品质改善计划副本XXXX-8-25

江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25品质改善计划长河公司2011-8-25江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25目录1、合格率的计算方法2、生产合格率现状调查3、实际与原目标值间的差距4、影响目前合格率低的原因分析5、目前合理的可执行的目标6、对目前影响合格率的主要原因的改善计划7、主要设备和环境因素改善8、各项实施计划时间表江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－251、合格率的计算方法长河公司合格率分为：（合格包括一次和返修合格）1、过程合格率：一个过程在被定义的一段时间内输出合格数量和输入的总数量的比值。2、批次合格率：批次生产入库的合格品数量与实际计划投入数量的比值3、过程综合合格率：定义为若干个过程合格率的连乘积。批次合格率=批次入库合格数量批次计划投入数量*100%过程输出合格数量过程输入的总数量*100%过程合格率=过程综合合格率=过程1合格率*过程2合格率*过程3合格率*。。。。。。*过程N合格率江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－252、生产合格率现状调查正极计82.13%-9.10%正极计算82.13%-9.10%负极计78.32%-12.91%负极计算78.32%-12.91%大工序期望目标当前合格率当前差值明细工序期望目标当前合格率当前差值1正极涂布98.00%93.84%-4.16%93.84%2正极压片99.80%99.77%-0.03%93.62%3正极分条99.80%99.88%0.08%93.50%4正极裁片98.50%95.81%-2.69%89.58%5负极涂布98.00%91.69%-6.31%91.69%6负极压片99.80%99.74%-0.06%91.45%7负极分条99.80%99.92%0.12%91.38%8负极裁片98.50%93.48%-5.02%85.43%9正极备料99.80%99.65%-0.15%85.13%10负极备料99.80%99.83%0.03%84.98%11卷绕99.00%98.86%-0.14%84.01%12底部焊接99.98%99.35%-0.63%83.47%13滚槽99.95%99.57%-0.38%83.10%14注液100.00%99.90%-0.10%83.02%15激光焊接99.80%99.81%0.01%82.87%16封口99.90%98.84%-1.06%81.91%17清洗100.00%99.98%-0.02%81.89%18热缩99.96%99.92%-0.04%81.82%19X-RAY99.90%99.93%0.03%81.76%20OCV099.70%99.44%-0.26%81.30%21分选97.50%96.43%-1.07%78.40%22外观检查99.50%99.89%0.39%78.32%96.59%95.62%-6.56%-10.72%-2.36%-0.97%序号过程合格率分析91.23%91.23%阶段A品率装配分容96.14%89.58%96.14%85.43%98.24%95.88%正极制片负极制片注：阶段A品合格率计算，制片采用正负极裁片两个较低者。2.1过程合格率现状调查江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25批次合格率50.00%55.00%60.00%65.00%70.00%75.00%80.00%85.00%90.00%入库合格率62.24%66.79%76.64%80.54%70.40%84.79%11050311105101NC11E19NC11E23NC11E30NC11F07批次型号投入数合格数正极报废数负极报废数B品C品入库合格率1105031INR18650A2200013693326464997812062.24%1105101INR18650B220001469439081010724812666.79%NC11E19INR18650C30000229914846481223683976.64%NC11E23INR18650C30000241623476518325426080.54%NC11E30INR18650C28000197117206924014113670.40%NC11F07INR18650C3000025438469889689881184.79%16200012068927398448091057119274.50%批次完工入库汇总批次平均值2.2批次合格率现状调查批次合格率与原目标91.23%，差距16.73%。江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－252.3过程直通率大工序期望目标明细工序期望目标1正极涂布93.84%93.84%2正极压片99.77%93.62%3正极分条99.88%93.50%4正极裁片95.81%89.58%5负极涂布91.69%91.69%6负极压片99.74%91.45%7负极分条99.92%91.38%8负极裁片93.48%85.43%9正极备料99.65%85.13%10负极备料99.82%84.97%11卷绕90.18%8.68%76.63%12底部焊接99.34%76.12%13滚槽99.56%75.79%14注液99.90%75.71%15激光焊接89.29%10.51%67.60%16封口98.84%66.82%17清洗99.98%66.81%18热缩99.92%66.75%19X-RAY99.93%66.70%20OCV099.44%66.33%21分选96.43%63.96%22外观检查99.89%63.89%装配78