PDCA-FTATraining-培训教材.pdf

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1、PDCA-FTA Training May 2010 I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 2 Agenda 1.介介绍绍 Introduction 2.问题问题描述描述(5W2H)通知通知 Problem characterisation(5W2H)-Notification 3.保保护护客客户户,从挑从挑选选中得到信息中得到信息 QR

2、How to secure the customer and learn from sorting-QR 4.找到根本原因找到根本原因 PD How to find the root causes-PD 5.对对策策实实施施,检查检查有效性有效性,经验经验学学习习卡卡 CA Counter-measure implementation,check of efficiency and LLC writing-CA 介绍 Introduction I Always place client logo on the right bottom corner,equidistant from the g

3、rey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 4 VALEO 5000 战略战略 Strategy 方法方法 Method 检查进度检查进度 Measure Progress 5 AXES Valeo 5000 QRQC activity 质量管理系统质量管理系统 Quality Management System 基于基于 三现主义三现主义 Based on San Gen Shugi attitude COST QUALITY GLOBAL PRESENCE TECHNOLOGY QRQCQu

4、ick Response Quality ControlQRQCQuick Response Quality Control P D C A 持续改进持续改进Continuous Improvement I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 5 SAN GEN SHUGI Attitude San means 3 Gen means rea

5、l or actual Shugi means ideology San Gen Shugi 1.Gen-ba:Real Place 现场现场 2.Gen-butsu:Real Parts 现物现物 3.Gen-jitsu:Reality(Real data)现实数据现实数据 要了解其含意要了解其含意 Need to understand what is behind I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equival

6、ent to the Valeo logo.I 2010.05 I 6 Genba=Real place 现场现场 态度态度:ATTITUDE:是否 Do you-用你自己的腿和眼睛?Use your legs and your eyes?-会见问题相关人员?Interview actors of problems 是否 Are you able to be:-出现在问题发生的地方 Where it happens-出现在问题发生的时间(及时)When it happens(now)好处好处:BENEFITS:-不靠猜想 No imagination-通过观察了解问题 Observe to u

7、nderstand-收集分析问题所需的信息 To be able to analyze I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 7 态度态度:ATTITUDE:是否 Do you-对比好/坏(零件,状态)和标准 Compare good and bad(parts,situation)versus standard 好处好处:BENEFITS

8、:-发现差异点 Detect differences-发现与标准的差异 Detect deviations to standard-识别相关”因素”Identify relevant factors Genbutsu=Real parts 现物现物 I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 8 Genjitsu=Real data 现实数据现实

9、数据 态度态度:ATTITUDE:是否 Can you:-用事实和数据说话 Speak with facts and data 是否 Do you:-要求得到证明和数据 Request evidences and data-不接受”我觉得,我相信，也许”Forbid words such as“I think,I believe,perhaps.”好处好处:BENEFITS:-准确性 Be accurate-自信，也令人信服 Be convinced and be convincing-节省时间 Gain time MAQMAQMAQI Always place client logo on

10、the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 9 QRQC Based on San Gen Shugi Video QRQC N1(9),N2(11)How to deal with a problem?I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum he

11、ight equivalent to the Valeo logo.I 2010.05 I 10 PDCA FTA 概况概况 Overview 什么是什么是PDCA-FTA?What is it?QRQC中使用的解决问题的方法 A methodology used during QRQC activities for problem solving.法雷奥用来对应各种问题的标准表格格式 It is a standard format in Valeo for all kind of problems.2个部分组成 2 majors steps:-快速反应 Quick response acti

12、vity -分析 Analysis activity I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 11 PDCA QR&Analysis overview 快速反应快速反应 Quick response activity:问题描述(5W2H)Problem characterization(5W2H)保护客户 Customer securisat

13、ion -挑选 Sorting -遏制措施 Containment actions -从挑选中得到信息(更新5W2H)Learning from sorting(update 5W2H).分析分析 Analysis activity:找到根本原因 Root cause identification FTA，5个为什么，缺陷复现 FTA,5 Whys,defect reproduction.对策实施 Countermeasures implementation 经验学习卡 Lessons learned card.检查有效性 Check of efficiency 24h 5 days 10 d

