教學(xué)課件 8D報告培訓(xùn)-2匯編

VishayCustomer

CorrectiveActionRequest(CAR)Guidelines

Vishay《客戶糾正措施要求CAR》應(yīng)用指南午涯芝還殿吵豐豫硬訖繳痊差宮酮恫肪煞信臻綿反理鉚補(bǔ)胰紹怖點(diǎn)江邪磨8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingVishayCustomer

CorrectiveAc1WhatisaCAR/8D?

何謂CAR/8D?ACAR/8DReportisamethodtodocument,communicate,trackanddriveresolutionsforqualityissues.CAR/8D是針對品質(zhì)問題而進(jìn)行文件化、溝通、追蹤及解決問題的方法。An8DreportisFordMotorCompany’sformatforproblemsolving.Itisthepreferredmethodusedthroughoutourindustry.CAR/8D報告是福特公司解決問題的格式。它是我們所有行業(yè)首選的解決問題的方法。砌印零擾裳刻鐐磁件任棒出訴稱喂屋騷磨處誼款飼蹤析噓站斃搬旋艱卻擾8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingWhatisaCAR/8D?

何謂CAR/8D?A2ImmediateContainment.

采取迅速的圍堵措施（短期對策）ClearidentificationofRootCause.

真正識別問題產(chǎn)生的根本原因（真因）RobustCorrectiveActions.充分的糾正措施VerifiedCorrectiveActions.驗證糾正措施Systemfixes.系統(tǒng)化（即糾正措施標(biāo)準(zhǔn)化或文件化）100%On-timeresponse.

100%準(zhǔn)時反應(yīng)（即及時解決問題，準(zhǔn)時回復(fù)客戶）Eliminatetheproblemsthefirsttime.做到第一次就消除問題所在Preventionoffutureproblems.實現(xiàn)潛在問題的預(yù)防CUSTOMER8DEXPECTATION

客戶應(yīng)用8D的期望日槐卷塢踞盔娥亂預(yù)潘情仲詭幾灘運(yùn)肇閣仙捂拍綜讕鉚剩疵郁佛輕沼難巢8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingImmediateContainment.CUSTOMER3CAR/8DReportProblems

完成CAR/8D報告存在的問題Notidentifyingthetrueprocesses,escape,andsystemrootcauses.

沒有識別出過程、流出（逃脫）及系統(tǒng)的根本原因（真因）Notimplementingsystemcorrectiveactions.

沒有實施系統(tǒng)性糾正措施Notproperlycontainingentirepipelineofproduct.

沒有針對產(chǎn)品的所有流程采取正確的圍堵措施Unclearorambiguouswording.

對問題采取的不明確或模棱兩可的描述Notmeetingcustomerexpectationsregardingcontentandcycletime.

不符合客戶關(guān)于內(nèi)容及回復(fù)時間的要求術(shù)最編剮閨棉呵譚姜餐規(guī)耪壕唱差摯董叛雄撐奧佛登叉癌香搐緒臼儒錢寥8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingCAR/8DReportProblems

完成CAR/84CAR/8DRequirements

CAR/8D的要求Allcorrectiveactionrequestsmustbecompletedusingan8Dreport(unlessadifferentmethodisrequiredbyCustomer).

所有的《糾正措施要求》必須采用8D報告形式（除非客戶要求采用不同的方法MustuseCorporateformat.

必須采用Vishay公司的格式Mustuse8Dchecklistasaguidelineincompletingthe8D’s.

在完成報告的過程中必須采用8D檢查表進(jìn)行檢查塞墅完逐用傷莖爺盅管餡鴕襲暇棘碑苔華氯咨皮世亦朽圍蚤樹楚宮墳稗盆8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingCAR/8DRequirements

CAR/8D的要求A58

DisciplinestoProblemSolving

解決問題的8個準(zhǔn)則D1EstablishaTeam組建問題解決小組D2DescribetheProblem描述問題D3Containtheproblem采取圍堵措施（即短期對策）D4Identifytherootcauses識別/確認(rèn)根本原因（真因）D5CorrectiveActions確認(rèn)糾正措施D6ImplementCorrectiveActions實施糾正措施（即長期對策）D7PreventRecurrence防止再發(fā)D8CongratulatetheTeam小組慶祝尋鉚也楞斑買沏鯉姑滁案斧架賭奧畜澡包贈禹施淌蛆巨伴么餐控漳械挨剔8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DisciplinestoProblemSolvi6D1EstablishTeam

D1組建問題解決小組EstablishCrossFunctionalTeam.

建立跨功能小組IdentifyaChampion.確定小組長Membersshouldbefromallaffectedareas,notjustquality!i.e.Sales,Logistics,Marketing,Engineering,LineOperators,ProductionMgmt.,etc…

小組成員應(yīng)來自于所有被涉及區(qū)域，并非只是質(zhì)量部！如銷售、物流、市場、工程、生產(chǎn)線操作工、生產(chǎn)管理等等······TheTeamshouldaskthemselvesdotheyhavethecorrectskillmixtosolvetheproblem?

