质量控制介绍

管理目标是不断的减少不良品,降低生产成本
Leadership MUST ensure, support and follow-up with implementation of FTQ in their facility to be successful 领导者必须保证,支持并遵循FTQ,以使其在工厂成功运用.
First Time Quality 一次下线合格率
PPM
TIME
First Time Quality
What First Time Quality Is 一次下线合格率是什么? Why It Is Important 它的重要性在于? Why We Need to Measure It 我们为什么要去测量它? How to Calculate It 如何进行计算? FTQ Deployment, Evaluation and Improvement FTQ调度,评估及改进程序 Responsibilities 职责 The Structured Approach Steps 结构化改进步骤 The Basic Quality Tools 基本质量工具 How to Apply the Quality Tools 工具使用方法 Monitoring and Reporting 检测及报告 Class Exercise
If we don’t fix our quality problems internally, we will never be able to fix our external customer issues
如果我们不能在内部解决质量问题的话,我们也不会有能力去解决外部的客户 问题.
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The fatal flaw of inspection 检查的致命缺陷
Operations
Tally Sheet 计数图
1 HR. 2 HRS. 3 HRS. 4 HRS. 5 HRS. 6 HRS. 7 HRS. 8 HRS.
1 2 3 28
1
2
3
28
4
5
6
16
4 5 6 16
Reject data is collected at operations 3 在工序3和6中采集到了不良品数据 Cell “A” produced 1040 good pieces during the first hour.



It is the early signal that a process is out of control 它对异常过程作出早期反映信号. It allows us to respond to problems internally before they reach our customers 它让我们在顾客发现问题前在内部做出反应. It measures improvement from corrective actions implemented 它可以对矫正措施的效果进行评估监测
Reaction Plan
ZERO Defects Forward
Initiate Structured Problem Solving Voice of the Customer 客户反馈 开始结构化问题的解决
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First Time Quality
FTQ can be viewed as a two phase approach: Immediate action and containment 快速反应及解决
40,590 PPM FTQ
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First Time Quality



What First Time Quality Is FTQ是什么 Why It Is Important 它为什么重要 Why We Need to Measure It 我们为什么要去测量它 How to Calculate It 如何进行计算 FTQ Deployment, Evaluation and Improvement Process FTQ的调度,评估及改进程序 Responsibilities 责任 The Structured Approach 结构性方法 The Basic Quality Tools 基本质量工具 How to Apply the Quality Tools 如何使用质量工具 Monitoring and Reporting 检测与报告 Class Exercise
REJEC TS
3
First Time Quality
Define ALARM LIMITS 确定警戒线 Catch and Count Defects 捕捉并计算不良品
1
A structured approach
2
React to ALARM LIMITS
对警戒作出反应
Follow Reaction Plan 根据应对计划
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First Time Quality
FTQ should be viewed as a tool to facilitate operational improvement in: FTQ应被视为用来促进生产改进的工具
Quality
PPM TIME
质量
Cost 成本
7
First Time Quality
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FTQ Improvement Process FTQ改进程序
Stakeholder involvement
投资者参与模式
Plant A车间A
CELL 1
CELL 生产单元
Plt C车间C
FTQ is Key to our Success to turn this FTQ是我们成功实现财富增值的秘诀
into this!
PPM
TIME
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First Time Quality
Why does FTQ need to be measured?
为什么FTQ需要被测量

Main Reasons: 主要原因:
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First Time Quality
Why is FTQ important? FTQ为什么重要?
Because if we don’t make good parts the first time, we have to “inspect in” quality 因为如果我们不能一次产出合格品,我们就必须对产品质量进行多次检验
To reduce manufacturing costs and defects through continual improvement (FTQ Tracker or Step Down Chart are tools to utilize) 通过使用FTQ追综表或SDC表,持续的改进可以降低生产成本,减少不良品. To monitor process stability and react quickly to potential issues (Alarm limits and process monitoring sheets) 通过警戒线表及过程监控表,我们可以监控过程的稳定性并对潜在问题快速应对
在第一个小时内生产了1040个合格品 At OP.3, 28 pcs. were rejected.
and 6.
在工序3,28件不合格品 At OP.6, 16 pcs. were rejected.
在工序6,16件不合格品 What is the FTQ in PPM for Cell A? A类电池的百万一次下线合格率是多少? 28 + 16 44 = X 1,000,000 = 1040 + 28 + 16 1084
Catch Defects 捕捉不良
Inspection is like a filter.
D
First Time Quality
D
Filter
检查就像过滤器 Inspection misses some defects 检查漏掉了一些不良品 Defects not caught
漏掉的不良品
过滤器
D
Total Number of Pcs. Attempted 总产量
X 1,000,000 = FTQ PPM
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First Time Quality 一次下线合格率
How is First Time Quality calculated? 一次下线合格率如何进行计算?
An example at the cell level: 举个电池的例子 Cell “A” has six operations A类电池需要六个工序
Whenever alarm limits are exceeded
一旦超过警戒线,及时做出反应 Helps ensure customer protection 提供帮助来保护客户
FTQ可以分为两个步骤
Continual Improvement
cost
持续的改进
Management objective to reduce quantity of rejects and operational
We know inspection is at best 85% effective 检验至多在85%的情况下是有效的 Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因此,当FTQ不为0时,我们只有依靠检验来保护客户的利益
Process
2
First Time Quality
What is First Time Quality? 一次下线合格率是什么? First Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted. 一次下线合格率是指在一次生产过程中所产生的不合 格品与总产量的比值
Voice of the Customer 客户的抱怨
Problem 问题
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First Time Quality
How is First Time Quality calculated? FTQ如何计算
FTQ is reported in parts per million (PPM) defective FTQ以每百万产品不良率来报告 It can be measured at any step in the manufacturing process where parts are rejected especially where the defect is originated. 它可以在生产过程中产生不合格品的任何一个步骤进行测量,尤其是不良品的起源 It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 它的计算方式是不良品总数与总产量的比 The total number of pieces attempted includes all good pieces produced plus all pieces rejected 总产量包括所有合格品与所有不良品. Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不良品包括所有还未流入下一工序的废料和重工品.具体计算方式如下: Number of Pcs. Rejected 不良品总数