七颗钻石流程-品质改善.ppt

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,1,7,Diamond Process,七颗钻石流程,2,What is the 7 Diamond Process?,七颗钻石的流程是什么？,The 7 Diamond Process is one of many tools that can be used in the problem solving process.,七颗钻石流程是可以用来解决质量问题的工具之一。,This tool is used to investigate discrepancies discovered by the following:,它可以用来调查以下方面发现的差异,Global Customer Audit System(GCAS),全球顾客评审,Yard Walk Audits,生产线上巡检,Verification Stations,检验工位,3,Purpose of the 7 Diamond Process,7,颗钻石流程的目的,The,7 Diamond Process,is a structured way of assessing our manufacturing process to determine whether of not it has failed to meet the quality standard demanded by our customers.,7,颗钻石流程,是一个构建好的评价我们的制造流程是否满足了顾客所要求的质量标准的一个方法,4,7,Diamond,Process,流程,Responsibility,责任,Production,第一步,1,Production,第二步,2,Production,第三步,3,Rel.Engineer/,SQA/Supplier,负责的,SQDE,工程师/供应商,4,Correct,Process,?,正确的工艺,Correct,Tool?,正确的工具,Correct,Part?,正确的零件,Parts,Quality?,零件质量,Responsibility,责任,Process Control,Managers,工艺控制负责人,5,a,Is Engineering,support required?,是否需要工程方面的支持,Problem Identified,Begin Interrogation,问题定义(开始调查),Responsibility,责任,QET,PST(Lead),5b,SMT,RGM (Lead),6,Statistical,Engineering,(Red X,Strategies),统计工程(红-,X,方法),7,Will,Process Change,Resolve?,工艺更改能解决问题吗,Product Change,Required?,产品更改需要吗？,Hardy,Perennial or,Extremely Complex,Problem,非常复杂的问题,SQA-Supplier Quality Assurance,QET-Quality Engineering Team,PST-Plant Support Team,SMT-Systems Management Team,RGM -Reliability Growth Management,5,Review of Responsibility,职责回顾,Diamonds 1-4Production&Reliability,钻石1-4 生产&可靠性,Filter 5aProcess Control Manager(PCM),5a,过滤 工艺控制负责人,Diamond 5b-7Product Engineering,钻石5,b-7,产品工程,6,Insert Sample Countermeasure,Card Here,此处插入对策卡样卡,7,7,Diamond Process Stages,流程的各步骤,Stages 1&2 of the process are used to determine if the Production organization is running the assembly process to design intent.,1、2,步是用来确定生产部门运行的装配流程满足设计内容。,The initial investigation(Stage 1)is done where the defect was identified.,最初的调查(第一步)应在发现缺陷的地方开始,Stage 2 is only used when the investigation in Stage 1 determined that the cause of the problem was from an upstream source.,第2步只能当第一步的调查,确定问题是来源其他方面时,才可开始,If the process isnt being managed to design intent,then it must be corrected and validated,prior to asking for Engineering assistance.,如果工艺没有满足设计内容，当需要工程方面的协助前，必须进行纠正并要有效。,Engineering referral(Stage 3)occurs when the manufacturing process does meet design intent and the problem still exists.,当制造过程满足设计内容并且问题依然存在时，第3步开始。,8,1-,Correct Process,正确的过程,Are the correct Best People Practice sheets posted?,是否有正确的操作指导文件？,Are the Best People Practices being followed?,是否执行操作文件？,Is the operators Key Point Chart being followed?,是否满足关键操作点控制图,Are the correct documents posted on the operation certification board?,是否在操作示板上有正确的文件,Is the job being performed to the PADs?,是否按照,PAD,操作,Can any of these cause the problem?,以下的问题有可能产生问题吗？