小組應(yīng)詢問自己是否具有解決問題所必需的能力?易蛛聳戰(zhàn)煤鑒抨拍貉痙屹惺救庇締熊駿恰子腫殉完鍛卑咽窒頌細(xì)渦籃榔額8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD1EstablishTeam

D1組建問題解決小組E7D2DescribetheProblem

D2描述問題ClearlyIdentifyandDefinetheProblem.

明確識別和定義問題InmanycasesProblemsareambiguousorimprecise.

在許多案例中，問題是模棱兩可或不明確的ClarityensuresthateveryoneistryingtosolvethesameProblem.

明確問題可確保任何人將盡力去解決問題勺嘴晨妥憑懶酬儲楔永雞淖牽傳桑芍閉澈俯綢駭捏唯壁藤獰勺局踩害杠找8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD2DescribetheProblem

D2描述問8D2DescribetheProblemElements

D2描述問題要素WhatistheProblem?Describethefailuremode.

問題是什么?描述失效模式Wherewasitdetected?問題是在哪里被發(fā)現(xiàn)?Whenwasitdetected?問題是什么時候被發(fā)現(xiàn)?Whatlots/datecodesareaffected?

被影響的批次/日期碼是那些?Howmanypiecesareaffected?

被影響的數(shù)量是多少?IstheCustomerinformationincluded?

是否包含客戶信息?邏畔芬?guī)炱轭惛G貨狂酸探主豪雇奪妒蚌枷沼捉補(bǔ)睜搏垮掛釉濤窗騰柜禍朋8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD2DescribetheProblemElemen9D2DescribetheProblemExamples

D2描述問題案例PoorProblemDescription差勁的問題描述“Customerreceivedwrongpart.”客戶接收到錯誤零件GoodProblemDescription完美的問題描述“CustomerreceivedincorrectvalueCRCW-0603resistorson4/1/02.CustomerP.O.441960(VishayP.O.X765644-30)specifiedCRCW-0603,8.2KohmandreceivedCRCW-0603,82Kohmparts.”客戶在4/1/02接收到阻值錯誤的CRCW-63電阻。客戶訂單號碼441960（Vishay訂單號碼X765644-30）指定的CRCW-63電阻的阻值為8.2歐姆，而收到的CRCW-63電阻的阻值為82歐姆。較徒頑逃碾寵掌雙將聘腹碼準(zhǔn)永骨賣嚙桌障浴久后芽憋璃呼椿濃謗絞幽華8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD2DescribetheProblemExampl10D3Containment

D3圍堵措施（短期對策）Containmentissimilartoquarantine.Quarantinedoesnotcureadisease,butitkeepsitfromspreading.

圍堵相似于病人隔離。隔離雖不能醫(yī)好疾病，但可以防止疾病的傳播FindandsegregatenonconformingproductstopreventshipmenttoCustomer.

查找和隔離不良品，防止發(fā)往客戶Shutdownprocesses/equipmentthatisproducingbadproduct.

停止正在制造不良的加工或裝配Makesurecontainmentactionsareeffective.

確保圍堵措施是有效的曙佳損繡注卜呸行淄坤倪賬費(fèi)鴿肖紹諜各我擇須鬃默鼻乳熾鉻啊擇急傘扎8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD3Containment

D3圍堵措施（短期對策）Co11D3ContainmentElements

D3圍堵措施要素Hasaneffectivecontainmentmethodbeenidentifiedanddocumented?

是否有有效的圍堵方法已經(jīng)被確定和文件化?Havedates(ordatecodes)fortemporarycontainmentactionsbeenidentified?

是否已經(jīng)確定了臨時圍堵措施實施的日期（日期碼）?Haveactionsbeenverifiedwithbeforeandafterdata?

是否已經(jīng)驗證了圍堵措施實施前后的效果?Hastheentirepipelinebeencontained(production,warehouse,distributors)?

是否對產(chǎn)品的所有流程采取了圍堵措施（如生產(chǎn)線、倉庫及發(fā)貨員）?Hasdetailedinstructionsoncontainmentbeenissuedtopeopleresponsibleforcontainment?

是否給負(fù)責(zé)實施圍堵措施的人員發(fā)放了詳細(xì)的圍堵作業(yè)指導(dǎo)書?講工靠鳳吩羽字洲亥穎墩隙訣浸鍛諜嘲呸場連尤陶棱橙總鳳矛貞愧飾妝抒8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD3ContainmentElements

D3圍堵措12D3ContainmentExample

D3

圍堵措施案例PoorContainment差勁的圍堵措施“Operatorwasalertedofthefailure.”讓操作工提防/注意此不良GoodContainment完美的圍堵措施“Productionandwarehousematerialwasinspectedon4/1/02byJ.Smith(qualityassurancepersonnel)andtherewere0lotsoutof320containingmixeddevices.”J.Smith（質(zhì)量保證人員）于4/1/02檢查了生產(chǎn)線及倉庫材料栗物步歉乳繪訊堰仰跋患您哥駭晉點(diǎn)威敵嶄踞躇鎬汛氈貳掃繁垃寬瓤毖贓8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD3ContainmentExample

D3圍堵措施13D4RootCause

D4根本原因（真因）Rootcauseisthedisease(startingpoint)thatsetsinmotionthecauseandeffectchainthatcreatestheproblemorproblems.

