8D培训
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Tenneco Automotive 8-D/2000 7
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 Activities临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
Tenneco Automotive 8-D/2000 8
D-2 Describe the Issue 描述问题
• Define the issue in terms of what is wrong with what 用“什么出现了什么问题”的方式 来进行描述 • WHAT 什么 – Object was the issue seen on 出现问题的事物 – What defect was seen 出现的问题 • WHERE 何处 – Seen on Object 在什么东西上 – Seen Geographically 在哪些地区 – (Supplier, Customer, Etc.) (哪些供应商,客户,等)
Correct 正确
Bushing 38427 produces a “clicking” sound – measures 6 decibels in the sound booth. Was reported by Ford Lorain assembly plant (MRR # BR-549 – 2/30/00 – 5000 pieces), confirmed in lab 3/4/00. 衬套 38427 发出一种’咔啦’声音—测 音室测量为 6 分贝。由福特 Lorain 组 装厂发现(MRR # BR-549 – 2/30/00 – 5000 件), 00 年 3 月 4 日试验室确认。 10840 piston rod nut has overall height Part is out of specification of .874; spec is .750 max. Seen in dept 零件不合格 13 assembly line on 5/4/00; caused discs to crush in asm. – causes 20% reject rate. 活塞杆螺栓 10840 整体高度为.874， 要求为最高.750。发生于 00 年 5 月 4 日第 13 部门的组装线上。导致轮盘 在总成内被压跨，继尔导致 20%次品 Tenneco Automotive 8-D/2000 率。
Tenneco Automotive 8-D/2000
4
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 Activities临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
Tenneco Automotive 8-D/2000 11
D-2 Describe the Issue描述问题 描述问题 Incorrect 不正确 Correct 正确
It doesn’t work 不好用 Scrap is too high
废品率太高
It is noisy 噪音太大 Part is out of specification 零件不合格 Audit was not successful
Tenneco Automotive 8-D/2000
3
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
10
D-2 Describe the Issue描述问题 描述问题
• TOOLS TO USE 可用工具
– Process flow diagram 工序流程图 – Check sheets to collect data 用检 查表来收集数据 – Any data that is reporting the issue 反映问题的任何数据 • Customer complaints 客户抱怨 • Current SPC/Data collection sheets 现有的SPC/数据收集表 • PFMEA 过程FMEA • Scrap/rework reports 废品/返工报表
Thanks to Kay Shreve (Monroe, MI), Michael Brown (Paragould, AR) and Eunice Spradlin (Cozad, NE) for their work on this project. 感谢 Kay Shreve (Monroe, MI), Michael Brown (Paragould, AR) 和 Eunice Spradlin (Cozad, NE) 对此项目所作的工作。
• HOW BIG 多大
– How many objects have the defect 有多少有缺陷的事物 – How many defects per object 每件 事物上有多少缺陷 – What is the trend 趋势如何
Tenneco Automotive 8-D/2000
Tenneco Automotive 8-D/2000 5
D-1 Form The Team建立团队 建立团队
• • Size 规模 – 5 to 7 Core Members 5-7位核心成员 Support Needed 所需支持 – What level of the organization 组织结构中的哪一层次 Change 改变 – According to needs 根据需要 Roles 角色 – Define roles/responsibilities 确定角色/责任 -- WHERE 何处 – Seen on Object 实物表示 – Seen Geographically 地理表示 – (Supplier/Customer/Etc) (供应商/客户/等)
6
•
•
Tenneco Automotive 8-D/2000
D-1 Form The Team建立团队 建立团队 CAUTIONS注意 ! ! !
