8Danalysistrainingmaterial

CopyrightLiebherr2009–EN018DAnalysisTraining8D分析培训-ReportedbyFosterZhang2012.4.13CopyrightLiebherr2009–EN01What’s8D2D0.Preparefor8Dprocess为8D过程作准备D1.Setupteam成立小组D2.Problemdescription问题的描述D3.DefineInterimContainmentAction确定临时的纠正措施ICAD4.Fixandvalidatetherootcause确定和验证根本原因D5.Fixandvalidatethepermanentactionbasedontherootcause确定和验证针对根本原因的永久纠正措施PCAD6.ExecuteandfixthePCA实施和确认PCAD7.Preventhappeningagain防止再发生D8.Rewardtheteamandpersonal’scontribution承认小组和个人的贡献CopyrightLiebherr2009–EN01Whatcould8Danswer?3What’stheproblem?问题是什么？D2Howtosolve?问题如何解决？D3-D6Howtoprevent?将来该问题如何预防？D7Whichcompanyareusing8D?哪些厂家在使用8D?LiebherrLMT利勃海尔Ford,VWandtheotherautocompany福特，大众等汽车厂Caterpillar卡特彼勒Manitowoc马尼托瓦克Appliedarea:Forinternalqualityandsupplierqualityproblemanalysisandsolving内部质量和供应商质量问题的分析解决.CopyrightLiebherr2009–EN01Benefitof8D4Fixtherootcauseandcorrecttheissues.确定根本原因和纠正问题,除此之外Troughsettingupthecrossfunctionteamrealizethedepartment’scooperation.通过建立小组实现内部的合作Pusheffectiveproblemsolvingandpreventivetechnical.推进有效的问题解决和预防技术Improvethequalityandtheefficiency.改进整个质量和生产效率Preventthesimilarandthesameproblemhappeningagain.防止相同或类似问题的再发生ImproveCustomersatisfaction.提高顾客满意度CopyrightLiebherr2009–EN01Thetoolsusedon8Dexecution5Reliability可靠性Designvalidation,productandprocessvalidation设计，产品和过程验证FMEA失效过程分析ControlPlan控制计划PPAP生产过程批准SPC统计过程控制DOE实验设计7qualitytools质量七大工具柏拉图CopyrightLiebherr2009–EN01SMARTprinciple6CopyrightLiebherr2009–EN01Theaimof8D7Throughthecompletionof8Dprocesstopreventthereoccurenceoftheproblem,soastoimprovethewholeproductionsystem.通过准确完成8D过程，防止问题的再发生并改进整个制造系统Theeffective8Danalysisreportfocusonfindingtherootcauseandsuccessfullyexecutepermanentcorrectiveaction.有效分析8D报告分析的焦点是确定根本原因，成功实施纠正措施计划.CopyrightLiebherr2009–EN01Findingtheproblem8QualityReport质量报告Incomingmaterialrejection来料拒收Troublefoundintheline生产线的发现Claiminformationfromtheaftermarketservice售后的市场的质量索赔CopyrightLiebherr2009–EN01Raisetheproblem9CLXcouldusethefollowingflow.Customermeansinternalupstepowner.Suppliermeansinternaldownstepowner.CopyrightLiebherr2009–EN01Respondoftheproblem10Nomatterwhoeverandhowevertheproblemraised,itisrequiredtogive8Drespond.不管问题怎么提出或来自于谁，都要求8D过程作为反应。Asthetroublefinder,theupstepownershouldassistthedownstepownertoprovidequickrespondwithin24hours.Itisgoodforbothpartiestofindtherootcausetogether.作为问题的发现者，上道工序应该协助下到工序在24小时内提供响应。连个工位共同发现根本原因将有助于问题的解决。Theslowertherespond,thehardertosolvetheproblem.反应越慢，问题解决越困难。Goodcooperationcouldmakethesolutionsmoothly.