FTQ_Translation_Delphi培训资料

Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystemsFirstTimeQualityPPMTIMEFtq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems2FirstTimeQualityTrainingModuleTrainingObjectives培训目标:ToUnderstand理解WhatFirstTimeQualityIs什么是一次下线合格率?WhyItIsImportant一次下线合格率的重要性WhyWeNeedtoMeasureIt为什么需要对一次下线合格率进行测量?HowtoCalculateIt如何计算?WhattheFTQDeploymentProcessis怎样进行FTQ?WhattheBasicQualityToolsAre基本质量工具是什么?HowtoApplytheQualityTools怎样运用基本质量工具?WhattheDeliverablesarethateachPlantWillbeResponsibleforMonitoringandReporting每个工厂应该监控和汇报什么?Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems3FirstTimeQualityTrainingModuleWhatisFirstTimeQuality?什么是一次下线合格率?FirstTimeQualityisameasureofthenumberofpiecesrejectedinamanufacturingprocessversusthetotalnumberofpiecesattempted一次下线合格率是测量制造过程中不合格品数与总产品数的比值.REJECTSFtq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems4FirstTimeQualityTrainingModuleWhyisFTQimportant?一次下线合格率的重要性Becauseifwedon’tmakegoodpartsthefirsttime,wehavetoinspectinquality因为如果我们第一次没有生产出好的产品,我们就必须进行检验.»Weknowinspectionisatbest85%effective我们知道检验至多只有85%有效.»Therefore,anytimeFTQisgreaterthan0,wearedependentoninspectiontoprotectthecustomer因而,如果任何时候一次下线合格率大于0,我们都需要依赖检验来保护客户.Toreducemanufacturingcosts降低制造成本Toeliminatewastethroughthevaluestreamandmeetcustomerrequirements(taketime)通过价值流和满足客户要求来消除浪费.Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems5CatchDefectsFilterInspectionmissessomedefects检验会遗漏一些缺陷Defectsnotcaught漏网缺陷VoiceoftheCustomer客户的意见Problem问题DDTheRoleofInspectionDInspectionislikeafilter检验好比一个筛子Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems612Catch&Countdefects抓住并计算缺陷ReacttoALARMLIMITS超过警戒线的反应FollowReactionPlan执行反应计划VoiceoftheCustomerTheRoleofFirstTimeQualityProcessReactionPlanZERODefectsForwardFtq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems7AnalyzeDataUnderstandDefectsandDecidetheOrderofPriority:理解缺陷并决定优先次序AssignproblemstoCross-FunctionalGroup:向跨功能小组提出问题SelectandPlantheImprovement:1.RightInformation2.RightCause3.RightTiming选择并计划改善问题正确的信息正确的原因正确的时间选择FixtheBiggestProblemsFirst:首先找到最大的问题所在12ABCDProblems1212ResponsibleTeamWorksProblemsDEFECT1.----------------------2.----------------------3.----------------------HourGlassTheRoleofFirstTimeQualityProcess4323221111Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems8FirstTimeQualityTrainingModuleWhydoesFTQneedtobemeasured?为什么需要测量FTQMainReasons主要原因:»Itisthefirstsignalthataprocessisoutofcontrol它是过程失控最先发出的信号»Itallowsustorespondtoproblemsinternallybeforetheyreachourcustomers它使我们能够在问题到达客户之前内部先对问题作出反应.»Itmeasuresimprovementfromcorrectiveactionsimplemented通过执行纠正措施后来衡量问题改善的情况.Ifwedon’tfixourqualityproblemsinternally,wewillneverbeabletofixourexternalcustomerissues如果我们不能在内部找到质量问题,我们就不能确定外部客户的问题.Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems9FirstTimeQualityTrainingModuleHowisFirstTimeQualitycalculated?如何计算FTQFTQisreportedinpartspermillion(PPM)defectiveFTQ反映每一百万个产品中的缺陷产品数.Itcanbemeasuredatanystepinthemanufacturingprocesswherepartsarerejected能够在制造过程的任何一步测量FTQ.Itiscalculatedbycountingthenumberofpiecesrejectedversusthetotalnumberofpiecesattempted通过以不合格品数除以总数来计算.Thetotalnumberofpiecesattemptedincludesallgoodpiecesproducedplusallpiecesrejected总的产品数包括所生产的合格品数和不合格品数之和.Piecesrejectedareallpartsscrappedorreworkedpriortousagebysubsequentprocesses.Theactualcalculationlookslikethis:不合格品数包括所有报废和经过返工后合格的产品数.公式:NumberofPcs.RejectedTotalNumberofPcs.Attempted不合格品数/总产品数X1,000,000=FTQPPMX1,000,000=FTQPPMFtq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems10FirstTimeQualityTrainingModuleHowisFirstTimeQualitycalculated?如何计算FTQ?Anexampleatthecelllevel:Cell“A”hassixoperationsA单元有6个操作工序Rejectdataiscollectedatoperations3and6第三和第六工序收集到不合格品数据Cell“A”produced1040goodpiecesduringthefirsthourofproduction.第一个小时A单元共生产好品1040件AtOP.3,28pcs.wererejected.第三工序发现28个不合格品AtOP.6,16pcs.wererejected.第六工序发现16个不合格品WhatistheFTQinPPMforCellA?A单元FTQ的PPM是多少?28+16441040+28+161084123456=X1,000,000=40590PPMFTQ2816Operations1HR.2HRS.3HRS.4HRS.5HRS.6HRS.7HRS.8HRS.1232845616TallySheetFtq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystems11FirstTimeQualityTrainingModuleWhatistheFirstTimeQualityImprovementProcess?什么是FTQ改善过程?FTQprocessdefinesacommonprocesstobeusedbyallDelphiE&Cmanufacturingplantstomeetthebusinessplanrequirementsanddrivedefect-freemanufacturingFTQ是DelphiE&C工厂常用的以达到商业计划要求和无缺陷生产要求的一个方法.TheFTQprocessdefinesFTQ定义:»ProcessSteps流程步骤»Stakeholders有关系的人»DeploymentChart(functionalflowchart)foridentifyingleadfunctions用于识别重要功能的布置图表(功能流程图)»ControlPlanforTrackingImplementation控制计划和跟踪执行Ftq_training.ppt/data/powerpoint/karen/H:(ct)RevisedJune11,2002Energy&ChassisSystemsIDENTIFY&COUNTDISCREPANTPARTSIMPLEMENTIMPROVEMENT执行改善EVALUATE评估INSTITUTION-ALIZELESSONSLEARNED系统化经验教训T