,Stages 1&2,Production,Corrects,正确的生产,Production,2,Production,3,Rel.Engineer/,SQA/Supplier,4,Correct,Process?,正确的工艺过程,Correct,Tool?,正确的工具,Correct,Part?,正确的零件,Parts,Quality?,零件的质量,8,1-,Correct Process,正确的过程,Has a mandatory sequence been identified?Is it being followed?,是否强制的操作序列号已识别，是否执行了,Is the job being done the same on both shifts?,在各班次中操作工作是否一致,Does the operator understand what the product standards are?,操作者是否理解产品标准,Is it the regular operator?Has there been a lot of turnover on the job?,是否为固定操作工？是否此操作有很多轮换人员,Has the operator been properly trained?,操作者是否正确培训过,Are the visual aids current?,目前是否有目视化的辅助措施,Does the operator understand the quality outcomes of her/his job?,操作者是否知道他/她的岗位的产品的输出质量,Does the operator know how to communicate when he/she has a problem?,操作者是否知道当他/她的岗位出现质量问题时如何传递沟通信息？,Can any of these cause the problem?,以下的问题有可能产生问题吗？,Stages 1&2,Production,Corrects,正确的生产,Production,2,Production,3,Rel.Engineer/,SQA/Supplier,4,Correct,Process?,正确的工艺过程,Correct,Tool?,正确的工具,Correct,Part?,正确的零件,Parts,Quality?,零件质量,9,Are the correct tools&fixtures being used?(both shifts),是否使用正确的工具/夹具(各班次),Are the tools set to the specified torque?,工具是否设置成规定的扭矩,Are they properly calibrated?,是否进行适当的校准,Are both shifts using the same tool?,是否各班次用同样的工具,Are the bits or sockets worn?,是否螺丝刀或套筒已磨损,Has an extra air hose been attached to the tool?,是否在工具上有多余的空气管,Is the tool tied to the,Andon,system?,工具是否与暗灯相连,Has the tool been put on Bypass?,是否工具被旁路,Do the tools&fixtures have mutilation protection?,是否工具/夹具有损毁保护,Has the workstation been error proofed?,工位是否有防错设施,Does the workstation layout allow the operator to work effectively?,是否工位的布置适合操作者有效的工作,Has the Preventive Maintenance been done?(check log),是否进行了预防性维修(检查表),Are tools functioning correctly?,工具功能是否正确,Stages 1&2,Production,Corrects,Production,1,Production,3,Rel.Engineer/,SQA/Supplier,4,Correct,Process?,正确的工艺过程,Correct,Tool?,正确的工具,Correct,Part?,正确的零件,Parts,Quality?,零件质量,2-,Correct Tool,正确的工具,Can any of these cause the problem?,10,Is the Parts Routing current?,零件的路径是否正确,Are the correct part numbers identified on the material racks?,是否在料架上标识有正确的零件号,Are parts stocked in correct location on the rack?,在料架上摆放位置是否正确,Do the part numbers on the boxes agree with the rack?,包装盒上零件号与料架上是否一致,Are all pull cards available?,拉动卡是否有效,Has a PAA been issued changing part usage?,是否有零件用途改变的,PAA,Has the PAA expired?,PAA,是否过期,Is error proofing needed?,是否需要防错措施,Is existing error proofing device working correctly?,是否已有的防错设备运行正确,Stages 1&2,Production,1,Rel.Engineer/,SQA/Supplier,4,Correct,Process?,正确的工艺过程,Production,Corrects,Correct,Part?,正确的零件,Production,2,Correct,Tool?,正确的工具,Parts,Quality?,零件质量,3-,Correct Part,正确的零件,Can any of these cause the problem?,11,The,Reliability Engineer,is responsible for determining if parts have changed and overall part quality.If parts quality(out of specification)is determined to be the problems root cause,then the RE will:,write PR&Rs to notify the supplier that there is a problem.,可靠性工程师确定零件是否更改过并对产品全部质量负责。