积极地合作将使问题的解决更加的平顺。CopyrightLiebherr2009–EN01Validatetheraisedproblem11Oncetheresponsibilityisfixed,itisthetimetofixwhattheproblemis:责任确定后，应确定问题的所在：(1)TheNonconformancepartsneedtobeprovided.不合格件的提供(2)ProvidetheNCpossiblefactoranalysissuchasthedimensionresult.对不合格可能因素的分析，比如测量尺寸。(3)Usingthedatatoshowtheproblem,suchashowmanyinspected,howmanyunqualified,andwhatisnotaccrequirement.量化问题，比如多少检查了，多少不合格，不合格多少？Ascommunicationmethodshallbeusedcooperationwaynotarguewaytoclearupself-responsibility.交流方法很重要，用合作的态度分析问题，而非用争吵撇开责任。CopyrightLiebherr2009–EN01Continual8Dprocess12Iftheresponsibilityfixed,buttheystillthinkthereisnorelationshiptothecauseoftheproblem,itisalsorequiredtouse8Dformatanddatatovalidatetherelationshipbetweenthefailureandcharacter.如果责任人被确认，即使责任人认为问题可能由其他原因引起，也需要以8D的形式予以支持，用数据验证失效和自身无关。Thisisacademicthinking;actually,weneedtosetupgoodconnectionbetweentheupstepowneranddownstepowneractivelywhichwouldhelpustosolvethetroublesmoothly.注意：这些事理论的方法，事实上供方和客户保持良好的沟通和联系将有助于问题的顺利解决。CopyrightLiebherr2009–EN01Complete8DprocessGenerally,itisrequiredtocompletethe8Dwithin30days.Ifthetimeisnotenough,thefollowinginformationshouldbeprovided:(1)Whytherootcausehaven’tbeenfixedandvalidated?为什么根本原因没有被确认和验证?(2)Howdoesthesupplierplantocompletethisprocess?供方将如何计划继续该过程?(3)What’sthetimescheduletocompleteit?供方打算完成该过程的时间框架?13CopyrightLiebherr2009–EN01Close8DprojectQualitydepartmentisinchargeof8Dprojectcontrolandmanagement.在CLX,质量部负责8D项目的控制和管理。14CopyrightLiebherr2009–EN01D0.Preparationfor8DprocessQuestions:Didwedefinethecharacters?征兆已经被定义了吗？Canweusethedatatodescribethecharacters?征兆已经被定量化了吗？Qualitytools质量工具：Trendchart趋势图，Paretochart排列图15CopyrightLiebherr2009–EN01D1.DefinetheteamQuestions:Whoistheteamleader?小组领导是谁？Doesthesuppliertobeinvolvedintheteam?小组中有供方吗?Doesthecustomertobeinvolvedintheteam?小组中有顾客吗？Dootherrelatedmembersbeinvolved?小组中有其他相关人员吗？Hastheteambrainstormingresultbeenrecorded?小组的头脑风暴又书面的文件吗？Commonfault常见性错误:8Dteammemberswithoutthetechnicalknowledge.8D成员没有技术知识Justoneortwopeopledeploytheaction.只有一两个人实施该过程16CopyrightLiebherr2009–EN01D2.ProblemdescriptionQuestions:Weretheproblemdescribedacc.tocustomer’sword.问题是否已经用客户的术语描述？What’sthestartandtheendoftheissues问题的开始和结束时间列出来了吗？What’sthefailurerate?缺陷率列出来了吗？What’stheproblemfrequency?问题的频率列出来了吗？Actualcheckingresultlistsubmittedtorelatedpersonsornot?实际报告测量列出来了吗？Hastherequirementandspecificationbeenclarified?要求规范列出来了吗？Commonfault常见性错误:Rootcauseisbasedonestimation,butnotrealfacts.针对征兆，而不是针对真正问题工作Therootcausehadbeensubmittedtooear