14、ays 30 days 30天，彻底杜绝 问题再发 30 days for permanent elimination 第一步是什么?What should you do first?描述问题 Characterize the problem I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 14 SYNRYN=0 km Return-Results

15、of sorting in after-sales stocksCUSTOMER VIEW-What happened?15VEHICLE/ENGINE/REF.CUSTOMER 9-What is the difference between good and bad parts?22VALEO VIEWPRODUCT SOP DATE 13Nb.SortedSORTING ACTIVITY to protect customer 32Nb.NG PartsPPM-Results of sorting in Customer plant 700-PPMTOTAL SORTING-Result

16、s of sorting in Valeo plant-Results of sorting in Transport-Results of sorting in Logistics platformMost recent partPPM-First certified good shipment:Production dates of sorted partsPeriod of NG partsFromOldest partPPMDateTo-GOODPART 30Origin of the part 31BADPART 29DATE 41QUALITY Manager 40DEPARTME

17、NT Manager 39PLANT Manager 38 LIMIT TIME:24 HrsDATEIdentification OK partsNumberRevision 6.35_engSafetyWarranty InternalSupplierLogisticProjectWHAT IS THE PROBLEM?Use 5W+2H to know what is the Current Situation(C/S)?LAST MODIFICATION DATE 14PROBLEM DESCRIPTION BY CUSTOMER/LOCATION OF THE PROBLEM 12Q

18、UICK RESPONSE PDCA PPMSorting dateIdentification OK partsWHO-Did a similar problem happen previously at customer or internally?281.IMMEDIATE COUNTERMEASURES IN VALEO PERIMETER?36WHAT ARE THE IMMEDIATE COUNTERMEASURES(24 hours)?DATEWHEREWHOWHOPPM2.IMMEDIATE COUNTERMEASURES IN CUSTOMER LINE?37PPM-Are

19、we capturing the defect when reinjecting product in normal process?27PRODUCT(Designation+Ref)VALEO 1011Leader 1Group 2CUSTOMER/Contact name 8Opened date&Time 6Valeo incident number 3Customer Incident number 4Date of customer notification 5-Where detected?19-How detected?20-Why is it a problem?16-Whe

20、n detected 17-Who detected?18(name of operator)-In which other application or processes product is used?26 WHERE-How many bad parts?21-Was part produced in the standard process?23-When was it manufactured at Valeo?24-Who manufactured?25TOTAL LINE REJECT SITUATION(Defect related)33Which LLC was alrea

21、dy issued on similar problem?34WHAT DID YOU LEARN from sorting(shift related,period related,operator related)?35Sorting results00,10,20,30,40,50,60,70,80,91Defects per shift00,20,40,60,811,2Produced per shiftDef.Shift 1 in sortingDef.Shift 2 in sortingDef.Shift 3 in sortingDef.Shift 1 at customerDef

22、.Shift 2 at customerDef.Shift 3 at customerTotal qty sorted Shift 1Total qty sorted Shift 2Total qty sorted Shift 300,20,40,60,811,20/1/000/1/000/1/000/1/000/1/000/1/000/1/000/1/000/1/00Quantity of defects00000111111Total Line RejectDefect quantityTotal Line reject PPMQR:Quick Response 弄清问题是什么 Under

23、stand what is the problem 进行彻底的挑选 Perform an exhaustive sorting activity 保护客户,直至措施有效性得以验证 Protect and secure your customer until the check of the efficiency of the corrective action 与客户紧密沟通 Customer intimacy 从挑选中得到什么信息?引导正确的分析方向 What you learnt from sorting activities?Lead to the right direction 保护客

24、户 Secure the customer I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 16 本步骤的目标本步骤的目标 Objectives of this phase 不超过不超过24小时小时 24H(maximum)客户不应当再被此问题打扰 The customer should not be disturbed anymore becaus

25、e of this defect.-如何保护客户 How to protect customer 彻底挑选彻底挑选 Total sorting 所有所有产品被挑选 All the parts are sorted 从挑选中得到什么信息从挑选中得到什么信息 What we learned from sorting activities 找到问题发生的规律 Find out when the problem is created -以引导正确的方向，去发现什么被改变了，什么时候被改变的 Lead to right direction to find out what changed and whe

