6sigmaGBProject

SixsigmaGBProjectName:DefineMeasureAnalyzeImproveControl2019/9/302ProjectnameFromtheFTTreportin2013(fromJantoOct,totalvolumeis2549units)2019/9/303ProjectnameDefectsClassify7419443170.48%88.58%92.39%96.20%99.06%100.00%0.00%20.00%40.00%60.00%80.00%100.00%120.00%-51535557595115135油漆流挂颗粒物光泽度不良表面刮伤漏喷厚度偏高系列1系列2FromVOCthroughCCRtoCTQVOC(Voiceofcustomer):–1.Internalcustomer:AssemblyLine–Reduceupperframe&lowframepaintingsagging–2.Internalcustomer:Managementgroup:–LessCOPQinpaintingprocessCCR(CriticalCustomerRequirement)–1.Reducepaintingsaggingfoundinpaintlineoffarea–2.ReducingrepaintcostinpaintlineoffareaCTQ(Criticaltoquality):–Reduceframepaintingsaggingratefrom1.5%to0.7%2019/9/304ProjectnameProjectMissionStatementProjectname:ReduceUpper/LowerFramePaintingSaggingProblemStatement:Asinternalsupplier,FabsupplyUpperFrameandLowerFrametoAss'y.Forthemainqualityissueispaintingsagging.Whenthesedefectsoccurred,therepairingcostwillincreaseincludingmanpower,materialandsometimesplanningadjustment.Calculationthecostof2013is13,320RMBandmeanwhileitpolluteenvironmentalso.InordertoreduceCOPQandeffectofenvironment,wewillreducethepaintingsagging.Objective:Reducesaggingfrom1.5%tolessthan0.7%bytheendofJun.2014,Itwillreducecurrentfailureratemorethan50%andtheexpectedCOPQsavingismorethan5,444RMB.2019/9/305ProjectnameProjectScopeInScope:Theprojectwillhandleallfactorstomakepaintingdefectproblemfrompaintinglineontopaintinglineoff.OutofScope:Thisprojectwillnothandletheprocessbeforethepartsdeliveredtopaintingline.2019/9/306ProjectnameProjectSchedulePlanActualOngoing2019/9/307ProcessStepJanFebMarAprMayJunRemarksSchedule123412341234123412341234Step1.D(Define)DefineprocesstobeimprovedDefinecustomers&CTQsDefineprojectscopeandsetgoalsDefineprojectcharterStep2.M(Measure)EstablishprojectYsListprossibleXsDatacollectionMeasurementsystemanalysisDetermineprocesscapabilityReviewprojectgoalsStep3.A(Analysis)IdentifypossibleXsSelectpotentialvitalXsHypothesistestofXsReviewvitalXsStep4.I(Improve)GeneratesolutionalternativesTestsolutionalternativesImplementation/VerificationStep5.C(Control)AssesspotentialriskDesignandimplementcontrolplantoAugEvaluateandcloseprojecttoAugHighLevelProcessMap(SIPOC)SUPPLIERINPUTPROCESSOUTPUTCUSTOMERCTQCRITICALTOQUALITY•Paintingdefects•Weldingline•Upper&LowerFrame•QualificationFrame•AssemblyPaintinglineonStartPrimerTopcoatPaintingLineOffEnd2019/9/308ProjectnameForecastedFinancialBenefitItemUnitAmountCOPQTotal#ofunitsproducedbeforeimprovement（basedon2013)Unit5974FailurerateUnit1.5%Reworktimeperdefectframemin90LaborcostRMB/h50MaterialcostperframeRMB/u73RepaircostperframeRMB/u75EstimatedtotalCOPQRMB13320GAINExpectedCOPQperyearwithoutimprovement(basedon2014volume4598)RMB10207FailurerateafterimprovementUnit0.7%ExpectedCOPQperyearafterimprovementRMB4763TotalsavingsperyearRMB5444INPUTLaborcostof3members(6monthsworkingdayswith3%devoted)RMB4550OtherinvestmentRMB0Travelcost.EctRMB0TotalcostRMB4550ROIGain/Input1.2Projectname2019/9/30TheestimatedCOPQandExpectedeffectsExpectedCOPQbeforeImprovement:13320RMB/YearExpectedCOPQSavingthroughtheproject:5444RMB/YearOperational/StrategicImpact:ALCplanning,MHandMRBcostwillbesavedthroughthisproject.2019/9/3010ProjectnameProjectname112019/9/30DefineMeasureAnalyzeImproveControlProjectname122019/9/30EstablishProjectYY:Saggingdefectrate(numbers)inU/F&L/F–Y1=季节性流挂–Y2=不同车型流挂–Y3=不同位置流挂Y的计算公式如下：流挂率=发生流挂车架数量/实际生产的车架数量*100%DMAIC-2013M-8DataCollectionPlan流挂类型操作定义数据来源和位置样本量数据采集人数据采集时间数据采集方法应同时采集的其他数据Y油漆流挂流挂率=发生流挂车架数量/实际生产的车架数量*100%取正常生产产品，在油漆下线区域进行检验2000套2013年2月~9月目测按季节、车型、位置采集油漆流挂数据DMAIC_v2010A-14结论–当前基线绩效:2013年2-9月平均不良率为：1.5%当前水平统计0.8%1.4%1.3%3.3%1.2%1.5%2.3%1.7%0.0%0.5%1.0%1.5%2.0%2.5%3.0%3.5%4.0%Feb-13Mar-13Apr-13May-13Jun-13Jul-13Aug-13Sep-13流挂缺陷率流挂缺陷率Projectname152019/9/30EstablishProjectYY1:季节性流挂注：未呈现明显的季节性趋势0.8%1.4%1.3%3.3%1.2%1.5%2.3%1.7%0.0%0.5%1.0%1.5%2.0%2.5%3.0%3.5%4.0%Feb-13Mar-13Apr-13May-13Jun-13Jul-13Aug-13Sep-13流挂缺陷率流挂缺陷率Projectname162019/9/30EstablishProjectYY2:不同车型流挂161312766443320.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%024681012141618系列1系列2注：未呈现明显的车型流挂趋势Projectname172019/9/30EstablishProjectYY3:不同位置流挂4025740.00%20.00%40.00%60.00%80.00%100.00%010203040506070边梁流挂前板流挂尾板流挂圆板流挂系列1系列2注：流挂明显的分布于边梁与前板位置DMAIC_v2010A-18输出指标描述基线(Z,Cpk,%,Time,ppm)目标(Z,Cpk,%,Time,ppm)差距y油漆流挂1.5%0.7%0.8%注：西格玛水平和PCE只是基线绩效指标，这里设定的是输出指标的目标，二者可互相转换。基线绩效汇总Projectname192019/9/30DefineMeasureAnalyzeImproveControlDMAIC_v2010A-20位置流挂Y3边梁流挂Y3.1前板1流挂（上车架）Y3.2前板2流挂（下车架）Y3.3PicturesForDefectsProjectname212019/9/30CauseanalysisforYY3.1边梁流挂通过观察发现：流挂产生的部位通常在距离两端面约1m的地方Projectname222019/9/30CauseanalysisforY边梁动作轨迹示意图通过观察发现：流挂产生的部位通常在距离两端面约1m的地方1m1m在此区域为两段之间接头，容易产生重复多次喷漆，造成油漆过多，产生流挂Projectname232019/9/30CauseanalysisforY5why分析边梁流挂原因为什么边梁流挂会产生在距离两端1m左右的地方？因为这些地方油漆厚为什么这些地方油漆厚？因为每次喷漆在这些地方有接头为什么每次在这些地方会有接头？因为边梁长，要分段喷漆为什么分段喷就会喷厚？因为一次性喷漆成型在接头的地方会造成重复喷漆Projectname242019/9/30CauseanalysisforYY3.2前板1流挂12Y3.3前板2流挂Projectname252019/9/30CauseanalysisforY11W12W13W14W动作观察前板1过程分析前板2过程分析前板1过程&输入CE分析前板2过程&输入CE分析P-FMEA分析计划实际前板流挂分析计划Project