• Ensure cross-functional team members 确保有多个功能部门的团队 成员 • Include process owners (those who do the work) 要包括过程当事人 (实际作这 项工作的人员) • Include champion and leader as road-block removers 要包括团队负责人和团队组 长作为路障排除人
Sc百度文库ap is too high 废品率太高
目前第 12 部门的焊透(代码 12)废品率 为 38%。目标为 3%。发生时间为过去 三个月。
Tenneco Automotive 8-D/2000 13
D-2 Describe the Issue
Incorrect 不正确
It is noisy 噪音太大
Tenneco Automotive 8-D/2000 9
D-2 Describe the Issue描述问题 描述问题
• WHEN 何时
– First seen 何时首次发现 – When else seen 何时重复发现 – When seen in the process 何时 在工序/程序中发现
Tenneco Automotive 8-D/2000
1
DISCIPLINES TO PROBLEM SOLVING 解决问题的8项纪律
8
8-D 2005
This course was developed by a team of Tenneco Automotive employees who have worked on problem solving efforts for the past fifteen to twenty years. This course is a summary of the problem solving process that was formerly known as PEP (People Eliminating Problems) within the ride control business unit and QUIP (Quality Improvement Process) within the exhaust business unit. Ford Motor Company is acknowledged as the developer of the “8-D” process. ) 该课程由一个由天纳克员工组成的，在过去的15-20年内致力于解决各 种问题的团队开发的，是对解决问题程序的总结。这一程序以前在减 震系统业务中被称为PEP(消除问题团队), 在排气系统业务中被称为 QUIP(质量改进程序)。福特公司被公认为是8-D程序的开发者。
审核未通过
Tenneco Automotive 8-D/2000 12
D-2 Describe the Issue描述问题 描述问题 Incorrect 不正确 Correct 正确
It doesn’t work 不好用
Welder 123 does not hold consistent dwell time – varies from 9 sec to 16 sec every 3 hrs. This was first seen 3/1/00 and has been reported each day since on all shifts. 焊机 123 停顿时间不一致，每三个小时会 从 3 秒变到 16 秒。首次发生在 00 年 3 月 1 日，以后每天每班都会发生。 Scrap for burn through (code 12) is currently at 38% in dept. 12. Goal is 3%. This has been seen for the past 3 months.
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 Activities临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
Tenneco Automotive 8-D/2000 8
D-2 Describe the Issue 描述问题
• Define the issue in terms of what is wrong with what 用“什么出现了什么问题”的方式 来进行描述 • WHAT 什么 – Object was the issue seen on 出现问题的事物 – What defect was seen 出现的问题 • WHERE 何处 – Seen on Object 在什么东西上 – Seen Geographically 在哪些地区 – (Supplier, Customer, Etc.) (哪些供应商,客户,等)
Correct 正确
Bushing 38427 produces a “clicking” sound – measures 6 decibels in the sound booth. Was reported by Ford Lorain assembly plant (MRR # BR-549 – 2/30/00 – 5000 pieces), confirmed in lab 3/4/00. 衬套 38427 发出一种’咔啦’声音—测 音室测量为 6 分贝。由福特 Lorain 组 装厂发现(MRR # BR-549 – 2/30/00 – 5000 件), 00 年 3 月 4 日试验室确认。 10840 piston rod nut has overall height Part is out of specification of .874; spec is .750 max. Seen in dept 零件不合格 13 assembly line on 5/4/00; caused discs to crush in asm. – causes 20% reject rate. 活塞杆螺栓 10840 整体高度为.874， 要求为最高.750。发生于 00 年 5 月 4 日第 13 部门的组装线上。导致轮盘 在总成内被压跨，继尔导致 20%次品 Tenneco Automotive 8-D/2000 率。
Tenneco Automotive 8-D/2000
4
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 Activities临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
Tenneco Automotive 8-D/2000 11
D-2 Describe the Issue描述问题 描述问题 Incorrect 不正确 Correct 正确
It doesn’t work 不好用 Scrap is too high
废品率太高
It is noisy 噪音太大 Part is out of specification 零件不合格 Audit was not successful
Tenneco Automotive 8-D/2000
3