根本原因是產(chǎn)生問題或問題群的原因和影響開始發(fā)作的病因（發(fā)作點(diǎn)）BewaryofselectingsymptomsinsteadofrootcausesIfyoufixasymptomyouwon’tsolvetheproblem.

必須提防以癥狀代替病因，如果你僅僅關(guān)注一個癥狀，你將不能解決問題Poorrootcauseselectionresultsinpoorcorrectiveactions.

選擇不正確的根本原因?qū)?dǎo)致不正確的糾正措施Usetoolssuchas5Whyanalysistoensurethattherootcausehasbeenidentified.

應(yīng)用象“5個為什么”分析法，確保根本原因被識別和確定舊湊劉吞竊瑰司炸渺伐柱藍(lán)撞磅哥閨嬰供巴帚壁掂駛鉀輾祟序濁綁聘語侯8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD4RootCause

D4根本原因（真因）Root14D4RootCauseElements

D4根本原因要素Hastheprocessrootcausebeenidentifiedandestablished?

制程根本原因是否已經(jīng)被識別和確定?Hastheescaperootcausebeenidentifiedandestablished?

流出（逃脫）根本原因是否已經(jīng)被識別和確定?Hasthesystemrootcausebeenidentifiedandestablished?

系統(tǒng)根本原因是否被識別和確定?Dothethreerootcausesexplainallweknowabouttheproblem(timing,failuremode,failureamount,etc…)?

三種根本原因是否可以解說我們所知道的問題所有方面（如時間、失效模式、失效數(shù)量等等）?Wastherootcauseanalysisperformedusingthe5whytechnique?

根本原因分析是否使用了“5個為什么”方法?際逸拆病鹽傲繡柒由做財癥岔箔糟殉揪鏡玲抹豐拙演苫儉舅醫(yī)西嘛槍硒喘8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD4RootCauseElements

D4根本原因15D4RootCauseExamples

D4根本原因案例PoorRootCauseStatement差勁的根本原因“OperatorplacedwronglabelonPackage.ItwasanOperatorError.”操作工在包裝箱上貼錯了標(biāo)簽，是操作工的錯。

GoodRootCauseStatement完美的根本原因“ProcessRootCause:Anincorrectlabelwasplacedonthepackagebecausethecurrentsystemallowsformultiplelotstobeprocessed(batchprinting)atoneworkstation.”制程根本原因：目前的系統(tǒng)允許在同一個崗位加工種類不同的批次，導(dǎo)致錯誤的標(biāo)簽被貼在包裝箱上“EscapeRootCause:Themis-labeledproductescapedbecausetherewasnoverificationstepatorafterthelabelprocess.”

流出根本原因：貼錯標(biāo)簽的產(chǎn)品流出是因為在該崗位或后續(xù)過程沒有標(biāo)簽驗證步驟暑滋糾撼怎廈壘鍍馮校僥濺攀嗚徹幾秋耍虱札缺披那蔑什滁揣匣螟主青崔8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD4RootCauseExamples

D4根本原因16D5CorrectiveActions

D5糾正措施Correctiveactionsshouldfixthediseaseorrootcause.

糾正措施必須是針對病因或根本原因（真因）Correctiveactionsshouldaddressprocess,escape,andsystemrootcauses.

糾正措施必須致力于制程、流出（逃脫）及系統(tǒng)的根本原因（真因）Negativeeffectsofcorrectiveactionsshouldbeconsidered.

必須考慮糾正措施帶來的負(fù)面影響（即邊界效應(yīng)）Retrainingofoperatorsisnotacorrectiveaction.

操作工的再教育不屬于糾正措施范疇Increasedinspectionisnotacorrectiveaction.

增加檢查（人員、數(shù)量、頻次等）也不屬于糾正措施范疇且縣之庭宇簾衙怒主睜房笛逼佩俘勵攙君腎已粒臣邵連款謅統(tǒng)霉攔耪娶陰8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD5CorrectiveActions

D5糾正措施C17D5CorrectiveActionsElements

D5糾正措施要素Haveprimaryandalternativecorrectiveactionsbeenidentified?

是否已識別和確定首選及多選的糾正措施Docorrectiveactionsaddressprocess,escape,andsystemrootcauses?

糾正措施是否是針對制程、流出（逃脫）及系統(tǒng)的根本原因Havenegativeeffectsofcorrectiveactionsbeenconsidered?

是否考慮了糾正措施的負(fù)面影響（即邊界效應(yīng)）佬袋籽磨鼻爐癸疑智鉸版敷揩敲揪隕凍贏奶叼檻壤炭敝揩譴誦余級企汁隨8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD5CorrectiveActionsElements18D5CorrectiveActionExamples

D5糾正措施案例PoorCorrectiveAction差勁的糾正措施“Re-trainoperator.”操作工再培訓(xùn)GoodCorrectiveAction完美的糾正措施“ProcessCorrectiveAction:Changeworkflowtoaserialprocesswherebyonlyonelotisattheprintingstationatalltimes.Thiswilleliminatethechanceofmixingtheproductlabels.”制程糾正措施：變更流程，在任何時間標(biāo)簽印刷崗位只加工單一批次“EscapeCorrectiveAction:Implementabarcodeverificationsteptoensurethatcustomerlabelmatchesthefactorylabel.”流出（逃脫）糾正措施：實施標(biāo)簽驗證步驟，確保工廠標(biāo)簽和客戶標(biāo)簽一致磨駐皺孕晃暴叼撣嘗追題娃汲瀉癰硬貴嗅浸冗琺粘秒仆承銷度絆煥嚏暫趣8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD5CorrectiveActionExamples

19D6ImplementCorrectiveActions

D6實施糾正措施（長期對策）Stepwherewemonitor/validatethatthecorrectiveactionshaveeliminatedtherootcause(s).

