RCCA(C)根因分析

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Objectives目标
At the end of this module, you will be able to该 单元学习完毕后,将能够:
• Use a method that will enable you to eliminate turnbacks identified through QCPC, equipment downtimes and defects in your products and services.使用方法来消除在在生产和服务中发生于 QCPC，设备停机和缺陷的重复问题。 • Understand the 8 steps that form the RCCA process 了解组成 RCCA 的8个步骤
拔草不除根，还会卷土重来
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Philosophy
• Each problem must be pursued and resolved rapidly • Solving problems requires a mindset that is alert, open-minded, patient, tenacious and persistent • Each problem is a golden nugget or treasure • Each problem tells a story about why and how it occurred (there are no isolated incidents) • The ―true‖ problem must be understood from the data before action is taken
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Table of contents目录
• • • • Objectives 目标 Introduction 简介 RCCA Steps 步骤 Conclusion 结论 page 4 page 5 page 18 page 36
• Know when to use it 掌握何时运用RCCA。
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Introduction简介
QCPC & MFA
Map process
Collect data
Survey customers
Байду номын сангаас
Select best opportunities
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UTC 目前的思想状态UTC Current Mindset
We must change the culture必须改变文化
• ―I have no time to address root cause, I must meet the delivery schedule!‖ ―我没有时间查找根源,我必须赶交付进度 !‖ • ―We have been doing this for 15 years with no substantial improvement, why is today going to be any different?‖ (George David, Ito University) ―我们已经如此工作了 15 年而没有实质性的改进，今天又会有什么区 别?‖ (George David, 伊滕大学) • ―You continually develop and release new products with known quality problems, why?‖ (UTC Customer) “你们不断研制和生产的新产品存在已知的质量问题，为什么?‖ (UTC 用户) We must have a “new spirit” for the future of our business! 对于我们业务发展的未来必须具有“新的精神 ”！
• 执行Implementation
– Eight-step process including tools 八个步骤
• 特征Characteristics
– – – – Define the problem 定义问题 Analyze the problem 分析问题 Identify the root cause 确定根本原因 Apply mistake proofing 运用错误预防
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Each problem is a golden nugget
Philosophy
每个问题都是一块金砖
Capacitor 电容器: $ 0.05 Circuit Board电路板: $ 34
Elevator 电梯: $ 350,000
We must work to build a trusting environment!
• 我们必须建立一个可信赖的环境
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Philosophy理念
Root Cause Corrective Action is the rapid and persistent pursuit of the fundamental breakdown or failure of the process that, when resolved, prevents a recurrence of the problem. 问题根源纠正行动是快速和持续跟踪过程中断和失败的根本 原因，一旦问题解决，就能避免重复发生。 Root cause analysis is like pulling weeds. 问题根源分析就象拔 草除根。 If you don’t get the root, the weed comes back!
3. Analyze分析
Why ? Why ? Why ?
4. Improve改进 5. Control控制
Ré pé table
Select opportunities
Efficace Efficient
Mistake Proofing
Standard Work
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1$ Very minor
10 $ Minor delays
100 $ Rework Reschedule of work
1 000 $ Significant rework Delay of delivery Additional inspection
10 000 $ Warranty cost Admin. cost Reputation Loss of market share
Chartered team
2. Measure衡量 1. Define定义
6 5%
Root Cause Analysis
Process Management 过程管理
Objectives Process A B C D E F G High Medium Low 1 30 % 2 20 % 3 20 % 4 15 % 5 10 %
问题根源纠正行动 (RCCA)
Training for Pilots and ACE Implementation Managers
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Overview概述
• 益处Benefits
– Standardize intervention at root cause to prevent problems from reoccurring 标准化解决方法,从根本上防止问题重复 出现
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Problem Escapes and the Rule of 10
Defect found at: Own process Next process End of line
Philosophy
Customer
Final inspection
Cost to the Company: Impact to the Company:
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Introduction
When do we use 何时使用RCCA?
• We have a recurring problem 问题重复出现... Or或 • We are not sure of the causes 不能确定原因 or 或 • The problem is not constant (it comes and goes) or 问题不持续（时有时无） • We want to take the time to solve the problem once and for all!我们需要花时间一次并彻底解 决问题
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Philosophy
问题遗漏造成的10倍规则
发现缺陷:
本工序
下一道 工序
加工结 束
终检 用户
公司成本 1$ 对公司的影响 10 $ 100 $
1 000 $
10 000 $
很小
短时延误
返工 重定进度
大返工 影响交付 额外检验
担保费用 管理费用 名誉损失 失去市场份 额
© 2002 Pratt & Whitney Canada All rights reserved
• 每个问题必须迅速跟踪和解决 • 解决问题需要警惕性高，思想开放，有耐心和顽强持久的精神 • 每个问题都是一块金砖或财富
• 每个问题都是一个故事，告诉你为什么和怎样发生的（没有孤立的事 件） • 在采取行动之前，必须通过数据了解―真实” 的问题
© 2002 Pratt & Whitney Canada All rights reserved
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Introduction
What is it used for 使用目的?
• Correct a problem methodically系统地纠正问题:
– By determining its root cause 通过确定根源 – By applying the best possible solutions通过应用最佳方案
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UTC 渴望的思想状态UTC Desired Mindset
The New Spirit of Management管理新精神
• ―We must be actively involved to find root causes‖
―必须积极参与寻找问题根源” • ―We must fix defects by fixing the process, not by adding more manpower‖
―必须通过解决过程问题来解决缺陷，而不是通过增加人力‖
• “85% of all quality problems are a result of the process, 15% are a result of the workers” (J. M. Juran) “85% 的质量问题起源于过程， 15%的问题来源于工人 ” (J. M. Juran)
• Prevent a problem from recurring 避免问题重复出现:
– By following through 跟踪全过程 – By standardizing the solutions 使解决方案标准化
?
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