFY確認 ANALYZE分析 PLAN計劃 EVALUATE評估 IMPLEMENT執(zhí)行 FTQ Improvement

25、Process 識別和清點有 差異的產(chǎn)品 15 FTQ Improvement Process Stakeholder Footprint Plant A Plt B Plt C CELL 1 2 3 4 5 7 8 N 6 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 OPERATOR 操作人員 TEAM LEADER 小組領導 CROSS- FUNCTIONAL TEAM 跨功能小組 MEMBERS成員 : - TEAM LEADER小組領導 - OPE

26、RATIONS/MANUFACTURING操作 /制造人員 - QUALITY ENGINEER質(zhì)量工程師 - PROCESS ENGINEER 工藝工程師 - INDUSTRIAL ENGINEER工業(yè)工程師 - MAINTENANCE設備維護 - PRODUCT ENGINEER產(chǎn)品工程師 - SUPPLIER QUALITY供應商品質(zhì)人員 PRODUCT ENGINEERING MANAGER 產(chǎn)品工程經(jīng)理 QUALITY MANAGER 質(zhì)量經(jīng)理 MAINTENANCE MANAGER 設備維護經(jīng)理 OPERATIONS MANAGER 制造經(jīng)理

27、 PROCESS ENGINEERING MANAGER 工藝工程經(jīng)理 PLANT MANAGER 工廠經(jīng)理 PC&L MANAGER 物流經(jīng)理 CELL 工作站 16 First Time Quality Improvement Process Deployment Flow Chart CFT 跨功能 小組 PROCESS過程 QUALITY ENGINEER 質(zhì)量經(jīng)理 OPERATIONS 操作人員 PROCESS ENGINEER 工藝工程師 PRODUCT ENGINEER 產(chǎn)品工程師 MAINTENANCE 設備維護 INDUSTRIAL ENGINEER

28、 工業(yè)工程師 DEFINE REACTION PLAN & ALARM LIMITS 定義反應計劃和警戒線 IDENTIFY & COUNT DISCREPANT PARTS 識別和清點異常產(chǎn)品 IMPLEMENT ALARM REACTION PLAN 執(zhí)行警戒反應計劃 (如果超過警戒線 ) RECORD DATA 記錄數(shù)據(jù) ANALYZE DATA 分析數(shù)據(jù) SELECT & PLAN IMPROVEMENT 選擇和計劃改善 IMPLEMENT IMPROVEMENT 執(zhí)行改善 EVALUATE 評價 INSTITUTIONALIZE LESSONS LEARNED 系

29、統(tǒng)性經(jīng)驗教訓 LEAD 負責 SUPPORT 支持 17 First Time Quality Training Module Process Step 1 第一步 Define reaction plan and alarm limits 定義反應計劃和警戒線 You have to start someplace Alarm limits must be based on current process reject data or available data from Run at Rate, historical data, etc. 警戒線必須基于在當前工藝

30、下生產(chǎn)的不合格品數(shù)據(jù) , 或源于按節(jié) 拍生產(chǎn) ,歷史數(shù)據(jù) ,等 . Alarm limits must be statistically calculated 警戒線必須進行統(tǒng)計計算 . Alarm limits must be communicated to operators so they can react 警戒線必須與操作人 員進行交流溝通 . If alarm limits are exceeded, there must be a reaction plan to implement 如果超過警戒 線 ,必須有一個可執(zhí)行的反應計劃 . The reaction p

31、lan must clearly define what actions are to be taken 反應計劃必須明確定 義所需采取的行動 . I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N T I F I C A T I O N

32、 : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C

33、E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C

34、 A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M P R O V E M E N

35、T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M P L E M E N T A

36、 L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T DEFINE REACTION PLANS & ALARM LIMITS 定義反應計劃 和警戒線 18 First Time Quality Training Module Process Step 2 第二步 Identify and count discrepant parts 識別和計算有差異的產(chǎn)品數(shù) Operators must h

