品質(zhì)成本（中英文版）課件

COSTOFUALITY

品質(zhì)成本QCOSTOFUALITYQ

PoorQuality… PoorBusiness!

品質(zhì)差，生意差!ItisatimebombwaitingtoExplode!COQ高，是一顆等待爆炸的定時炸彈！IFCOQhigh,如果COQ高Why?PoorQuality…Itisatimeb

Hiddenfailurecost隱藏的失效成本Commonlymeasuredfailurecost通常量度的失效成本TrueFailureCosts真正的失效成本

Scrap報廢Rework翻工

Warranty保證

Engineeringtime工程設(shè)計時間Managementtime管理時間Shopandfielddowntime工場壞機時間Increasedinventory增加存貨Decreasedcapacity削弱生產(chǎn)能力Deliveryproblems交貨問題Lostorders訂單減損CommonlymeasuredfailurecostisonlythetipoftheTrueFailureCosts.通常量度的失效成本只是真正失效成本中的冰山一角。Qualitycostisameasureoftheachievementandnonachievementofproductquality.TipoftheIceBerg

冰山一角Why?HiddenfailurecostCommonlymBasicPremisesforQualityCost:品質(zhì)成本基本前提:1.Itislessexpensivetopreventratherthandetectnonconformity預(yù)防比檢測更省錢。2.Processandproductperformancecanbeappraised(measured)工序和產(chǎn)品性能可以評估(量度)3.Thecausesfornonconformancecanbeidentifiedandtheireffectscanbereducedoreliminated產(chǎn)品不符的原因可以確認，其影響可以減小或消除Why?BasicPremisesforQualityCosWhyExaminetheCostofQuality?為何要審視品質(zhì)成本?1.Getmanagementattention引起管理層的關(guān)注2.Changethewayemployeethinkabouterrors改變雇員看待錯誤的方法3.Providebetterreturnonthequalityimprovementprogram提供更好的回報4.Provideatooltomeasureimpactofcorrectiveactions為改正行動提供量度的工具5.Provideatooltomeasuretheimpactofpoor-qualityonprofits為惡劣品質(zhì)對利潤的影響提供量度的工具Why?PreventionScrap預(yù)防報廢WhyExaminetheCostofQualitTheCostPyramid成本金字塔ProcessControl工藝控制Inspection檢查FieldService服務(wù)Design設(shè)計CostofQualityQFDSPCDOEWhy?Moneyspendtofixanissueatdifferentstages:不同階段修正某個問題所花的金錢：Design:1$設(shè)計:1$Production:100$生產(chǎn):100$Customer:1000$

到客戶手中:1000$TheCostPyramid成本金字塔ProcessResultantCost結(jié)果成本=FailureCost失效成本，DefectCost次品成本.ControllableCost可控成本=PreventionandAppraisalCost.預(yù)防和評估成本.PoorQualityisPoorBusiness品質(zhì)差即是生意差0102030405060ControllableEffort

CostTotalCost總成本ControllableCost可控成本ResultantCost結(jié)果成本ALowHighWhy?ResultantCost結(jié)果成本=FailureEffectofGoodPreventiveActivities良好的預(yù)防活動產(chǎn)生的效果0102030405060ControllableEffortCostABOldTotal舊的總成本ControllableCost可控成本ResultantCost結(jié)果成本LowHighNewTota新的總成本lGoodPreventiveactivitiesusuallybeginatfrontendofprocesswithbettereffectonresultantcost.良好的預(yù)防活動通常開始于工序前沿，對結(jié)果成本產(chǎn)生較好的影響。Why?在報廢和預(yù)防維護/檢測之間尋求一平衡點EffectofGoodPreventiveActiTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)Qualitycostareusuallyquantifiedintermsoftangiblecostsuchasreworkandscrapcost,andcustomerwarranty.Theselossesconstituteonlythetipoftheiceberg.品質(zhì)成本通常以有形成本如翻工，報廢，給客戶提供擔(dān)保等等而被量化，這些損失只是冰山一角。Whatabouttheintangiblecostssuchasmanagement/engineeringtime,inventory,customerdissatisfaction,andlossmarketshare?那些無形的成本代價如管理/設(shè)計時間，存貨，客戶的失望，市場份額損失等，又怎樣呢？QLFisamethodusedtoapproximatethesehiddenandlongtermlosses.QLF是用于估算這些隱藏的而且是長期損失的方法。Why?TaguchiQualityLossFunctionTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)Wecannotreducecostwithoutaffectingquality.我們不能削減成本而不影響品質(zhì)Wecanimprovequalitywithoutincreasingcost.我們可以不增加成本而改善品質(zhì).