確定我們監(jiān)控/驗證糾正措施是否已經(jīng)消除了根本原因的步驟Datesforthestartandcompletionofthecorrectiveactionshouldbeidentifiedalongwiththeresponsibleperson.

和糾正措施實施責(zé)任人一起確定糾正措施開始實施和完成的日期丘腋巴酮烤槽臥芬閃放蠻絆搖俊或臥憫擒戰(zhàn)綸吳起酒茬恫湊露七肖竣沖醒8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD6ImplementCorrectiveAction20D6ImplementCorrectiveActionsElements

糾正措施實施要素Havecorrectiveactiondatesalongwithresponsibleindividualbeenidentified?

是否已經(jīng)確定糾正措施實施日期和責(zé)任人?Havecorrectiveactionsbeenvalidatedtoeliminaterootcause(s)?

對糾正挫傷是否進(jìn)行了驗證，它能否消除根本原因?埔刁衷橇幼乳勘綠州雪未徹踐婿允鈕窯活罕餡氰鼠褥惠氣彩渝瘟留脾歪浪8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD6ImplementCorrectiveAction21D6ImplementCorrectiveActionsExamples

D6糾正措施實施案例PoorCorrectiveAction差勁的糾正措施“Complete.”已完成GoodCorrectiveAction完美的糾正措施“CorrectiveactionsstatedinD5werecompletedon4/1/02byJ.Smith.Postlabelinginspectionhasdiscovered0failuresoutof400lotsinspectedasof5/1/02.”

J.Smith已于4/1/02完成了D%中描述的糾正措施。5/1/02在標(biāo)簽檢查崗位共檢查了400個批次，沒有發(fā)現(xiàn)一批標(biāo)簽不良敝永虞逢遜摹諾裳石浸京懂機(jī)磕乳陰降靴贈硒圖禽告械工咀舊鋤跨纏詭定8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD6ImplementCorrectiveAction22D7PreventRecurrence

D7防止再發(fā)Preventtheproblemfromreturningbyaddressingproduction,business,management,orengineeringprocesses.

通過向生產(chǎn)、業(yè)務(wù)、管理層、工程傳達(dá)，以防止問題再發(fā)沮示控蠕殼酣靡趙當(dāng)?shù)仃@碰刁石羽瑣笛黑殘艷凜幅二麥行熄酥獅茶沸賬性8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD7PreventRecurrence

D7防止再發(fā)P23D7PreventRecurrenceElements

D7防止再發(fā)要素Dopreventiveactionsaddressbasicsystemissues?

預(yù)防措施闡述是否基于基本的系統(tǒng)問題HaveFMEA’s,controlplans,and/orproceduresbeenupdatedtoensurethatthesystemswillpreventissuesfromre-occurring?

FMEA、控制計劃及/或程序是否已經(jīng)被更新，以確保系統(tǒng)可以防止問題再發(fā)Havepreventiveactionsbeenagreeduponbyallaffectedareas?

預(yù)防措施是否已經(jīng)征得被影響區(qū)域的認(rèn)可Dounfinishedpreventiveactionshaveachampionandaprojectedcompletiondate?

未完成預(yù)防措施是否確定了組長和其完成日期

吐貯壕蘿轎墮弛彤貍腳操剛也啪攪聽修疙蔽刃悲痛栗咨保嘲瓷鉚蹬揣偉箭8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD7PreventRecurrenceElements24D7PreventRecurrenceExamples

D7防止再發(fā)案例PoorPreventiveAction差勁的預(yù)防措施“Sameascorrectiveactions.”預(yù)防措施同于糾正措施GoodPreventiveActions完美的預(yù)防措施“Workinstructionandcontrolplanhavebeenchangedon4/1/02toeliminatebatchprocessingandtoaddbarcodeverificationprocesses”作業(yè)指導(dǎo)書及控制計劃已于4/1/02進(jìn)行變更，以消除批次處理問題及增加標(biāo)簽驗證過程“CorrectiveandPreventiveactionswerealsoappliedtoVishay’ssisterfactoriesinChinaon4/1/02.”糾正/預(yù)防措施已于4/1/02應(yīng)用于Vishay在中國的兄弟工廠“Auditchecklistwasmodifiedon4/1/02toincludemonthlycheckstoensuresinglelotprocessing.”檢查表已于4/1/02修訂，包括月檢以確保單一批次被加工偽帳厲廚額覺堯蝶琺患涸遺定宿駒萬諺練終勃寨凹遲含汞輿英投莢豢故期8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD7PreventRecurrenceExamples25D8CongratulateTeam

D8小組慶祝Variesbyfacilitybutmostoftenoverlooked.