37、ave sufficient tools and skills in order to identify product discrepancies 操作人員必須有足夠的途徑和技能來確認產(chǎn)品的差異 . Tools to enhance the operators ability to identify product discrepancies include 用于加 強操作人員確認產(chǎn)品差異的途徑有 : Boundary Samples 極限樣品 Illustrations 圖表 Photographs 照片 Gages 量具 Tools for counting di

38、screpant parts include 用于清點差異產(chǎn)品的工具有 : Parts Counters 產(chǎn)品計數(shù)器 Tally Sheets 計數(shù)表 Sized Containers 容量固定的容器 I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F

39、 O R I D E N T I F I C A T I O N : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T (

40、 F I S H B O N E ) - C O N C E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U

41、C T I O N - S T A T I S T I C A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T &

42、 P L A N I M P R O V E M E N T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E

43、E D E D ? I M P L E M E N T A L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T IDENTIFY & COUNT DISCREPANT PARTS 識別和清點 有差異的產(chǎn)品 19 First Time Quality Training Module Process Step 3 第三步 Implement Alarm Reaction Plan if Limit Exc

44、eeded 超過警戒線時反應計劃的執(zhí)行 Reaction Plan 反應計劃 : I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N T I F I C A T I O N : - P R O C E S S C O N T R

45、 O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C E N T R A T I O N D I A G R

46、A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C A L E N G I N E E R I N G P

47、 R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M P R O V E M E N T N E W L E V E L O F Q U A L I

48、 T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M P L E M E N T A L A R M R E A C T I O N P L A N

49、YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T IMPLEMENT ALARM REACTION PLAN 執(zhí)行警戒反應計劃 Alarm Limit Exceeded 是否超過警戒線 ? Contain 遏制 Investigate 調(diào)查 Implement Containment Plan Until Problem Fixed 執(zhí)行遏制計劃直到找到問題 Yes Containment Plan遏制計劃 20 First Time Quality

50、Training Module Process Step 4 第四步 Record Data 記錄數(shù)據(jù) Data must be recorded and plotted over time 必須按時間記錄數(shù)據(jù) : What chart should be used 應使用什么圖表 ? Since the area of opportunity varies from sample to sample, the reject count must be converted into a rate prior to charting 如果單位時間內(nèi)生產(chǎn) 的樣品數(shù)有很大不同，在

51、制表時，需將拒收數(shù)轉(zhuǎn)換為比率 . We do this by measuring FTQ in PPM 用 PPM計算 FTQ PPM is a rate PPM是一個比率 . I D E N T I F Y & C O U N T D I S C R E P A N T P A R T S I M P L E M E N T I M P R O V E M E N T E V A L U A T E I N S T I T U T I O N - A L I Z E L E S S O N S L E A R N E D T O O L S F O R I D E N

52、T I F I C A T I O N : - P R O C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N

53、 E ) - C O N C E N T R A T I O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N -

54、S T A T I S T I C A L E N G I N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & P L A N I M

55、P R O V E M E N T N E W L E V E L O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D D A T A T O O L S : - C O N T R O L C H A R T A N A L Y Z E D A T A T O O L : - R U N C H A R T - G A T E C H A R T A L A R M E X C E E D E D ? I M

56、P L E M E N T A L A R M R E A C T I O N P L A N YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T RECORD DATA 記錄數(shù)據(jù) 21 Hour s or Day s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Non- c on f or m i ng 8 10 9 11 9 8 6 8 7 11 12 11 13 18 17 12

57、 9 10 7 8 5 9 11 8 7 Sa m pl e S i z e ( Av g) 18 Def ec ts w i ng m ar k 2 1 5 4 2 1 3 4 2 2 1 3 1 2 1 1 2 1 1 1 w i ng / bo dy f ol d 3 2 1 2 5 1 2 2 2 5 2 3 4 5 1 2 4 5 6 7 1 1 2 2 3 w r on g p ai nt d ot 2 2 1 5 1 2 3 5 4 3 3 6 8 1 1 3 1 4 3 3 pa i nt l oc ati on 3 4 2 1 2 3 7 2 2 2 2 4 w r on g