Wecanreducecostbyimprovingquality.我們可以通過改善品質(zhì)而降低成本.Wecanreducecostbyreducingvariations.我們可以通過減少差異而降低成本.

TaguchiQLFstriveforminimalvariationaroundtargetvalueswithoutaddingcost.Hedefineslossas“…thelostimpartedtosocietyfromthetimetheproductisshipped”,thislossincludes TaguchiQLF努力達致接近目標值的最小差異而不增加成本。他將損失定為：“從產(chǎn)品裝運時流失的那部分損失“這種損失包括

：customerdissatisfaction,客戶不滿意addedwarrantycosttotheproducer,生產(chǎn)商增加擔(dān)保成本lossduethecompany’sbadreputation,公司信譽惡劣引致的損失

whichwouldleadtoeventuallossofmarketshare.這種損失終將導(dǎo)致市場份額的喪失。Why?TaguchiQualityLossFunctionTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)ThewayQLFisestablisheddependsonthetypeofqualitycharacteristicsinvolved.Aqualitycharacteristicsiswhateverwemeasuretojudgeperformance(quality).QLF的建立有賴于有關(guān)的品質(zhì)特性。品質(zhì)特性是用來判斷性能(品質(zhì))而進行的一切量度。Therearefivetypesofqualitycharacteristics.有五種品質(zhì)特性.Nominalthebest. Achievingadesiredtargetvaluewithminimalvariations,suchasdimensions&outputvoltage.名義上的最好

達致理想的目標值，差異最小，如尺寸和輸出電壓。Smallerthebetter.Minimizingaresponse,suchasshrinkageandwear.越小越好

如收縮和磨損Largerthebetter.Maximizingaresponse,suchaspulloffforceandtensilestrength.越大越好

如拉力和張力Attribute. Classifyingand/orcountingdata,suchasappearance.屬性 澄清并且/或者清點數(shù)據(jù)，如外觀Dynamic. Responsevariesdependingoninput,suchasafandrivespeedshouldvarywithenginetemperature.動態(tài)回復(fù)有賴於輸入，如風(fēng)扇的變速必須根據(jù)引擎溫度而變化。Why?TaguchiQualityLossFunctionTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)Valueofqualitycharacteristics品質(zhì)特性值Loss$yL=k(y-T)2L=Lossin$’s以美元計的損失k=Costcoefficient成本系數(shù)y=Valueofqualitycharacteristics品質(zhì)特性值T=Targetvalue.目標值LSLUSLWhy?TaguchiQualityLossFunction1.PreventionCost預(yù)防成本-Costofallactivitiesspecificallydesignedtopreventpoorqualityinproducts.專門設(shè)計用于防止產(chǎn)品惡劣品質(zhì)的一切活動成本。2.AppraisalCosts..評估成本-Costassociatedwithmeasuring,evaluatingorauditingproductstoensureconformancetoqualitystandards.為確保符合品質(zhì)標準所進行的與產(chǎn)品量度、評估或?qū)徍说扔嘘P(guān)的成本。3.InternalFailureCosts.內(nèi)部失效成本-Failurecostsoccurringpriortodeliveryorshipmentoftheproduct.在產(chǎn)品交運前發(fā)生的失效成本4.ExternalFailureCosts.外部失效成本-Failurecostsoccurringafterdeliveryorshipmentoftheproduct.產(chǎn)品交運之後發(fā)生的失效成本ElementsofCOQ.COQ的要素What?1.PreventionCost預(yù)防成本ElementsCostofConformance:What?