26、n I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 17 如何保护客户如何保护客户?How to secure the customer?询问如下问题，关键词询问如下问题，关键词=给我看给我看 Asked questions,Key words=Show me.-零件在哪里?Where are the parts?-多少好的，多少坏的?How man

27、y good and how many bad?-什么时候生产的?When it was manufactured?-挑选流程，作业指导书有吗?Sorting procedure?-谁去挑选?Who will sort?-如何保证沟通?（内部，与客户）How to communicate?-如何能”快速”，”有效”?（任务分解）How(split the tasks)to do quickly and efficiently?-如何整合处理结果?How to gather result?-何时能确保客户安全?When is it guaranteed?-如何使用挑选中发现的信息,引导正确的分析

28、方向?How what you learned from sorting to lead to right direction?I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 18-不同颜色代表不同的任务，分派不同的人负责执行 Different colours for different persons-程序.如何去制定和批准程序规定?Proced

29、ure.How to do defined and validated procedure?-及时交流结果.Result is immediately communicated-更新对问题的理解和描述.Update your problems understanding 挑选挑选 Organize sorting =-Results of sorting in after-sales stocksNb.SortedSORTING ACTIVITY to protect customer 32Nb.NG PartsPPM-Results of sorting in Customer plant0

30、0-PPMTOTAL SORTING-Results of sorting in Valeo plant-Results of sorting in Transport-Results of sorting in Logistics platformMost recent partPPM-First certified good shipment:Production dates of sorted partsPeriod of NG partsFromOldest partPPMDateTo-Identification OK partsNumberPPMSorting dateIdenti

31、fication OK partsWHOPPMPPM-I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 19 生产线不良率TLR是多少?What is the TLR situation on the line?有多少是这个问题?有多少是别的问题?For this problem?For other problems?生产线QRQC板上的信息对你有帮助

32、吗?What does the Line QRQC board teach you?生产线不良状况生产线不良状况 Total Line Reject Situation 50 100 150 200 250 I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 20 之前类似问题的之前类似问题的LLC?LLCs have already been writ

33、ten for similar problems?在在Google Search里通过关键词搜索工厂，专业公司的类似问题里通过关键词搜索工厂，专业公司的类似问题的的LLC。(仅法雷奥内部使用仅法雷奥内部使用)Specify the search words used in Google Search to find out if a similar problem has happened before,in your site,your Branch and in Valeo.查阅之前相关的查阅之前相关的LLC Review the relevant LLCs to learn:-哪些因素被

34、检查 Factors to be checked -分析后采取的解决方案 Solutions to be considered after the analysis has been completed -查看PFMEA/DFMEA里设定的该问题发生率 Review the occurrence rating in the PFMEA/DFMEA I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the

35、Valeo logo.I 2010.05 I 21 从挑选中得到什么信息从挑选中得到什么信息?What did you learn from sorting?要记录要记录 In this section you should record:从挑选活动中得到什么信息:What was learned from the physical sorting activity:是否与特定生产日期，特定生产班次相关 date or shift related 是否与特定生产员工相关 person related 是否与特定产品门类相关 product family specific 是否与特定模具（型腔）

36、相关 tooling specific 是否与特定设备相关 machine specific 是否与特定原物料相关 material specific 随机出现的/连续出现的 random/consecutive （所有不良产品）不良状态始终一致的或者不良状态有些许变化 symptom is repetitive or varies in form 从查阅中得到信息 What was learned about the situation:在不良品生产时段中发生的:如，维护保养，新批次的原物料，新设备，新模具，新员工（未培训），停电，气温变化，客户来访.Events which occurre

37、d during the production period of the NOK parts eg.Maintenance action,new batch of a component,new equipment or tooling,untrained person on the line,power failure,temperature,customer visit.查阅PFMEA/DFMEA Review of PFMEA/DFMEA:该问题风险有没有在该问题风险有没有在 FMEA识别识别?Is the risk identified in the FMEA?FMEA里定义的控制方

38、法是什么里定义的控制方法是什么?该控制方法是否达到了预期效果该控制方法是否达到了预期效果?Which control method is defined in the FMEA?Is it still working as expected?I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 22 制定遏制措施以保护客户，直至问题得以彻底根除制定遏制措施