澄豹泅敗輩精胖賈姓賴失纂貝云誨蟻瞧肛票趴搗赦售隨逛裴傲鍘拇裁鬃揪8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingD8CongratulateTeam

D8小組慶祝Va26OtherComments

其他內(nèi)容8Dshouldsupplyfactsnotemotions.

8D應(yīng)該提供事實，不應(yīng)帶有感情色彩Avoidusinginternalacronyms.

避免使用公司內(nèi)部縮寫B(tài)ecompleteinyourdescriptions.

敘述應(yīng)該完整ItisourresponsibilitytofixVishayproblemsevenifwedonothavetraceabilityinformation.

即使沒有可追溯的信息，但關(guān)注Vishay問題是我們的責(zé)任簡漠句佰藹采粱菲挪噸釩路麓忱床揭詠筷從墾條索恍頻邊鴦碼瘡炕睡舌念8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingOtherComments

其他內(nèi)容8Dshoulds278DExampleHeartInc,amanufacturerofHeartdefibulators,returned25shortedpartswithmultipledatecodeson5/1/02.Heartstatedthatthe25partsfailedattherefinaltest.Heart’sfailurerateis10PPM.Theyexpressedconcernthatfaileddefibulatorsmightreachtheircustomers.

InternalanalysisbyVishayindicatesthatthe25partsareindeedshortedandtheyarenotthedevicetype(PN#V123)thatVishaysellstoHeartInc.Infact,the25partsareamixtureofdifferentVishaydevicesspanningthelast3monthsofproduction(February,March,andApril).AllreturneddeviceshadalowerpowerratingthanwhatissuppliedtoHeart,whichiswhytheyshortedinHeart’sapplication.Additionalanalysis,pointstothefactthatthepartsweremixedatmarking.Themarkingequipmenthasaknowndefectinwhichthelastfewpartsmightgetstuckinthetrackduetorandombutfrequentstickingofthepushpinmechanismwhenthebowlfeederbecomesempty.Tocombatthisissue,theengineerduringtheinitialdiscoveryoftheissueinstructedtheoperatorstoinspectthetrackpriortostartinganewlot.Intheeventthatpartswereleftovertheoperatorwastoremovethedevicesandcallthetechniciantorepairthepushpin.Inadditiontothechangeinprocedure,productionimplementedasampleoutgoingelectricaltest(200piecesper20,000piecelot)toeliminatemixedlots.Theoperatoronthemarkingequipmentwasnew(approximatelyworkingforVishayfor3months)andwasnotperformingtheinspectionasrequiredbytheprocedure.臥女云箕休醫(yī)迷蛀審忌接博返款葉櫻筐跺秩架攫絆枕署箋蔫京枚濾軸巴抵8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExampleHeartInc,amanufac288DExample8D案例

D1EstablishTeamD1建立小組NameFunctionChampionJ.SmithProductEngManagerTeamLeaderJ.DoeQualityEngineerMembersR.NeilProductionSupervisorB.DellProductionEngineerV.ChambersLogisticSupervisorA.MayMaintenanceEngineerN.PhillipsTrainingSupervisorS.RobinSales物暫慷岸凄殘毆睹樸茂同始絕盒論弱躺博櫻漏毯封包說蛔低作眼奮禾中晰8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D1Establish298DExample8D案例

D2DescribeProblemD2描述問題HeartInc.returned25V123partson5/1/02withthefollowingdatecodesthatfailedshortattheirfinaltest.Heart公司在5/1/02返回25個V123產(chǎn)品，產(chǎn)品日期碼如下，這些產(chǎn)品是其產(chǎn)品終檢時發(fā)現(xiàn)短路的#ofPartsDateCode10 0202 10 020350204Theestimatedfailurerateis10PPMandthecustomerisconcernedaboutfieldreliability.估計失效率為10PPM，而且客戶非常擔(dān)心已流入市場舶溪法亂稱濾整號攻閣卯早巧怨?fàn)揸J母神焚按促孔吶說爵鍋霍脈氦蔫反烯8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D2DescribeP308DExample8D案例

D3ContainmentActionsD3圍堵措施AllproductinproductionandinVishay’swarehouseswasquarantined(byV.Chamberson5/2/02)and100%electricallytested(byB.Dellon5/4/02)toeliminatethemixedproduct.12mixedpartswereremovedoutof60,000partstested.Allretestedlotswillbemarkedwitha“green”stickertoidentifythattheyhavebeenretested.所有在線及在庫品全部隔離（V.Chambers已于5/2/02完成），并進(jìn)行100%電性測試以消除混入產(chǎn)品（B.Dell已于5/4/02完成），從60,000個中剔除出12個異類產(chǎn)品。所有重測的產(chǎn)品批均用“綠色”標(biāo)簽標(biāo)識以示重測。還軸記奮雹誤瘟賦歪則緯在襄券掣濱薪緩痢扎素院醋餓鋅跋薦績攪載嘯砰8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D3Containment318DExample8D案例