Prevention-Costassociatedwithdesign,implementationandmaintainingaqualitysystem預(yù)防---與設(shè)計，實施和維護品質(zhì)系統(tǒng)有關(guān)的成本。Appraisal-Costassociatedwithmeasuringconformance評估---與符合標準量度有關(guān)的成本。符合標準的成本:CostofConformance:What?PrevCostofNon-conformance:與標準不符的成本:What?InternalFailure-Costassociatedwithinternalnon-conformance(detectedpriortodeliveryofaproductorservice)內(nèi)部失效---與內(nèi)部標準不符有關(guān)的成本(產(chǎn)品或服務(wù)提供給客戶之前檢測發(fā)現(xiàn))Appraisal-Costassociatedwithexternalnon-conformance(detectedafterdeliveryofaproductorservice)評估---與外部標準不符有關(guān)的成本(產(chǎn)品或服務(wù)交付之後檢測發(fā)現(xiàn))CostofNon-conformance:What?IExamplesofPreventionCosts預(yù)防成本的例子

Developingthequality/processcontrolplan開發(fā)品質(zhì)/工序控制計劃Qualityeducationandtraining.品質(zhì)教育和訓(xùn)練Vendorsurveys(SupplierQualityAssurance)供應(yīng)商調(diào)查(供應(yīng)商品質(zhì)保證)Designreviews.設(shè)計檢討QualityImprovementTeamprojects.品質(zhì)改善小組項目計劃What?ExamplesofPreventionCostsDExamplesofAppraisalCosts評估成本範例

Qualityauditsoftheprocess.工序品質(zhì)審核.Inspectionandtestingofproducts.產(chǎn)品檢查和測試Inspectionofpurchasedmaterials.采購物料的檢查Calibrationoftestequipment.測試設(shè)備的校準Qualitydataprocessing.品質(zhì)數(shù)據(jù)資料處理Fieldperformancetesting.性能測試What?ExamplesofAppraisalCostsQExamplesofInternalFailureCosts內(nèi)部失效成本的例子

InProcessscrapandrework

線上報廢與翻工Engineeringchanges(ECN)工程改動Reinspectionafterrework翻工之後重檢Downgrading級別降低Expediting(Freight)加速(貨運)Terminatedprojects項目中止What?ExamplesofInternalFailureCExamplesofExternalFailureCosts

外部失效成本範例

Warrantyadministration

擔(dān)保管理Fieldrepairstock工場待修理Productrecallandfieldupdates產(chǎn)品追溯Customerrejectsandreturns客戶拒收和退貨Cancelingsuppliers取消供應(yīng)商Productliabilitysuit產(chǎn)品配套服務(wù)What?ExamplesofExternalFailureCSupplierQualityCost

供應(yīng)商品質(zhì)成本SupplierQualityCostcanbecategorizedaspartofPreventionCostasitinvolvesQualityAssuranceofincomingmaterials.

供應(yīng)商品質(zhì)成本可歸為預(yù)防成本的一部分，因為其和來料的品質(zhì)保證有關(guān)。ApparentSupplierQualityCost

明顯的供應(yīng)商品質(zhì)成本CostofSupplierQualitySurveys.供應(yīng)商品質(zhì)調(diào)查成本CostofReceivingandSourceInspection.接收和源頭檢查成本Costofdispositioningnonconformancepurchasedmaterials.采購錯位與不符的物料Costofscrapandreworkofsuppliercausednonconformance.供應(yīng)商的原因引起的報廢和翻工Costofsitevisittocorrectsupplierserviceproblems.走訪供應(yīng)商改正問題所需的成本HiddenSupplierCosts隱含的供應(yīng)商成本Costincurredbysupplieratthesupplier’sfacility供應(yīng)商設(shè)備引致的成本Costincurredbybuyerinsolvingproblemsatthesupplier’sfacility采購人員用供應(yīng)商設(shè)備解決問題時發(fā)生的成本W(wǎng)hat?SupplierQualityCostSupplierSupplierQualityCost供應(yīng)商品質(zhì)成本Index指標(QCPI)1.000-1.009 Excellent卓越1.010-1.039 Good