如果由于零件质量(超差)是根本原因，那么应：填写,PR&R,通知供应商：,work with Supplier Quality to validate the corrections.,同供应商共同确认纠正措施,set up sorting operations and production will support sorting of material at the operation.,采取筛选措施，制造应支持在工位上的物料筛选,work with Group Leaders to validate countermeasures or containment.,同工段长共同确认对策和遏制措施,If part variation within specification is the root cause,then the RE will:,如果确认零件在规范内，那么,RE,应：,work with the supplier and SQA to move the part back to the needed range within the specification,同供应商共同工作，,SQA,将零件返回到规范内需要的范围,work with Quality Engineering to determine if an Engineering Change is required to provide irreversible corrective action,同质量工程师合作，确定是否需要工程更改这种不能消除的纠正措施,Stages 1&2,Production,1,Correct,Process?,正确的工艺流程,Rel.Engineer/,SQA/Supplier,Parts,Quality?,零件质量,Production,2,Correct,Tool?,正确的工具,Correct,Part?,正确的零件,Production,3,4-,Part Quality,零件质量,12,Diamonds 1-4 in Review,钻石,1-4,步回顾,Diamonds 1-4 are for evaluating the stability of the process.,1-4,步用来评价工艺过程的稳定性,Once a problem has been identified,the automatic response must be to immediately step thru diamonds 1-4.,当问题被定义后，1-4步的负责人员就自动确定下来,It,must,become inherent in our problem solving thought process.,这些步骤是问题解决过程中固定的流程,Responsibility,职责,Process Control,Managers,过程控制负责人,5,a,Is Engineering,support required?,是否需要工程的支持,13,5,a-Engineering Filter 5a-,工程过滤,Is Engineering support required?,需要工程方面的支持吗,5,a is a step to filter out and resolve less-complex issues before seeking help from Quality Engineering.,5a,是一步过滤出并将不复杂的问题在寻求质量工程帮助前解决,The,Process Control Manager,is responsible for conducting initial studies prior to escalating the issue.,过程控制负责人负责在提升问题前指导初始研究,These studies may include but are not limited to:,这些研究应包括但不局限在:,Problem Definition Tree,问题定义树,5,Whys,5,个为什么,Statistical Process Control,统计过程控制,Design of Experiment(DOE),试验设计,Shainin,Techniques(quick&dirty),技术(快速&脏),If after the initial studies the cause of variation has not been determined,the issue is referred to Product Engineering.The problem definition tree is the minimum exit criteria to go from Diamond 5a to 5b.,如果经过初始研究，变差的产生原因还没有确定，就需要产品工程的支持。问题定义树是从5,a-5b,的基本方法。,Quality,Engineering,质量工程,5,a,Problem Solving Toolbox,问题解决工具箱,Project title:Poor adjustment of RR door panel 805-830,Leader:Pedro Aranda Alfaro,Sponsor:Juan Carlos Licea,Area:VAET,Coach:Leonardo Chvez salcedo,Initial date:oct-04-2002,Final date:oct-29-2002,Problem description:,This month it was reported by the shipping lot in USA a problem of quality existed in the 805/830 vehicles.The problem is the poor adjustment in RR door panel.,Projects statement:,Find and improve the Red X that produce the poor adjustment in the RR door panel for the model 805/830 in Silao Assembly plant.,Strategy:,We initiated this project using the model to model strategy,because there was a good contrast and good leverage based on multi-vari see pag 6.,Measurement system:,As measurement system a Force gage was used.,This measurement system passed the isoplot with DR=13.6,D,M=1.0 lbs,and,D,P=13.6 lbs (see page 4),Clue generation:,Stage 1 shows that the Red X doesnt live in the