德勤-供应链管理.ppt

QUALITY.PPTPage 18/24/99 9:36 AMIntroductionTemplate DefinitionThe Quality template contains two themes that will be used to determine the degree to which quality is a problem,the cost of quality problems,and the drivers of the quality problems.The two themes that are used to determine this information are Product and Process Quality and Continuous Improvement.Why is it Important to the Supply Chain?The importance of quality products and processes to the supply chain is represented in both strategic and tactical areas.The strategic importance of quality is defined by an organizations competitive environment.The competitive environment may dictate the level of quality that is required to merely be a viable competitor or the competitive environment may allow the organization to use quality as a strategic differentiator.The tactical importance of quality is defined in terms of the cost of rejects,rework,and scrap and in disruptions to operations resulting from quality problems.Quality TemplateQUALITY.PPTPage 28/24/99 9:36 AMIntroductionTheme DescriptionsProduct and Process QualityThe Product and Process Quality theme consists of three main steps.First,the theme will determine if quality problems exist and the extent to which they exist.Second,the theme will quantify the quality problems in terms of cost to the organization.Third,the drivers of the quality problems will be identified.Continuous ImprovementThe Continuous Improvement theme is used to compare the organizations quality program(s)to the characteristics of a formal continuous improvement program.A checklist containing the characteristics of a continuous improvement program will be used to conduct this assessment.QUALITY.PPTPage 38/24/99 9:36 AMAnalytical WorkstepsQUALITY.PPTPage 48/24/99 9:36 AM1)Collect the following data for a key product line for a defined period of time(e.g.1 year)-Scrap(Waste produced during manufacturing process)-Reject(Product that does not meet quality criteria and cannot be reworked)-Rework(Product that does not meet quality criteria but can be repaired)-Production volume(unit cost x units produced)2)Calculate the non-conformance rateNon-conformance rate=($scrap+$rework+$reject)/$production volume3)Graph the results of the the non-conformance rate calculation.EXAMPLE A14)Analyze this data for indicators of problems.Typical questions to ask include:-Is the non-conformance rate stable,trending up,or trending down?-How does the non-conformance rate trend compare to the production trend?QUALITYA.Product and Process QualityCRITICAL QUESTIONSWhat is the magnitude of product and process quality problems?What is the cost of non-conformance?What are the drivers of non-conformance?EXAMPLE A1QUALITY.PPTPage 58/24/99 9:36 AMQUALITYA.Product and Process QualityEXAMPLE A25)Based on the product line identified in the previous steps,collect the following data:acceptable units output by work center(WC)total units output by work center6)Calculate work center yieldYield=acceptable units output/total units input7)Create a process map depicting the process and the yield at each work center in the process.Inspection points can also be depicted on this flow.8)Calculate the Cumulative First Pass Yield for the process.FPY=YWC1 x YWC2 x YWCn EXAMPLE A2QUALITY.PPTPage 68/24/99 9:36 AM9)Collect the following data for each work center of the product line identified in the previous steps-labor cost-material cost-overhead cost-yield(use the data collected in the previous steps)10)Calculate the per unit cost by work center after accounting for yield lossActual Unit Cost per Work Center=(labor+material+overhead)/workcenter yield11)Determine the difference in unit cost before yield loss and after yield loss at each work center.The work centers with the largest cost variance have the greatest potential for improvement in the reduction of cost.Be aware that the highest yield loss(%)may not have the largest cost impact.EXAMPLE A3QUALITYA.Product and Process QualityEXAMPLE A3QUALITY.PPTPage 78/24/99 9:36 AM12)Collect the following data for the product line identified in the previous steps.