遏制和质量门培训资料

©2010DanaLimited.ThispresentationcontainscopyrightedandconfidentialinformationofDanaHoldingCorporationand/oritssubsidiaries.Thosehavingaccesstothisworkmaynotcopyit,useit,ordisclosetheinformationcontainedwithinitwithoutwrittenauthorizationofDanaHoldingCorporation.Unauthorizedusemayresultinprosecution.Containment遏制Isolatingthecustomerfromdefects.将不合格产品隔离，防止流到客户Containment遏制Purpose–Process–Product目的-流程-产品Purpose目的:Provideafocusedefforttoisolatethecustomerfromdiscrepantproducts–especiallywhenthenormalprocessisknowntobeweak通过努力，将不合格产品隔离，防止流到客户-特别是过程很弱时。Process流程:Definitionandimplementationofaformalprocessto:定义和实施一个正式的流程Conductredundantinspection指导额外的检验Collectdataandinformation收集数据和信息PerformDatadrivencorrectiveactions基于数据制定纠正措施Product产品:Customersisolatedfrombadpartsresultingingreatercustomersatisfactionandmorebusinessforthesupplier防止不合格品流到客户，从而使客户更满意，为供应商带来更多的业务(Pathwayto0PPM通往0PPM的路径)CLASSACTIVITY#1–30minInitialDefect课堂活动#1–30分钟最初的缺陷BUILDINGHONGBAOs建立红包Supplier供应商Receiving进料检验AssemblyCoinToEnvelope将硬币装进红包AssemblyNoteToEnvelope将标签装进红包AssemblyTabToEnvelope将红包封上Warehouse仓库Shipping发交Customer客户Step1第一步:StoptheFlowofBadParts停止不合格品流动Lookforthespecificdefect找具体的缺陷Differentiatethe“good”fromthe“suspect”将合格产品和可疑产品区分开。Establishunderstandableproductstandards建立易理解的产品标准Begindatacollection开展数据收集Beginsortingorinspection开展分类和检查IdentifyandHOLDanyquestionableparts识别并隔离任何可疑产品ProperContainmentProcessInputs正常的遏制流程的输入Action行动:AssureacomprehensiveandproperlyManagedContainmentActivityisdefined,organizedandcapableofbeingimplementedwithin4hoursifrequired确保全面的、合适的遏制管理活动被定义，组织，如果需要的话在4小时内实施Properlydesignatedarea合适的指定的区域Distinctlocation清晰的位置ProperLighting,equipmentandmaterialflowspace合适的灯光、设备和物料流动空间DesignatedMaterialLocations制定的物料位置VerifiedGoodProducts被验证是合格产品VerifiedBadProduct被验证是不合格产品Questionable(productsawaitingmanagement/customerdisposition)可疑产品（等待管理层或者是客户处置的产品）Productstobesorted产品分类Properwallspacetopostandrecordresults张贴和记录结果合适的位置AdequateSpaceforProceduresandBoundarySamples有放置程序和限度样件的充足的空间WellDefinedmethods很好的方法Howtosortandhandlematerials如何挑选和处置物料DefinedPartandContainerMarkingstrategy定义产品和器具的标识策略DefinedMaterialQuarantine,Captureandreturnmethods定义物料隔离、获取和回收的方法。DataCollectionandreportingprocess数据收集和报告流程Correctiveactionmonitoringmethods纠正措施的监控方法DefinedCriteriatosupportContainmentExit定义支持遏制解除的准则CLASSACTIVITY#1.1–30minDefectControl课堂活动#1.1-30分钟不合格的控制BUILDINGHONGBAOs建立红包Supplier供应商Receiving进料检验AssemblyCoinToEnvelope将硬币装进红包AssemblyNoteToEnvelope将标签装进红包AssemblyTabToEnvelope将红包的封上Containment遏制Warehouse仓库Shipping发交Customer客户ExplanationofContainment遏制的解释Explainingeffectivecontainment解释一个有效的遏制ContainedStateContainmentProcess遏制的流程Expectationsofeffectivecontainment–Phases期望的有效遏制-阶段StoptheFlow停止流动InstallFilter安装过滤ProtectCustomer保护客户CollectData&Improve收集数据改进Data数据DailyMeeting日常会议TrackResults跟中结果CleanPipeline清理途径RetrieveSuspect召回可以产品ReleaseGood放行合格产品KeyPoints关键点1.Stoptheflowofdiscrepantparts.停止不合格品的流动2.Definethecontainmentactions(Sort–Rework–Dispose).定义遏制行动（挑选-返工-处置）3.Collectdataanddrivecorrectiveactions收集数据，制定纠正措施4.CleanthePipeline清理途径Definethematerialidentificationplan(partsandcontainers).定义物料识别计划（产品和器具）Establishthescopeofexposurewithlocationandreturnofquestionablestock.建立工厂的范围，召回有问题的库存Step2第二步:DefineContainmentActions定义遏制行动CLASSACTIVITY#2–30min(LogSheet)课堂活动#2-30分钟（记录表）BUILDINGHONGBAOs建立红包Supplier供应商Receiving进料检验AssemblyCoinToEnvelope将硬币装进红包AssemblyNoteToEnvelope将标签装进红包AssemblyTabToEnvelope将红包的封上Containment遏制Warehouse仓库Shipping发交Customer客户Step3第三步:DefineMaterialIdentificationPlan定义物料识别计划Clearandeasilyidentifiable(Parts&Containers)清晰的，易于识别的（产品&器具）Identifiespartsindifferentcategories识别不同类别下的产品•OKPartsthathavebeensorted已经分类的合格产品•SuspectPartsthatrequiresorting需要分类的可疑产品•KnownBadParts已识别的不合格产品•Questionableparts–awaitingdisposition有问题的产品-需要处置Step4第四步:Scope&LocationofQuestionableStock问题产品的范围&位置WorkwithMaterialControlPeople和物料控制人员一起Identifythepartsandcreateaninventory识别零件和建立库存Adjustinventory/feedback调整库存/反馈Retrievethepartsthatneedcontainment召回需要遏制的零件SpecialCustomers–LikeServiceParts特殊的客户-备件Speciallocationslikesecondaryprocessors特殊的位置-二级加工Step4第四步:DefineContainment/MaterialReturnPlan定义遏制/物料召回计划•Suspectmaterialcanenter可疑物料能够进入•Materialisevaluatedandcategorized物料被评估和分类•Propertymarkedgoodmaterialcanexittofinishedgoods标识为合格物料能够到最终的成品•Properlymarkedbadmaterialcanexittodisposal标识为不合格物料进入到处置•Uncertainmaterialisheld不确定的物料隔离CLASSACTIVITY#3–30minTraceMultiple课堂活动#3-30分钟追溯各类别产品BUILDINGHONGBAOs建立红包Supplier供应商Receiving进料检验AssemblyCoinToEnvelope将硬币装进红包AssemblyNoteToEnvelope将标签装进红包AssemblyTabToEnvelope将红包的封上Containment遏制Warehouse仓库Shipping发交Customer客户Step5第五步:DefineExitStrategy定义退出策略•Materialremainsincontainmentuntilpermanentcorrectiveactionisinplace物料处于遏制状态，直到永久对策实施到位•Containmentcouldlastdays,weeksoryears.Thisisalluptoyourabilityandattitudetoaddresstherootcause遏制可以持续几天、几周、几年。主要取决于找到根本原因的能力和态度•UseContainmentasaformofcorrectiveactionvalidation–把遏制当成纠正措施验证的一种形式–resultshouldbe0结果应该是0•Materialisevaluate