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EightDisciplines(8D)ProblemSolvingMethodology8-D问题解决方法团队合作解决问题PreparedBy:LeoYinDate:2009-6-25--TeamOrientedProblemSolving(TOPS)APhilosophyandAPartOfContinuousImprovement一种哲学和持续改善的一部分WhileFordhasmadethe8-Dsystempopularinautomotivemanufacturing,itisnotanewsystemor,byanymeans,aFordsystem.FromMil-Std-1520C:福特汽车将8D系统在汽车制造行业应用的非常广泛，其实8D不是一个新的系统，或是福特特有的系统，该系统来自于美国军用标准1520C.Origins:Mil-Std1520起源：军用标准1520TheUSGovernmentfirst‘standardized’thesysteminMil-Std-1520‘CorrectiveActionandDispositionSystemforNonconformingMaterial‘美国政府首次标准化该系统在美国军用标准1520为“不符合材料改善措施和处理系统”Mil-Std-1520-Firstreleased:1974军用标准-1520-首次发行：1974LastRevisionwasCof1986最后一版是1996年的C版Canceledin19951995年取消8DSystemBackground8D系统背景MFLEXConfidential3Eight–Discipline(8D)ProblemSolvingDefinition8-D解决问题定义Introduction介绍8-D:EightDiscipline，asystemicapproachutilizedforrootcausefindingandproblemsolving.8-D：用于寻找根本原因并解决问题的系统方法.CAR:CorrectiveActionReport,thisreportisuse8Dmethodologytocompile.改善措施报告:应用8D方法处理编写的报告.8DProblemsolvingprocesstoidentify,correctandeliminatetherecurrenceofQualityproblems,The8Disamethodologyforproductandprocessimprovement.itisstructuredinto8discipline,emphasizingteamsynergy.8-D解决问题的过程是识别，纠正和减少质量问题再发生的过程，8D是产品和过程提升的方法论.主要有8个原则，强调团队合作.Definition定义Discipline1:Useateamapproach原则1：使用团队的方法Discipline2:Describetheproblem原则2：描述问题Discipline3:ContainmentPlan原则3：围堵计划Discipline4:Rootcauseanalysis原则4：根本原因分析Discipline5:Correctactionplan原则5：纠正措施计划Discipline6:Verificationofeffectiveness原则6：有效性确认Discipline7:Preventrecurrence原则7：防止再发生Discipline8:Congratulateyourteam,caseclose原则8：祝贺团队，关闭报告8D系统意识问题应用团队方法描述问题执行和确认围堵计划识别潜在可能原因选择最可能的原因是否潜在的原因是根本原因识别可能的解决方案选择/确认改善措施执行长期的改善措施防止再发生祝贺团队8DProcessIntroduction8D过程介绍D1:UseTeamApproach应用团队的方法---Crossfunctionalteammember多功能小组成员---Rolesandresponsibilityinateam(selectateamchampionandateamleader)团队角色和职责定义（选择团队主席和小组组长）实例1：XXXD2:DescribetheProblem描述问题---Describedintermsthathavethesamemeaningtoeveryone描述的术语需要每个人都明白---DescribetheproblemPhases(PhaseI/PhaseII)描述问题有两个状态（状态1/状态2）PhaseI：Statethesymptom,extentandconsequenceoftheproblem.描述现象程度和问题的重要性PhaseII：IdentifyWho,What,Where,When,Why,HowandHowMuch.识别谁，什么，什么地方，什么时候，为什么，如何，和多少---Expresstheconditioninquantifiableterm说明状况用量化的术语实例2：AssessingQuestions评估问题1.Hastheproblembeenstatedfromthecustomer’sperspective?问题是否已经按客户的观点被陈述？-HasCustomernameandcustomer’scodebeenspecified?客户的名称和客户代码是否被详细说明？-HasCPNbeenincluded?客户料号是否包含？-Hasquantityoffailuresbeenspecified?Hasfailureratebeenincluded?失效的数量是否被详细说明？失效比率是否有被包含？