-#of Units Input-First Pass Yield represented as Acceptable Product Output(from previous steps)-Unit Cost(before accounting for yield loss)(from previous steps)-Annual Production Volume(from previous steps)13)Calculate the per unit cost after yield is taken into account.Actual Unit Cost=(#of units input x unit cost)/#units acceptable output14)Annualize the actual yield loss(total$)for the given product.(unit cost after yield loss-unit cost)x annual sales volume15)Identify the cost impact due to incremental yield improvements.EXAMPLE A4Notes:-The costs associated with quality can also be represented using the internal non-conformance rate.-The cost of yield loss can also be represented in terms of the revenue lost due to a reduction in the output of the facility.-Yield loss can also contribute to intangible costs as well(e.g.lower customer satisfaction,reduced customer loyalty,and lost customers.)EXAMPLE A4QUALITYA.Product and Process QualityActual unit cost calculated to account for yield loss(1,000 x$10.00)/651=$15.36 per unitAnnual cost attributable to yield loss($15.36-$10.00)x 100,000 units=$536,000QUALITY.PPTPage 88/24/99 9:36 AMEXAMPLE A5QUALITYA.Product and Process Quality16)Investigate the drivers of yield loss.Collect system generated reports on quality issue reason codes.If this information is not available,develop a sampling program to track the yield loss drivers for a predetermined period of time.Request operators to track the number of occurrences associated with each yield loss driver in a logbook.17)Plot these drivers in rank order as a percentage of total yield loss EXAMPLE A5QUALITY.PPTPage 98/24/99 9:36 AMQUALITYA.Product and Process QualityEXAMPLE A618)Based on the major drivers of yield loss identified in previous steps,perform a cause and effect analysis.To conduct a cause and effect analysis:19)Place the main problem under investigation in a box.20)Conduct a group working session to identify all potential sources of the problem.21)Sort the identified problems into 4-6 major categories.22)Construct the cause and effect diagram by creating the main branches with the major categories and then position all of the identified problems on sub-branches.EXAMPLE A623)Ensure that the cause at the end of each sub-branch is specific,measurable,and controllable.Tips:-Ensure causes,not symptoms,are identified.-Keep asking if the identified item has a“root cause”driver until no lower level can be identified-Self-adhesive notes can be used to construct the diagramHigh-level viewMaterials branch detailed viewQUALITY.PPTPage 108/24/99 9:36 AM1)Request documentation describing the organizations continuous improvement program and documentation of recent improvements initiatives.2)Interview the appropriate personnel to understand the organizations commitment to continuous improvement initiatives.-Chief Operating Officer-VP of Quality-VP of Manufacturing-Line Operators3)Assess the effectiveness of the organizations quality programs using the Continuous Improvement Checklist.EXAMPLE B14)Identify the strengths and weaknesses of the organizations continuous improvement program.EXAMPLE B1CRITICAL QUESTIONSWhat are the strengths and weaknesses of the organizations quality programs?QUALITYB.Continuous ImprovementQUALITY.PPTPage 118/24/99 9:36 AMEXAMPLE B1(continued)QUALITYB.Continuous Improvement4)Identify the strengths and weaknesses of the organizations continuous improvement program.QUALITY.PPTPage 128/24/99 9:36 AM个人道德素养个人道德素养QUALITY.PPTPage 138/24/99 9:36 AM 做好個人道德素養；不要因為貪小便宜，貪一時方便而不顧道德品行丟失把人格尊嚴都降低了。QUALITY.PPTPage 148/24/99 9:36 AM 因為一個人把道德品質丟失了，再想建立起來將是萬分的困難。QUALITY.PPTPage 158/24/99 9:36 AM所以每個人都應該尊首道德底線，不應敗壞基本道德品質。QUALITY.PPTPage 168/24/99 9:36 AM以下是公司裡面出現的不好的現象：1、厕所紙巾偷到宿舍去用2、車間應急藥箱裡面的藥偷走（偷盜行為可恥）QUALITY.PPTPage 178/24/99 9:36 AM以下是公司裡面出現的不好的現象：1、公共场所随意扔垃圾2、電視房垃圾亂丟QUALITY.PPTPage 188/24/99 9:36 AM以下是公司裡面出現的不好的現象：恶意损坏公共财物QUALITY.PPTPage 198/24/99 9:36 AM以下是公司裡面出現的不好的現象：吃饭不要浪废食物QUALITY.PPTPage 208/24/99 9:36 AM道德與生活道德與生活從字義看兩者的意義與差別:1、倫理的意義倫理的意義:倫類別、關係；理紋理、道理。倫理人類社會裡種種身分間合理的關係，行為分際(做人要守本分做人要守本分)。(哪些人際關係、身分)2、道德的意義道德的意義:道道路、道理；德獲得。道德走人走的道路，便可獲得人的待遇。(不走捷徑、不誤入歧途尊嚴、榮譽)人道人道 (ps.如何批評一個人罔顧為人?)QUALITY.PPTPage 218/24/99 9:36 AM道德與生活道德與生活1、利己利己:理性認識到遵守規範有利於己。(奸商/信譽商人)2、利人利人:追求人性中的真、善、美。(崇高的可能性)。(愛人者人恆愛之，敬人者人恆敬之；德不孤必有鄰。)(典範在夙昔-林靖娟、鐵達尼號的樂師、德雷莎修女、史懷德.)3、利己利人利己利人:兼顧自我理想與社會進步。Bill Gates?不做”損人利己”之事。Ps.回想郭爾堡的道德認知理論、馬斯洛的需求層次理論。QUALITY.PPTPage 228/24/99 9:36 AM-THE END-