39、以保护客户，直至问题得以彻底根除Organize efficient containment action to protect customer until eradication of the issue LIMIT TIME:24 HrsDATEQUALITY ManagerAPU ManagerPLANT Manager1.IMMEDIATE COUNTERMEASURES IN VALEO PERIMETER?WHOWHAT ARE THE IMMEDIATE COUNTERMEASURES(24 hours)?DATEWHEREWHODATEWHERE2.IMMEDIATE COU

40、NTERMEASURES IN CUSTOMER LINE?自问自问 Questions:-如何确保挑选活动能发现不良品如何确保挑选活动能发现不良品?How to make sure to catch the defect?-在哪里在哪里(阶段阶段)最便于发现不良最便于发现不良?Where is the best place to catch it?-挑选活动是否有可能造成新的不良挑选活动是否有可能造成新的不良(如如,贴错标签贴错标签)Is there any risk to create an other defect(mislabeling for example)?-遏制措施是否得到客户

41、认可遏制措施是否得到客户认可?Have you made your action approved by the customer?I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 23 在实施保护客户措施时想走捷径在实施保护客户措施时想走捷径 Cutting corners during the securization actions 你是否觉得发

42、生问题你是否觉得发生问题 已经很糟糕了已经很糟糕了.If you think you had a bad day.I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 24 加快速度的方法加快速度的方法-分派任务分派任务 Speed up the process Assign Task 为了加快速度，我们要把工作分解成能够被快速处理为了加快速度，我们要把工

43、作分解成能够被快速处理(24H内内)的多个小任务的多个小任务 To speed up,we need to split in small tasks that can be treated quickly(24H maximum)1个任务个任务=1个负责人个负责人 1 task=1 responsible 以事实和数据来评价完成的进度以事实和数据来评价完成的进度 Review the progress based on facts and data 分派任务分派任务 Assigning tasks 关键词关键词:请你负责去请你负责去.，在，在XX小时小时(24)内带着数据和事实结果回来汇报内带

44、着数据和事实结果回来汇报 Key words:Please do.and come back to me in xxH(Check the implementation of the solution Communicate for standardization Factor to control Description of the problem 5W2H Cause treated by the LLC:should be only one per LLC Situation with the countermeasure How is it controlled What is th

45、e criteria for OK and NOK Type of LLC:occurrence/detection/management The Lesson Learned Card I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 43 经验学习经验学习 Lesson learned 如何确保避免再次发生如何确保避免再次发生 How to mak

46、e sure to avoid occurrence 如何从这次的问题得到教训，并进行预防如何从这次的问题得到教训，并进行预防:How to learn from this mistake and prevent in:其他生产线 other lines 其他工厂 other plants 其他公司 other divisions 其他专业公司 other branches 如何保留并传递得到的教训如何保留并传递得到的教训 How to keep the knowledge I Always place client logo on the right bottom corner,equidi

47、stant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 44 目的目的 Objectives 实施对策，消除问题或者在内部能够控制住实施对策，消除问题或者在内部能够控制住 Implement the countermeasure to eradicate the problem or to stop it internally 履行对客户的承诺履行对客户的承诺 Respect our promises to customer 审核审核/检查检查 Audit and check

48、 如何从中受益如何从中受益 How to capitalize 从问题的根本原因学到经验从问题的根本原因学到经验 Learn from our mistakes root causes from 发生的原因，没有发现的原因，管理系统的原因发生的原因，没有发现的原因，管理系统的原因 Occurrence,Non detection,Management 如何分享如何分享 How to share 目的是预防目的是预防 In order to prevent I Always place client logo on the right bottom corner,equidistant from

49、 the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 45 100%保护行动最多保护行动最多24小时内完成小时内完成 100%securisation done within maximum 24 H 100%Do 最多最多5天内完成天内完成 100%Do done within 5 days maximum 100%Act 10天内完成（经验学习卡）天内完成（经验学习卡）100%Act done within 10 days(LLC)100%验证验证,稳定性审核，稳定性审核，30天内确认天内

50、确认 100%verification and stability audit confirmed within 30 days 总结总结 Summary of Objectives I Always place client logo on the right bottom corner,equidistant from the grey line,with a maximum height equivalent to the Valeo logo.I 2010.05 I 46 一些常见问题一些常见问题 空白格，空白格，PDCA-FTA表没有完整填写表没有完整填写 没有遵守没有遵守PDCA-