8 - Disciplines of Problem Solving 解决问题的8项纪律 解决问题的 项纪律
D-1 Form the Team 建立团队 D-2 Describe the Issue描述问题 描述问题 D-3 Containment Activities临时控制措施 临时控制措施 D-4 Find and Verify Root Cause查找并确定根本原因 查找并确定根本原因 D-5 Select the Best Solution选择最佳解决方案 选择最佳解决方案 D-6 Verification of Corrective Action纠正措施验证 纠正措施验证 D-7 D-8 Prevent Recurrence预防问题重复发生 预防问题重复发生 Congratulate the Team祝贺团队 祝贺团队
10
D-2 Describe the Issue描述问题 描述问题
• TOOLS TO USE 可用工具
– Process flow diagram 工序流程图 – Check sheets to collect data 用检 查表来收集数据 – Any data that is reporting the issue 反映问题的任何数据 • Customer complaints 客户抱怨 • Current SPC/Data collection sheets 现有的SPC/数据收集表 • PFMEA 过程FMEA • Scrap/rework reports 废品/返工报表
Thanks to Kay Shreve (Monroe, MI), Michael Brown (Paragould, AR) and Eunice Spradlin (Cozad, NE) for their work on this project. 感谢 Kay Shreve (Monroe, MI), Michael Brown (Paragould, AR) 和 Eunice Spradlin (Cozad, NE) 对此项目所作的工作。
• HOW BIG 多大
– How many objects have the defect 有多少有缺陷的事物 – How many defects per object 每件 事物上有多少缺陷 – What is the trend 趋势如何
Tenneco Automotive 8-D/2000
Tenneco Automotive 8-D/2000 5
D-1 Form The Team建立团队 建立团队
• • Size 规模 – 5 to 7 Core Members 5-7位核心成员 Support Needed 所需支持 – What level of the organization 组织结构中的哪一层次 Change 改变 – According to needs 根据需要 Roles 角色 – Define roles/responsibilities 确定角色/责任 -- WHERE 何处 – Seen on Object 实物表示 – Seen Geographically 地理表示 – (Supplier/Customer/Etc) (供应商/客户/等)
6
•
•
Tenneco Automotive 8-D/2000
D-1 Form The Team建立团队 建立团队 CAUTIONS注意 ! ! !
• Ensure cross-functional team members 确保有多个功能部门的团队 成员 • Include process owners (those who do the work) 要包括过程当事人 (实际作这 项工作的人员) • Include champion and leader as road-block removers 要包括团队负责人和团队组 长作为路障排除人
Sc百度文库ap is too high 废品率太高
目前第 12 部门的焊透(代码 12)废品率 为 38%。目标为 3%。发生时间为过去 三个月。
Tenneco Automotive 8-D/2000 13
D-2 Describe the Issue
Incorrect 不正确
It is noisy 噪音太大
Tenneco Automotive 8-D/2000 9
D-2 Describe the Issue描述问题 描述问题
• WHEN 何时
– First seen 何时首次发现 – When else seen 何时重复发现 – When seen in the process 何时 在工序/程序中发现
Tenneco Automotive 8-D/2000
1
DISCIPLINES TO PROBLEM SOLVING 解决问题的8项纪律
8
8-D 2005
This course was developed by a team of Tenneco Automotive employees who have worked on problem solving efforts for the past fifteen to twenty years. This course is a summary of the problem solving process that was formerly known as PEP (People Eliminating Problems) within the ride control business unit and QUIP (Quality Improvement Process) within the exhaust business unit. Ford Motor Company is acknowledged as the developer of the “8-D” process. ) 该课程由一个由天纳克员工组成的，在过去的15-20年内致力于解决各 种问题的团队开发的，是对解决问题程序的总结。这一程序以前在减 震系统业务中被称为PEP(消除问题团队), 在排气系统业务中被称为 QUIP(质量改进程序)。福特公司被公认为是8-D程序的开发者。
审核未通过
Tenneco Automotive 8-D/2000 12
D-2 Describe the Issue描述问题 描述问题 Incorrect 不正确 Correct 正确
It doesn’t work 不好用
Welder 123 does not hold consistent dwell time – varies from 9 sec to 16 sec every 3 hrs. This was first seen 3/1/00 and has been reported each day since on all shifts. 焊机 123 停顿时间不一致，每三个小时会 从 3 秒变到 16 秒。首次发生在 00 年 3 月 1 日，以后每天每班都会发生。 Scrap for burn through (code 12) is currently at 38% in dept. 12. Goal is 3%. This has been seen for the past 3 months.