process.The stage 2 shows that the Red X lives in the door panel.The pair comparison shows that the door molding is the part with the best contrast.,Statistical confirmation:,Once we detected the Red X candidate,I decided to do a B vs C six pack trial,in order to confirm the door molding is the influence to make the customer satisfaction.The six pack passed with 95%of confidence and end count of 6.,Irreversible corrective action:,To modified the flange 1.5 mm in length to keep a better position and avoid that the door panel take out of position.,Improvements:,Reduce warranty cost to repair the door panel caused by poor fit(loose)and eliminate the condition in 100%in vehicles 805/830 models.The amount of money from jul 01 to jul 02 was 11,084.77 USD.,Lessons learned:,We learned that is necessary looking other alternatives using other strategy when is not possible invest money but always focus to guarantee the customer enthusiasm,therefore this project is an example of this.,Executive Summary,执行总结,项目题目,：右后门板调整不好(805/830车型)。,领导,；,Pedro Adranda Alfaro,发起人,：,Juan Carlos Licea,区域,：,VAET,教练,：,Leonardo Chavez salcedo,起使日,：2002年10月4日,截止日,：2002年10月29日,问题描述,：,本月收到报告，在美国有关于门饰板的质量问题，,右后门饰板调整不好。(805/830型),项目综述,：,针对,Lilao,装配厂805/830车型的右后门饰板，发现并,解决其配合不好的问题。,策略,：,我们起初应用车型对车型策略，因为多车之间有很好的对比度和平衡关系。(见见第6页),测量系统,：,用测力计作为测量系统。这种测量系统通过等量图。,(,DR=13.6,M=1.0lbs,P=13.6lbs,见第4页,线索产生,：,阶段1表明红,X,不在过程中。阶段2表明红,X,产生在门饰板处。成对比较表明门型是成对比较点。,统计确认,：,一旦我们查到了候选的红,X，,我们决定做,B vs C,六组数据比较，这是为了确认门型影响客户满意度。用6对数据进行比较具有95%的可信度和最大累加值为6.,不可撤销的纠正措施,：,为使门边缘加长1.5,mm,以保证正确的位置不偏离。,改进措施,：,减少保修费用来修复由于配合不好产生的门饰板问题，并且100%消除803/805车型的缺陷。,学到的经验,：,我们学到了,:,当投资不会太多的情况下，用其它策略以寻求可选择的方法解决问题。但始终要关注顾客热忱。此项目便是一个这样的例子。,Project Definition Tree/,项目定义树,Problem characterization,问题描述,Warranty condition/,保修条件,The problem is presented only in the rear door,问题只是在后侧车门出现,BASED,:DISTRIBUTON LOT CAMPAING,CURRENT,:100%door panel 805830 models loose,目前状态：805/830型车门饰板100%松动。,GOAL,:eliminate 100%the poor fit.,目标：100%消除不良的配合,Project statement,项目综述,Need energy to release the trim door panel,需要用力才能卸下门饰板,Customer is calling the problem in both sides,客户现在对两侧都在抱怨,Effort to release(lbs)/,释放力(磅),Frequency,频率,CURRENT,现有,DESIRED,希望,Solution tree,项目解决树,TARGET:Eliminate condition 100%,目标：,100%消除现有问题,PASSED ISOPLOT DR=15.2 SEE PAG 4,通过等量图验证,DR=15.2,参见第4页,PASSED STAGE 1 SO THE RED X DOESNT LIVE IN THE PROCESS SEE PAG#7.,通过第一阶段验证，因此红,X,不在装配过程中，参见第7页。,THE COMPONENT SEARCH STAGE 2 SHOWS THAT THE RED X DOES NOT LIVE IN THE TRIM DOOR PANEL SO LIVES IN THE REST OF THE DOOR PANEL.SEE PAG#7./,零部件分析阶段2显示红,X,不是由车门内饰板造成的,所以应是由车门板的其余部分引起的,见7页.,PAIR COMPARISON SHOWS THAT THE DOOR PANEL MOLDING HAS THE CHARACTERISTIC THAT PRODUCE THE DIFFERENCE SEE PAG 9/,配对对比显示车门饰板饰件有造成差异的特征，参见第9页,THIS IS THE BEST STRATEGY BASED ON MULTIVARI SEE PAG 5.,这是基于多重变换比较得出的最佳策略，参见第5页。,PASSED B vs C WHERE IT SHOWS THAT THE DOOR MOLDING KEEP IN POSITION THE DOOR PANEL SEE PAG 10,BUT WE CHOICE OTHER CHARACTERISTIC THAT KEEP IN POSITION THE DOOR PANEL AND WITOUT INVEST MONEY SEE PAG 11&13.,通过,BC,对比试验，显示车门饰板饰件能够使车门饰板保持正确位置，见第10页。