58、 o r no c l i p 1 2 2 1 1 1 3 1 1 3 2 6 1 2 1 1 4 3 T o t al no n con f o r m in g : 8 10 9 11 9 8 6 8 7 11 12 11 13 18 17 12 9 10 7 8 5 9 11 8 7 Produ c ti on 18 18 19 18 20 18 17 18 18 19 18 19 19 18 17 18 18 19 18 20 18 18 20 18 19 PP M Def ec ti v e np 1+ np 2+ ? .np k w he r e n p= nu m be r no

59、 nc on f or m i n, k = s ub gr ou ps k = SUM( C3:AA 3) /25 UCL np = 0 UCL np = 0 LCL np = 0 LCL np = 0 0 5 10 15 20 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 UC L= LCL= N o n c o n f o r m i n g a v g= NP Ch ar t in g f o r F T Q Sub g r o u p s ( Day s) np np 0 10 20

60、 30 40 50 60 70 80 90 100 Def ec ts Pa r eto U C L =n p + 3 * ( n p ( 1 - n p / n ) ) L C L =n p - 3 * ( n p ( 1 - n p / n ) ) n = avg sample size (18) np = number nonconforming k = subgroups (25) __ np = np1+np2+ ..npk k 0 2 4 6 8 10 12 14 16 18 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1

61、6 17 18 19 20 21 22 23 24 25 U C L = 1 6 . 1 L C L = 3 . 4 avg= 9.8 Alarm Limit Calculation using np Chart 22 First Time Quality Training Module Process Step 5 第五步 Analyze Data 分析數(shù)據(jù) The basic quality tools are 基本質(zhì)量工具 : Flow Charting 流程圖 Check Sheets 檢查表 Pareto 柏拉圖 Cause and Effect 原因和結(jié)

62、果 Run Chart 運行圖表 Histogram 柱圖 Scatter Diagram 散點圖 Control Chart 控制圖 I D E N T I F Y & C O U N T D I S C R E P A N T PARTS I M P L E M E N T I M P R O V E M E N T EVALUATE I N S T I T U T I O N - A L I Z E L E S S O N S LEARNED T O O L S F O R I D E N T I F I C A T I O N : - P R O

63、 C E S S C O N T R O L P L A N - B O U N D A R Y S A M P L E S T O O L S F O R C O U N T I N G : - P A R T S C O U N T E R S - T A L L Y S H E E T S - S I Z E D C O N T A I N E R S T O O L S : - P A R E T O - C A U S E & E F F E C T ( F I S H B O N E ) - C O N C E N T R A T I

64、 O N D I A G R A M - F L O W C H A R T - H I S T O G R A M - S C A T T E R D I A G R A M - C H E C K S H E E T - 5 W H Y S E X A M P L E S : - C R O S S - F U N C T I O N A L T E A M S - C H A N G E B O A R D S - R P N R E D U C T I O N - S T A T I S T I C A L E N G I

65、N E E R I N G P R O J E C T S A C T I O N P L A N : - W H A T , W H E N , W H O T O O L : - A C T I O N P L A N T O O L S : - P F M E A - P R O C E S S C O N T R O L P L A N - L O O K - A C R O S S - C H A R T - 5 W H Y S S E L E C T & PLAN I M P R O V E M E N T N E W L E V E L

66、 O F Q U A L I T Y ? D E F I N E R E A C T I O N P L A N & A L A R M L I M I T S R E C O R D DATA T O O L S : - C O N T R O L C H A R T ANALYZE DATA T O O L : - R U N C H A R T - G A T E C H A R T ALARM EXCEEDED ? I M P L E M E N T ALARM R E A C T I O N PLAN YES NO NO YES I D E N T I F Y A N A L Y Z E P L A N E V A L U A T EI M P L E M E N T ANALYZE DATA 分析數(shù)據(jù) 23 First Time Quality Training Module Process Step 5 第五步 Analyze Data 分析數(shù)據(jù) Problem Identification 確認問題 Prob