美国福特汽车总装物流(1)

External Customer
Internal Customer
Rating Score
Hazardous w/o warning
* Safety or Government regulation issue * Safety issue by w/o warning
10
by w/o warning
Hazardous w/ warning
* Safety or Government regulation issue * Safety issue by w/ warning
8
by w/ warning
High Moderate
* Function inoperable and Customer very * Can not drive or can not produce or
Failure Mode and Effect Analysis (FMEA) Evaluation Criteria
Formula for RPN (Risk Priority Number)
RPN
= Severity Rate x Occurrence Rate x Detection Rate
= SxOxD
RPN Number
1 <= RPN <= 1,000
Complexity Parts Grouping Criteria
Group A = 201 <= RPN <= 1,000 ( First priority for improvement)
Group B = 101 <= RPN <= 200 ( Second priority for improvement)
TCF & PT Complexity Control Project
COMPLEXITY ISSUE ANALYSIS AND IMPROVEMENT IDEA
All Parts List Complexity Parts List Complexity Parts List
Complexity of Model 1) J48 (Mazda 3) 2) U204 & J14 (Escape & Tribute) 3) C206 (Lynx/Laser)
* Using GO / NO GO gauge or can detect by next
3
process
* Using variable gauge
6
Low
D : Check by Manual
* Using visual check by eyes, hands and ears
8
Very low
Complexity of Parts
Complexity of Operations
Add
Step :
#0
Responsibility : Staff
#1 Staff
#2 Staff
#3
Staff Supv TL
#4
Staff Supv TL
#4
Staff Supv TL
Applied FMEA Concept in identifying/prioritizing parts for improvement
Group C = 1 <= RPN <= 100
( Third priority for improvement)
TCF & PT Complexity Control Project
1) Severity Rate Evaluation Criteria
Effect
Effected to Customer
Criteria No. of Complexity parts
(Kind of parts)
Likely failure rate
Very high
More than 10 items
More than or equal 1% : (10 / 1,000)
Rating Score
10
High
5 - 10
* In line reprocess
3
or noise issue
Normal
* No discernible effect
* No effect
1
TCF & PT Complexity Control Project
2) Occurrence Rate Evaluation Criteria
Probability
7
dissatisfy
Fra Baidu bibliotek
stop line
* Function of comfortable or convenience * Off line reprocess or more reprocess time
5
items inoperable and Customer dissatisfy
Low
* Poor appearance or squeak & rattle
E : No checking
* No item to check
10
TCF & PT Complexity Control Project
Detection
Very high
Type or Method
A : Error Proofed
Inspection
Description
* Defect can not pass
Rating Score
1
High Moderate
B : Check by Measurement tools C : Check by Measurement tools
0.5% : (5 / 1,000)
8
Moderate
4
0.1% : (1 / 1,000)
6
Low
3
0.05% : (0.5 / 1,000)
3
Very low
2
0.01% : (0.1 / 1,000)
1
TCF & PT Complexity Control Project
3) Detection Rate Evaluation Criteria
Affecting MSQCDE
TCF Responsibility : B/C & Control system
MP&L Responsibility : Sequence parts & ILVS
Detailed plan to improve
TCF & PT Complexity Control Project