D4ProcessRootCauseD4制程根本原因Problem:ShortedParts問題：短路Why?WrongpartsweresenttoCustomerandthepartswereunderratedfortheapplication.為什么：錯誤的元件發(fā)給客戶及其用途被低估Why?Residualpartswereleftinthemarkingequipmentcausingthesubsequentlottocontainmixedparts.為什么：殘留的元件被遺留在打標(biāo)機(jī)上導(dǎo)致其混入后續(xù)的批次Why?Thepushpinfailedtocleartheresidualparts.為什么：推針失效而無法清除殘留元件醉彩柄捂銷繁卉貿(mào)漆介褂泅壯元塵遞箔還配蔭蘋搪銅箱毅艾涕潘寒溜鞭商8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D4ProcessRo328DExample8D案例

D4SystemRootCauseD4系統(tǒng)根本原因Problem:ShortedParts問題描述：短路Why?WrongpartsweresenttoCustomerandthepartswereunderratedfortheApp.為什么：錯誤的元件發(fā)給客戶及其用途被低估Why?Residualpartswereleftinthemarkingequipmentcausingthesubsequentlottocontainmixedparts.為什么：殘留的元件被遺留在打標(biāo)機(jī)上導(dǎo)致其混入后續(xù)的批次Why?Thepushpinfailedtocleartheresidualparts.為什么：推針失效而無法清除殘留元件Why?Theactuatorsonthepushpinareoldandneedtobereplaced.為什么：推針執(zhí)行器老化而需要更換Why?Wedonothaveadetailpreventivemaintenanceplanforreplacementofworn-out/oldequipment.為什么：我們沒有一個詳細(xì)的針對替換破損/老化設(shè)備的維護(hù)計劃杏蛋蕉蜀型氟蟹否來古饑蘸秋茁海緒篩瞥敗拒悲級親桑重里攔蛾邱菩辜請8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D4SystemRoo338DExample8D案例

D4EscapeRootCauseD4流出根本原因Problem:MixedPartsEscapedtoCustomer問題描述：混入產(chǎn)品流到客戶Why?SampletestpostmarkingwillnotalwaysdetectPPMissues.為什么：抽樣檢查崗位無法發(fā)現(xiàn)PPM級缺陷Why?Samplesizeistoosmall.為什么：抽樣量非常少駛賈她譯奄警蹄刷更類三哪寵鉗豺梨蒲平害燼哇辦浴摻對還喻哆哮瞞庫忘8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D4EscapeRoo348DExample8D案例

D5RootCauseD5根本原因Analysis:Vishayverifiedthatthepartsareshorted.ItwasdeterminedthattheshortedpartsweremixeddevicesthathadlowerpowerratingsthantheonessuppliedtoHeart.ThemixoccurredatVishay'smarkingoperationduetoresidualunitsleftonthemarkingmachineduringFebruary,MarchandApril.Vishayhadaprocedureinplacefortheoperatortoverifythetrackwasemptypriortothestartofanewlot.Theprocedurewasnotfollowed.分析：Vishay確認(rèn)產(chǎn)品是短路，最終原因被確定為被發(fā)給Heart公司額定功率低的產(chǎn)品混入到設(shè)備中，混入現(xiàn)象發(fā)生在Vishay的打標(biāo)崗位，是在2月、三月份及四月份殘留元件被遺留在打標(biāo)崗位所致。Vishay在操作崗位有作業(yè)程序，規(guī)定在開始打標(biāo)新的批次時須檢查軌道是干凈的，但程序沒有被執(zhí)行。ProcessRootCause:Theactuatorinthepushpinmechanismusedtoflushresidualunitsfromthetrackstopworking.制程根本原因：推針執(zhí)行器被用來剔除軌道停滯工作時的殘留元件EscapeRootCause:ThesamplesizeforthepostmarkingtestisnotsufficientenoughtodetectPPMmixturelevels.流出根本原因：在打標(biāo)崗位的抽樣檢查數(shù)對混入水平在PPM級的不良來說是不足的SystemRootCause1:Theactuatorsarenotincludedonapreventivemaintenanceschedulethusallowingactuatortodegradeandbecomedefective.系統(tǒng)根本原因1：執(zhí)行器沒有被納入保養(yǎng)計劃，這樣允許執(zhí)行器劣化及沒有效力SystemRootCause2:Currenttrainingplandoesnotrequiretrainingverificationthereforeitwasnotknownthattheoperatorwasnotfollowingtheoperatingprocedure.系統(tǒng)根本原因1：目前的培訓(xùn)計劃中沒有要求進(jìn)行培訓(xùn)效果驗證，所以并不知道操作工沒有遵守作業(yè)程序的規(guī)定恤代潮曙址倘哪石故掖輻竭燒盼孜優(yōu)喬施沖綴膛燙凝排轟吧帕瀕粕揭沙閹8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D5RootCause358DExample8D案例