良好1.040-1.069 Fair一般1.070-1.099 Poor差1.100+ Immediatecorrectiveactionrequired.要即刻采取改正行動SupplierRatingProgramUsingQualityCost.用品質(zhì)成本評估供應(yīng)商程序.-FirstPortion-Traditionalpriceanddeliverytracking.第一部分-傳統(tǒng)價格與發(fā)貨跟蹤-SecondPortion-EvaluatessupplierQualityCostPerformanceusinganIndex第二部分-用指數(shù)表示供應(yīng)商品質(zhì)成本表現(xiàn)

SupplierQualityCost+PurchasedCost供應(yīng)商品質(zhì)成本+采購成本PurchasedCost采購成本QCPI

=What?SupplierQualityCost供應(yīng)商品質(zhì)成本InExample:SupplierhavingtworejectedlotformonthofJune:

舉例：供應(yīng)商六月份有二批退貨1.Costofprocessingincomingrejection(documentation,returnexpenses):Studyshowthateachrejectedlotwouldrequire$100toprocess處理退貨成本(記錄，退費)處理一批貨要100元($)Tworejectedlots=2LotsX$100/Lot=$200(2批需要200元)2.Costofcomplaintinvestigation(BUQE)投訴原因調(diào)查成本Manhoursrequiredtoinvestigatetherootcause.Studyshowcostpermanhouris$20調(diào)查根本原因需要的工時。研究表明每工時成本為20$10Manhoursrequired=10manhrsX$20/manhr=$2003.CostofreceivingInspection(IQA)收貨檢查成本UseIQAinspectorlaborstandardandaveragehourlywagestoprocesstheproblematiclots.Inspectorrequire1.2hourstoprocessonelot,andtheirhourlywageis$15.根據(jù)IQA檢查員標準工時的每小時平均工資水平來計算貨物的成本1.2laborhrs/LotX$15/laborhourX2Lots=$361.2小時/每批X$15/工時X2批=$364.Totalpurchasedfromsupplier=$10,000.來處供應(yīng)商的總采購成本=$10,000.

($36+$200+$200)+$10,000$10,000QCPI=FAIR=1.044

What?Example:SupplierhavingtwoJEcalculateCOQ?DefinitionHow?JECOQ計算定義JEcalculateCOQ?How?JECOQ計QualityCostCollectionandAnalysisExternalFailureCost(外部報廢成本)How?質(zhì)量成本的數(shù)據(jù)采集及分析QualityCostCollectionandAnQualityCostCollectionandAnalysisHow?ReturnScrap/Replacementcost.-Customerreturnforscrap顧客退貨報廢/換貨費用Dataobtainedfrom(ReturnAuthorization)RAdatabasewherebyeverycustomerreturnsiseitherrejectedorapprovedforreceipt.ReturnPartsRework/Sorting.-Customerreturnforreworkorsorting顧客退貨返工或挑撿DataobtainedfromeachindividualBUwherebyactualcostforreworkorsortingiscalculatedbyrespectiveBU.LiabilityClaims&Compensation.-Customerclaimsforlossesincurredduetoourproductproblem.DataobtainedfromAOsalesofficewherephysicalproductisnotreturnedto301/P12orfromcustomerclaimsforlossesduetoJEmotorproblems.顧客產(chǎn)品事故補償(由于我們產(chǎn)品原因)EmergencyTravelExpense.-Traveltocustomersiteduetoemergencyqualityissue.解決顧客問題發(fā)生的緊急旅行費用EngineeringExpenses.-Expensesforengineerstosettlecustomercomplaint.CombinationofBUQEmanhrsneededtosettleacomplaintandEngineeringdeptengineersteamtotalmanhrsneededtosolveacomplaint.解決顧客問題的工程費用質(zhì)量成本的數(shù)據(jù)采集及分析ExternalFailureCost(外部報廢成本)QualityCostCollectionandAnQualityCostCollectionandAnalysisInternalFailureCost(內(nèi)部報廢成本)