.22%分容95.62%正极制片89.58%负极制片85.43%实际过程直通率阶段A品目标率序号合格率63.89%合格率63.89%工序综合直通率63.96%63.89%66.33%66.70%66.75%66.81%66.82%67.60%75.71%75.79%76.12%76.63%84.97%85.13%85.43%91.38%91.45%91.69%89.58%93.62%93.50%93.84%55.00%60.00%65.00%70.00%75.00%80.00%85.00%90.00%95.00%100.00%正极涂布正极压片正极分条正极裁片负极涂布负极压片负极分条负极裁片正极备料负极备料卷绕底部焊接滚槽注液激光焊接封口清洗热缩X-RAYOCV0分选外观检查正极制片负极制片装配分容江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25明细工序合格率90.00%92.00%94.00%96.00%98.00%100.00%102.00%正极涂布正极压片正极分条正极裁片负极涂布负极压片负极分条负极裁片正极备料负极备料卷绕底部焊接滚槽注液激光焊接封口清洗热缩X-RAYOCV0分选外观检查期望目标当前合格率大工序：正极制片、负极制片装配、分容都不达标。明细工序：涂布、裁片、点底焊接、滚槽、封口、分选都不达标明细工序当前差值正极涂布-4.16%正极裁片-2.69%负极涂布-6.31%负极裁片-5.02%底部焊接-0.63%滚槽-0.38%封口-1.06%分选-1.07%3、实际与原目标值间的差距大工序当前差值正极制片-6.56%负极制片-10.72%装配-2.36%分容-0.97%大工序合格率75.00%80.00%85.00%90.00%95.00%100.00%期望目标96.14%96.14%98.24%96.59%当前合格率89.58%85.43%95.88%96.43%正极制片负极制片装配分容批次合格率与原目标91.23%，差距16.73%。江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25生产数合格数报废品期望目标合格率报废率断带首件涂布单面破损换卷浆料损耗重量不良涂布取样调机粘胶头部偏厚尺寸不良涂布暗痕冷压不良极片超宽露箔正极涂布3820003584572354398.00%93.84%6.16%16562207110745701835376326正极压片35701735624777099.80%99.78%0.22%6721410928正极分条35617735572345499.80%99.87%0.13%41525正极裁片3390293248501417998.50%95.82%4.18%403320371253101112102711033494041092881合格率96.14%89.60%67762232214719988418353108732610940102711033494041092881当日/生产数状况报废项目工序正极涂布合格率80.00%85.00%90.00%95.00%100.00%NC11E19NC11E23NC11E30NC11F07NC11F13NC11F22NC11F27NC11F27NA11G07NC11G11NA11G18NA11G21NA11G25NA11G25NA11G28正极裁片合格率80.00%82.50%85.00%87.50%90.00%92.50%95.00%97.50%100.00%NC11E19NC11E19NC11E23NC11E23NC11E30NC11F07NC11F07NC11F13NC11F13NC11F22NC11F22NC11F27NA11G07NC11G11NA11G18NA11G214.1目前情况---正极涂布-裁片1、正极压片和分条都达到目标，涂布和裁片未达到目标。2、涂布和裁片批次间波动较大。4影响目前合格率低的原因分析江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25正极涂布至裁片柏拉图1835367762881223221471998110310871027404349326109109844002000400060008000100001200014000160001800020000浆料损耗断带露箔首件涂布单面破损尺寸不良重量不良头部偏厚冷压不良涂布暗痕涂布取样极片超宽调机换卷粘胶0.00%20.00%40.00%60.00%80.00%100.00%120.00%不良项目浆料损耗断带露箔首件涂布单面破损尺寸不良重量不良头部偏厚冷压不良涂布暗痕涂布取样极片超宽调机换卷粘胶数量18353677628812232214719981103108710274043493261091098440比率47.03%17.36%7.38%5.72%5.50%5.12%2.83%2.79%2.63%1.04%0.89%0.84%0.28%0.28%0.22%0.10%合计比率47.03%64.39%71.77%77.49%83.00%88.12%90.94%93.73%96.36%97.39%98.29%99.12%99.40%99.68%99.90%100.00%工序期望目标合格率正极涂布98.00%93.84%正极压片99.80%99.78%正极分条99.80%99.87%正极裁片98.50%95.82%合格率96.14%89.60%正极涂布-裁片工序合格率90.00%92.00%94.00%96.00%98.00%100.00%102.00%目标值98.00%99.80%99.80%98.50%实际值93.84%99.78%99.87%95.82%正极涂布正极压片正极分条正极裁片4.2目前情况---正极涂布-裁片不良柏拉图江西长河新电池有限公司CHCGREENBATTERYCo.,LTD品质部拥彦江2011－8－25生产数合格数