D5CorrectiveActionsD5糾正措施ProcessRootCause:Replaceactuatorsonallmarkingequipmenttoeliminateresidualparts.制程根原因：在打標(biāo)機(jī)上替換執(zhí)行器以除去殘留部件EscapeRootCause:Implement100%qualitytestpostmarkingtoensurethatmixedpartswillnotbeshippedtoHeart.流出根本原因：在打標(biāo)崗位實施100%檢查確?；烊氲牟考槐话l(fā)送Heart公司SystemRootCause1:Incorporateapartreplacement/refurbishprogramintotheexistingpreventivemaintenancescheduletoensurethatpartsarereplacebeforetheycauseaproblem.系統(tǒng)根本原因1：在現(xiàn)有的檢修計劃中增加部件置換/刷新項目，以確保部件產(chǎn)生問題時被置換SystemRootCause2:Modifytrainingprogramtoincludeaverificationsteppriortograntingcertification.系統(tǒng)根本原因2：修訂培訓(xùn)程序，包含在批準(zhǔn)合格前有一個檢驗步驟汾譴燈童扇政鄒漏算孜飄演僅睦喬趣櫻燃禮丸挾賞妝栓履灌說昆矽曳儀頻8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D5Corrective368DExample8D案例

D6ImplementCorrectiveActions

D6實施糾正措施ProcessRootCause:CompletedbyA.Mayon5/10/02.Severallotswereprocessedthroughthemarkingmachineandthepushpinproperlyremovedtheresidualparts.制程根本原因：A.May于5/10/02完成打標(biāo)機(jī)打標(biāo)多個批次時，推針可正確的推離殘留部件EscapeRootCause:CompletedbyB.Bellon5/10/02.Severalmixeddeviceswereplacedthroughthetestertoverifythatthetestprogramwouldremovealldefectiveunits.Allincorrectdeviceswereremoved.流出根本原因：B.Bell于5/10/02完成多臺混料裝置被安置在檢查儀上以驗證檢查程序可以剔除不良品，所有不好的測量儀已被移走SystemRootCause1:Projectedcompletion6/1/02byA.May.系統(tǒng)根本原因1：A.May已于6/1/02完成SystemRootCause2:Projectedcompletion6/15/02byN.Philips.系統(tǒng)根本原因2：N.Philips已于6/15/02完成驕勛套承霖碾閣弟愛負(fù)奶曳娟呸刻裳毆創(chuàng)度殊尚柞遜樞燴南自陣侖往比待8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D6ImplementC378DExample8D案例

D7PreventRecurrence

防止再發(fā)UpdateFMEAandControlPlantoreflectcorrectiveactions.CompletedbyR.Neilon5/10/02

反映糾正措施的FMEA及控制計劃的更新已于5/10/02被R.Neil完成UpdatetrainingandPMprocedurestoreflectcorrectiveactions.ProjectedCompletion6/15/02byN.Philips

反映糾正措施的培訓(xùn)和PM程序的更新已于6/15/02被N.Philips完成Addpartcountertomarkingequipmenttomeasurepartsinandouttoensurethatallunitsareaccountedfor.Projectedcompletion6/15/02byA.May

A.May已于6/15/02完成了在打標(biāo)機(jī)上增加計數(shù)器以記錄流入和流出的部件數(shù)量的項目，以確保所有單件被正確計數(shù)Placeanalarmthatwillsoundifthepushpindoesnotoperate.Projectedcompletion6/15/02byA.May

A.May已于6/15/02完成了在推針無法動作時增加報警器的項目筑果矽覓卵繩憫凱打鋸汁披擠沃隨實傀嘴鄒粵個蓖怔勒焚斜睬絆祿恃扶棗8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DExample8D案例

D7PreventRe38ProtectTheCustomer

保護(hù)客戶Wemusttakecustomerissuespersonally,respondingwithurgencyanddecisivenesstoquicklyresolvethem.

我們必須親自處理客戶問題，緊急和明確的反應(yīng)，以快速解決問題

Quickimplementationofsolutionsthateliminatetheproblemforever,acrossallrelevantproducts,processesandapplications.

針對所有相關(guān)產(chǎn)品、制程和應(yīng)用，快速采取解決方案，以徹底消除問題Selfimposecontainment,withouthesitation,wherevariationisanissueortheroot-causeisnotknownandeliminated.

倉促、自我欺瞞的圍堵措施若被實施，則變差作為問題或根本原因不會被知道和消除Everyoneintheorganizationmustbeaccountableforqualityimprovement.

任何組織成員均應(yīng)致力于品質(zhì)改善Wemustchangeourexpectation,behavior,andaccountability;onlyaccepting,andgiving,thecustomerexcellence!

我們必須完善我們的愿望、行為和責(zé)任，不僅僅是接受和付出，實現(xiàn)客戶卓越矽子榮臀紅猿暇輻槳輕吃痞棵華枚耿繭油踐魔慧穿筑不謾噶張吹盔陡駕祝8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingProtectTheCustomer

保護(hù)客戶Wemu39VishayManagementExpectations

Vishay經(jīng)營期望Workingtogetherinanopenandhonestway--wecanexceedourcustomers’expectations!開放和誠實的合作態(tài)度—我們將超越顧客的期望!IfwedonotmakeChanges,NothingwillChange!MustWantToMakeADifferencePersonalizeIt.AchieveResults!如果我們不求變革，將不會有任何變化!力求創(chuàng)新!人性化!達(dá)成結(jié)果!哆箔呢農(nóng)沛俞署朝倉盎稈瑣茄藩頑淳牢沒抗房踴撅璃犬萍堵屆罐篆濘朗疥8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingVishayManagementExpectations40VishayCustomer

CorrectiveActionRequest(CAR)Guidelines

Vishay《客戶糾正措施要求CAR》應(yīng)用指南午涯芝還殿吵豐豫硬訖繳痊差宮酮恫肪煞信臻綿反理鉚補(bǔ)胰紹怖點(diǎn)江邪磨8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingVishayCustomer

CorrectiveAc41WhatisaCAR/8D?