但是我们选择能够保证车门饰板位置并且不用增加投资的其它特性，参见第11和13页。,Frequency,频率,GREEN Y RUN CHART SEE PAG 17/,绿,Y,字流程图参见第17页。,DESIRED,希望,CURRENT,现有,BASED:DISTRIBUTON LOT CAMPAING,Effort to release(lbs),释放力(磅),D,M=1.0 lbs,D,P=13.6 lbs,DR=13.6,Passed Isoplot,Isoplot,A Force gage was used,as the measurement system,拉力计作为测量工具,通过,ISOPLOT,评估,POINT,TO,POINT,There are no contrast in this strategy there are no difference.,There is a good contrast but the leverage is not enough because we dont have tools to measure it.,This strategy provide good contrast and the best leverage based on multi-vari chart see pag 6,There are no contrast through the time,Strategy diagram,PLANT,TO,PLANT,MODEL,TO,MODEL,TRUCK,TO,TRUCK,SIDE,TO,SIDE,SAME PANEL,SAME PLANT,SAME MODEL,SAME TRUCK,There is a contrast between truck to truck and good leverage but the contrast is not enough based on multi-vari see page 6.,EVENT,TO,EVENT,SAME POINT,There are no contrast in this strategy there are no difference event to event.,策略图,事件,对,事件,同一个点,点,对,点,同一块扳,同一侧,对,同一侧,同一台车,车,对,车,同一型号,型号,对,型号,同一个工厂,工厂,对,工厂,在这个对比中,无差异.,在这个对比中,无差异.,在这个对比中,有差异.但无测量工具.,在车与车的对比中,有差异.但不能满足,MULTI-VARI,的要求.,在这个对比中,有差异.且能满足,MULTI-VARI,的要求.,在这个对比中,无差异.,Multi-vari,NOTE:This graphic shows that the best contrast is model to model.,Side,Truck,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 26 27 28 29 30 31,EFFORT TO TAKE OFF(lbs),R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L R L,Customer satisfaction limit,BOB,WOW,Model,C C C C A A A A A A A A A A A S S S S S S S S S S S S S S S S,NOTE,:,S,:,SUBURBAN 830 MODEL,A,:,AVALANCHE 805 MODEL,C,:,CADILLAC 806 MODEL,注:,SAC,三种车型,最好,最坏,顾客的满意底线,注:此图显示出在型号与型号的对比中有最大的差异.,松脱力(磅),Component search,NOTE:This graphic shows that the Red X suspect does not live in the process because it passed the stage#1.The stage 2 shows that the Red X suspect does not live in the seal window.So the Red X suspect lives in the molding door panel.,Effort(lbs),BOB,WOW,STAGE 1,STAGE 2,第一阶段,第二阶段,最好,最坏,原状态,第一次拆装,第二次拆装,第三次拆装,门窗密封条,门饰板,门饰板饰条,铰链,注:这个图显示因为通过了第一阶段的试验,所以,RED X,不是由操作造成.,第二阶段的试验显示门窗密封条不是,RED X,门饰板饰条是,RED X,要素查找,规则,Rule 1.,There are complete separation between the BOB and WOW values.,将最好和最坏的值完全分开,规则,Rule 2.DYV1R,设,Where:,R=,R,BOB,+R,WOW,2,那么,then,R,BOB,=1.9,R,WOW,=1.2,R=,1.9 +1.2,=,3.1,=1.55.,2 2,DY=Y,BOB,-Y,WOW,=46.8 -8.1 =38.7,如果,if,DY V1R,那么,then,38.7 (0.89)(1.55),所以,so,38.7 1.38,所以满足规则1和规则2的要求,so passed Rule 1 and Rule 2,通过问题为每个单元设定判定极限,Set decision limits for each unit by using the questions:,DL,BOB,=Y,BOB,+V2R,DL,WOW,=Y,WOW,+V2R,那么,Then,udl=48.83,DL,BOB,=46.8+1.31(1.55)=,ldl=44.77,udl=10.13,DL,WOW,=8.1+1.31(1.55)=,ldl=6.07,结果,Results,Paired Comparison,备注,NOTE:We consider that the door panel molding is the Red X candidate in the pair comparison because is the only difference between panel to panel.In 805/830 vs 806 models.,我们认为门板装饰件是可能的,Red X,因为在车型805/830 和 车型806对比后只有门板有差异。,WOW,BOB,DOOR MOLDING,RED X CANDIDATE,Passed B vs C with 95