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TennecoAutomotive8-D/200018DISCIPLINESTOPROBLEMSOLVING解决问题的8项纪律8-D2005TennecoAutomotive8-D/20003ThiscoursewasdevelopedbyateamofTennecoAutomotiveemployeeswhohaveworkedonproblemsolvingeffortsforthepastfifteentotwentyyears.ThiscourseisasummaryoftheproblemsolvingprocessthatwasformerlyknownasPEP(PeopleEliminatingProblems)withintheridecontrolbusinessunitandQUIP(QualityImprovementProcess)withintheexhaustbusinessunit.FordMotorCompanyisacknowledgedasthedeveloperofthe“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。ThankstoKayShreve(Monroe,MI),MichaelBrown(Paragould,AR)andEuniceSpradlin(Cozad,NE)fortheirworkonthisproject.感谢KayShreve(Monroe,MI),MichaelBrown(Paragould,AR)和EuniceSpradlin(Cozad,NE)对此项目所作的工作。TennecoAutomotive8-D/20004D-1FormtheTeam建立团队D-2DescribetheIssue描述问题D-3ContainmentActivities临时控制措施D-4FindandVerifyRootCause查找并确定根本原因D-5SelecttheBestSolution选择最佳解决方案D-6VerificationofCorrectiveAction纠正措施验证D-7PreventRecurrence预防问题重复发生D-8CongratulatetheTeam祝贺团队8-DisciplinesofProblemSolving解决问题的8项纪律TennecoAutomotive8-D/200058-DisciplinesofProblemSolving解决问题的8项纪律D-1FormtheTeam建立团队D-2DescribetheIssue描述问题D-3ContainmentActivities临时控制措施D-4FindandVerifyRootCause查找并确定根本原因D-5SelecttheBestSolution选择最佳解决方案D-6VerificationofCorrectiveAction纠正措施验证D-7PreventRecurrence预防问题重复发生D-8CongratulatetheTeam祝贺团队TennecoAutomotive8-D/20006D-1FormTheTeam建立团队•Size规模–5to7CoreMembers5-7位核心成员•SupportNeeded所需支持–Whatleveloftheorganization组织结构中的哪一层次•Change改变–Accordingtoneeds根据需要•Roles角色–Defineroles/responsibilities确定角色/责任--WHERE何处–SeenonObject实物表示–SeenGeographically地理表示–(Supplier/Customer/Etc)(供应商/客户/等)TennecoAutomotive8-D/20007D-1FormTheTeam建立团队CAUTIONS注意!!!•Ensurecross-functionalteammembers确保有多个功能部门的团队成员•Includeprocessowners(thosewhodothework)要包括过程当事人(实际作这项工作的人员)•Includechampionandleaderasroad-blockremovers要包括团队负责人和团队组长作为路障排除人TennecoAutomotive8-D/200088-DisciplinesofProblemSolving解决问题的8项纪律D-1FormtheTeam建立团队D-2DescribetheIssue描述问题D-3ContainmentActivities临时控制措施D-4FindandVerifyRootCause查找并确定根本原因D-5SelecttheBestSolution选择最佳解决方案D-6VerificationofCorrectiveAction纠正措施验证D-7PreventRecurrence预防问题重复发生D-8CongratulatetheTeam祝贺团队TennecoAutomotive8-D/20009D-2DescribetheIssue描述问题•Definetheissueintermsofwhatiswrongwithwhat用“什么出现了什么问题”的方式来进行描述•WHAT什么–Objectwastheissueseenon出现问题的事物–Whatdefectwasseen出现的问题•WHERE何处–SeenonObject在什么东西上–SeenGeographically在哪些地区–(Supplier,Customer,Etc.)(哪些供应商,客户,等)TennecoAutomotive8-D/200010D-2DescribetheIssue描述问题•WHEN何时–Firstseen何时首次发现–Whenelseseen何时重复发现–Whenseenintheprocess何时在工序/程序中发现•HOWBIG多大–Howmanyobjectshavethedefect有多少有缺陷的事物–Howmanydefectsperobject每件事物上有多少缺陷–Whatisthetrend趋势如何TennecoAutomotive8-D/200011D-2DescribetheIssue描述问题•TOOLSTOUSE可用工具–Processflowdiagram工序流程图–Checksheetstocollectdata用检查表来收集数据–Anydatathatisreportingtheissue反映问题的任何数据•Customercomplaints客户抱怨•CurrentSPC/Datacollectionsheets现有的SPC/数据收集表•PFMEA过程FMEA•Scrap/reworkreports废品/返工报表TennecoAutomotive8-D/200012D-2DescribetheIssue描述问题Incorrect不正确Correct正确Itdoesn’twork不好用Scrapistoohigh废品率太高Itisnoisy噪音太大Partisoutofspecification零件不合格Auditwasnotsuccessful审核未通过TennecoAutomotive8-D/200013D-2DescribetheIssue描述问题Incorrect不正确Correct正确Itdoesn’twork不好用Welder123doesnotholdconsistentdwelltime–variesfrom9secto16secevery3hrs.Thiswasfirstseen3/1/00andhasbeenreportedeachdaysinceonallshifts.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。Scrapistoohigh废品率太高Scrapforburnthrough(code12)iscurrentlyat38%indept.12.Goalis3%.Thishasbeenseenforthepast3months.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。TennecoAutomotive8-D/200014D-2DescribetheIssueIncorrect不正确Correct正确Itisnoisy噪音太大Bushing38427producesa“clicking”sound–measures6decibelsinthesoundbooth.WasreportedbyFordLorainassemblyplant(MRR#BR-549–2/30/00–5000pieces),confirmedinlab3/4/00.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。Partisoutofspecification零件不合格10840pistonrodnuthasoverallheightof.874;specis.750max.Seenindept13assemblylineon5/4/00;causeddiscstocrushinasm.–causes20%rejectrate.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%次品率。TennecoAutomotive8-D/200015D-2DescribetheIssueIncorrect不正确Correct正确Auditwasnotsuccessful审核未通过LRQAauditof3/15/00identifiednon-compliance(LRQA#00/03/01)forfailuretocompletemanagementreviewcomplianttoprocedureP-01dated6/3/98,revisionC,section5.4.2.00年3月15日LRQA审核确定不符合项(LRQA#00/03/01)。没有按程序文件P-01(日期6/3/98，修订C)5.4.2部分完成管理评审。TennecoAutomotive8-D/200016D-2DescribetheIssue描述问题CAUTIONS注意!!!•Stateissueinquantifiableterms用可量化的术语来描述问题•Usedatatosupportproblemstatement用数据来支持问题描述•Describesymptom/effectoftheissue描述问题的症状/影响•Avoidjumpingtoconclusionofcause避免跳至总结原因TennecoAutomotive8-D/2000178-DisciplinesofProblemSolving解决问题的8项纪律D-1FormtheTeam建立团队D-2DescribetheIssue描述问题D-3ContainmentActivities临时控制措施D-4FindandVerifyRootCause查找并确定根本原因D-5SelecttheBestSolution选择最佳解决方案D-6VerificationofCorrectiveAction纠正措施验证D-7PreventRecurrence预防问题重复发生D-8CongratulatetheTeam祝贺团队TennecoAutomotive8-D/200018D-3ContainmentActions