-Haspointoffailureatthecustomerbeenincluded?在客户端的失效点是否被包含？。。。。。。2.HastheproblembeenstatedfromM-Flex‘sperspective?问题是否已经按照M-Flex的观点陈述？-Hasthepartnumberbeenstated?料号是否被陈述？-Hasthestartandstopdatebeenspecified?开始和结束的日期是否被说明？-Havespecificationrequirementsbeenincluded?规格要求是否被包含？-Hasthedatecodeoftheproductbeenincluded?specified?产品的生产周期是否被包含？详细说明？。。。。。。D3:ContainmentActions围堵措施DefineandImplementcontainmentactionstoisolatetheeffectoftheproblemfromanyinternal/externalcustomeruntilcorrectiveactionisimplemented.定义和执行围堵措施去减少对任何内部/外部客户影响直到改善措施已经执行.CommonContainmentActions通常的围堵措施1.100%Sortingparts/products100%筛选部件/产品2.Productsinspectbeforeshipment出货前对产品进行检验3.Singleresource单一的资源。。。。。。Action/Method措施/方法Status状态Resp.责任人Dates日期Start开始End结束Action:1.Implementanadditional100%inspectionfollowingmoldingtocontainHeatsinkburrs.A100%inspectionaftermoldiscurrentlypartoftheprocessflow.Thisshorttermactionwillresultina200%visualinspection.对策1.：执行额外的100%检验，在Method:Lowpoweropticalexaminationat30X方法：在低能量的30X光学检查Complete完成LiMing李明6-159-15Results:结果Duringthetimeframethatthiscontainmentactionwasinplace,279lotsofT0220materialovera12weekperiodwereinspectedwiththefollowingresults:在这个时间范围内围堵措施已经存在，279个批次的TO220材料在12周内被检验，结果如下：WorkWeek#Rejects#Inspected982535750098262910000982720120009828371100098292650009830317500983147140009832521500098334614500Iftwoinspectionscatch82.75%ofallrejects,theabovesamplelikelycontained:82.75%ofX=323or390rejectdevicestotal.Wecanexpecttoship:390-323=67rejectsor67rejects/96500=694PPM如果两次检验抓到所有拒收产品中的82.75%，如上样本可能包含：产品中82.75%总共等于323或390拒收产品。我们可以认为出货：390-323=67个拒收产品或者67/96500*1000000=694PPMAction2.Forallwarehousematerial,inspect100%ofT0220.Inspectionwillbecompletedatlowpowerinspectionof30X所有仓库中的TO220进行100%检验，检验用低功率的30X放大镜下检验Complete完成LiMing李明6-159-15Verification确认Seeverificationofopticalinspectioninsection3Containment.在小节3中的围堵措施中的目检确认Results:5000unitswereinspectedwith2failuresduetoheatsinkburrsbeingdetected.检验5000片有2片有散热片有毛刺Action3.100%visuallyinspectallinprocesspostmold,prewarehouse,T0220materialat30X对铸型后的所有在线制品，未入库TO220在30X放大镜下做100%目检，Complete完成LiMing李明6-159-15VerificationSeeverificationofopticalinspection查看目检确认Results:7500unitswereinspectedwith3failuresduetoheatsinkburrsbeingdetected.检查7500片有3片有散热片有毛刺AssessingQuestions评估问题1.Hasthecontainmentaction(s)beenlistedincludinghowitcomparestopreviousprocedures?是否围堵措施被列出包含和之前的程序的对比结果2.Ifaninspectionisused,hasthemethodofinspectionbeenstated(i.e.visuallyinspected,X-rayed,etc.)?是否采用一个检验，是否检验方法有描述（如目检，X-Ray检验，等）3.Hastheindividualresponsibleforimplementationofeachofthecontainment