汽车七颗钻石流程(7 Diamond Process)培训

¨1
Correct
Process? 正确的工艺
Production 第二步 ¨2
Correct
Tool? 正确的工具
Is Engineering support required? 是否需要工程方面的支持
Responsibility 责任
Process Control Managers
工艺控制负责人 ¨5a
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
Team
RGM - Reliability Growth Management
Hardy Perennial or Extremely Complex
Problem 非常复杂的问题
Statistical Engineering
(Red X Strategies) 统计工程(红-X方法)
¨7
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
Responsibility 责任
Will Process Change
Resolve? 工艺更改能解决问题吗
QET
PST (Lead) ¨5b
Product Change
Required? 产品更改需要吗？
SMT
RGM (Lead) ¨6
Production 第三步 ¨3
Correct
Part? 正确的零件
汽车技术培训-
汽车七颗钻石流程（7 Diamond Process）培训
Welcome to this training 欢迎参加本次培训
• 主 讲 人：
XXX
• 学 时：
2
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
1
汽车技术培训-
7 Diamond Process
What is the 7 Diamond Process? 七颗钻石的流程是什么？
Product Engineering 产品工程
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
5
汽车技术培训-
7 Diamond Process
Insert Sample Countermeasure Card Here
此处插入对策卡样卡
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
3
汽车技术培训-
7
Diamond
Process
7 Diamond
Process
流程
Problem Identified
Begin Interrogation 问题定义(开始调查)
Responsibility责 任
Production 第一步
Rel. Engineer/
SQA/Supplier 负责的SQDE工
程师/供应商 ¨4
Parts
Quality? 零件质量
SQA
- Supplier Quality
Assurance
QET
- Quality Engineering
Team
PST
- Plant Support Team
SMT
- Systems Management
6
汽车技术培训-
7 Diamond Process
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。
• 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
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
2
汽车技术培训-
7 Diamond Process
Production ¨2
Correct
Tool? 正确的工具
Production ¨3
Correct
Part? 正确的零件
Rel. Engineer/
SQA/Supplier ¨4
Parts
Quality? 零件的质量
• 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 PAD’s? •是否按照PAD操作 •
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 isn’t 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。
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
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
9
7 Diamond Process ¨2 - Correct Tool正确的工具
Stages 1&2
Production ¨1
Correct
Process? 正确的工艺过程
Production Corrects
Correct
Correct
Tool? 正确的工具
Production ¨3
Correct
Part? 正确的零件
Rel. Engineer/
SQA/Supplier ¨4
Parts
Quality? oblem?以下的问题有可能产生问题吗？
• 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？
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。
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
8
汽车技术培训-
7 Diamond Process
Stages 1&2
¨1 - Correct Process正确的过程
Production
Corrects 正确的生产
Correct
Process? 正确的工艺过程
Production ¨2
Tool? 正确的工具
Production ¨3
Correct
Part? 正确的零件
Rel. Engineer/
SQA/Supplier ¨4
Parts
Quality? 零件质量
Can any of these cause the problem?
• 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
4
汽车技术培训-
7 Diamond Process
Review of Responsibility 职责回顾
• Diamonds 1-4 •钻石1-4
• Filter 5a •5a 过滤
• Diamond 5b-7 •钻石5b-7
Production & Reliability 生产&可靠性
Process Control Manager (PCM) 工艺控制负责人
汽车技术培训-汽车七颗钻石流程（7 Diamond Process）培训
7
汽车技术培训-
7 Diamond Process
Stages 1&2
Production
Corrects 正确的生产
¨1 - Correct Process正确的过程
Correct
Process?
正确的工艺过程
Can any of these cause the problem?以下的问题有可能产生问题吗？