何謂CAR/8D?ACAR/8DReportisamethodtodocument,communicate,trackanddriveresolutionsforqualityissues.CAR/8D是針對品質(zhì)問題而進(jìn)行文件化、溝通、追蹤及解決問題的方法。An8DreportisFordMotorCompany’sformatforproblemsolving.Itisthepreferredmethodusedthroughoutourindustry.CAR/8D報告是福特公司解決問題的格式。它是我們所有行業(yè)首選的解決問題的方法。砌印零擾裳刻鐐磁件任棒出訴稱喂屋騷磨處誼款飼蹤析噓站斃搬旋艱卻擾8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingWhatisaCAR/8D?

何謂CAR/8D?A42ImmediateContainment.

采取迅速的圍堵措施（短期對策）ClearidentificationofRootCause.

真正識別問題產(chǎn)生的根本原因（真因）RobustCorrectiveActions.充分的糾正措施VerifiedCorrectiveActions.驗證糾正措施Systemfixes.系統(tǒng)化（即糾正措施標(biāo)準(zhǔn)化或文件化）100%On-timeresponse.

100%準(zhǔn)時反應(yīng)（即及時解決問題，準(zhǔn)時回復(fù)客戶）Eliminatetheproblemsthefirsttime.做到第一次就消除問題所在Preventionoffutureproblems.實現(xiàn)潛在問題的預(yù)防CUSTOMER8DEXPECTATION

客戶應(yīng)用8D的期望日槐卷塢踞盔娥亂預(yù)潘情仲詭幾灘運(yùn)肇閣仙捂拍綜讕鉚剩疵郁佛輕沼難巢8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingImmediateContainment.CUSTOMER43CAR/8DReportProblems

完成CAR/8D報告存在的問題Notidentifyingthetrueprocesses,escape,andsystemrootcauses.

沒有識別出過程、流出（逃脫）及系統(tǒng)的根本原因（真因）Notimplementingsystemcorrectiveactions.

沒有實施系統(tǒng)性糾正措施Notproperlycontainingentirepipelineofproduct.

沒有針對產(chǎn)品的所有流程采取正確的圍堵措施Unclearorambiguouswording.

對問題采取的不明確或模棱兩可的描述Notmeetingcustomerexpectationsregardingcontentandcycletime.

不符合客戶關(guān)于內(nèi)容及回復(fù)時間的要求術(shù)最編剮閨棉呵譚姜餐規(guī)耪壕唱差摯董叛雄撐奧佛登叉癌香搐緒臼儒錢寥8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingCAR/8DReportProblems

完成CAR/844CAR/8DRequirements

CAR/8D的要求Allcorrectiveactionrequestsmustbecompletedusingan8Dreport(unlessadifferentmethodisrequiredbyCustomer).

所有的《糾正措施要求》必須采用8D報告形式（除非客戶要求采用不同的方法MustuseCorporateformat.

必須采用Vishay公司的格式Mustuse8Dchecklistasaguidelineincompletingthe8D’s.

在完成報告的過程中必須采用8D檢查表進(jìn)行檢查塞墅完逐用傷莖爺盅管餡鴕襲暇棘碑苔華氯咨皮世亦朽圍蚤樹楚宮墳稗盆8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrainingCAR/8DRequirements

CAR/8D的要求A458

DisciplinestoProblemSolving

解決問題的8個準(zhǔn)則D1EstablishaTeam組建問題解決小組D2DescribetheProblem描述問題D3Containtheproblem采取圍堵措施（即短期對策）D4Identifytherootcauses識別/確認(rèn)根本原因（真因）D5CorrectiveActions確認(rèn)糾正措施D6ImplementCorrectiveActions實施糾正措施（即長期對策）D7PreventRecurrence防止再發(fā)D8CongratulatetheTeam小組慶祝尋鉚也楞斑買沏鯉姑滁案斧架賭奧畜澡包贈禹施淌蛆巨伴么餐控漳械挨剔8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTraining8DisciplinestoProblemSolvi46D1EstablishTeam

D1組建問題解決小組EstablishCrossFunctionalTeam.

建立跨功能小組IdentifyaChampion.確定小組長Membersshouldbefromallaffectedareas,notjustquality!i.e.Sales,Logistics,Marketing,Engineering,LineOperators,ProductionMgmt.,etc…

小組成員應(yīng)來自于所有被涉及區(qū)域，并非只是質(zhì)量部！如銷售、物流、市場、工程、生產(chǎn)線操作工、生產(chǎn)管理等等······TheTeamshouldaskthemselvesdotheyhavethecorrectskillmixtosolvetheproblem?

小組應(yīng)詢問自己是否具有解決問題所必需的能力?易蛛聳戰(zhàn)煤鑒抨拍貉痙屹惺救庇締熊駿恰子腫殉完鍛卑咽窒頌細(xì)渦籃榔額8D報告培訓(xùn)資料_28D報告培訓(xùn)資料_25/30/2002Rev.Orig8DTrain