BusinessUnitsScrapReasonsAutomobilesPowerToolsPersonalCare&BusinessEquipAudio&VideoHomeApplianceTotalOver-productionScrap63

-

-

-

-

63

0.0%ObsoleteScrap117

54

295

-

2,969

3,435

1.2%LineSet-upScrap26

5,158

408

-

6,886

12,478

4.5%ProcessScrap75,964

91,049

21,227

11,637

46,555

246,433

89.4%-

152

-

-

1,723

1,875

0.7%Scrapduetotherawmaterialsissue-

37

36

-

11,441

11,515

4.2%Total76,171

96,450

21,967

11,637

69,574

275,799

27.6%35.0%8.0%4.2%25.2%100.0%How?質(zhì)量成本的數(shù)據(jù)采集及分析Rework,re-sortingandre-testing)QualityCostCollectionandAnLineSetupScrap-Partscrapbytechnicianduringlinesetup.調(diào)機報廢Partsscrapduringnewlinesetup,changeline,alsoincludescrapaftermachinerepairoradjustmentIn-processScrap生產(chǎn)過程中的報廢Over-production&obsoleteScrap過量生產(chǎn)或產(chǎn)品過時報廢Incomingmaterialdisposition來料不合格報廢Sorting&Re-inspection不合格批產(chǎn)品挑選或重檢測Rework(includingmachinedepreciationandlaborcost)返工成本Correctiveactionevaluation改正行動及評估成本QualityCostCollectionandAnalysis質(zhì)量成本的數(shù)據(jù)采集及分析InternalFailureCost(內(nèi)部報廢成本)LineSetupScrap-PartscrapbQualityInspection&Testing質(zhì)量檢測和測試Consistqualitylineinspectors,PPA&QA.CalculationbasedonworkinghourstimesstandardlaborcostIn-processInspection&Testing(includingfinalinspection)生產(chǎn)過程中的檢測和測試Consistofproductionoperatorsinvolvedininspectionandtestingprocess.Calculationbasedonworkinghourstimesstandardlaborcost.DestructiveTestScrap破壞測試報廢Partsscrappedindestructivetestasdescribeinprocessmanual(includingexperiments)IncomingQualityInspection-IQCcostcenter來料檢驗ReliabilityTesting-ReliabilityTestCentercostcenter可靠性測試Testequipmentcalibration&repair測量設(shè)備的校正和維修Processevaluation工藝評估Qualityaudits質(zhì)量審核Qualityassurancetesting質(zhì)量保証測試QualityCostCollectionandAnalysis質(zhì)量成本的數(shù)據(jù)采集及分析AppraisalCost(評估成本)QualityInspection&TestingQualityCostCollectionandAnalysis質(zhì)量成本的數(shù)據(jù)采集及分析Preventioncost(預(yù)防成本)Qualityadministration質(zhì)量管理Qualitytraining質(zhì)量培訓(xùn)Qualityassurancesystem質(zhì)量保証體系Productandprocessqualification產(chǎn)品及工藝的認証Qualityrequirementplanning質(zhì)量計劃Supplierevaluation&certification供應(yīng)商的評估和認証Extratooling/fixturesduetoenhancedPMactivitiesPM計劃以外額外的工具和夾具的維護QualityCostCollectionandAn應(yīng)用范例--汽車馬達BU應(yīng)用范例--汽車馬達BU應(yīng)用范例--汽車馬達BU應(yīng)用范例--汽車馬達BUQualityCostCollectionandAnalysisCOQ/Sales%isanormalizedindexbyoffsettingthedifferencesinsalesvolume,sothatanappletoapplecomparisonispossible.How?質(zhì)量成本收集與分析QualityCostCollectionandAnTheCOQforIndustryLeaders Note:COQshouldIncludeallthequalityrelatedcostandexpenses業(yè)界領(lǐng)導(dǎo)者的COQ數(shù)據(jù)注:COQ需對所有質(zhì)量成本項目的數(shù)據(jù)收集完全TheCOQforIndustryLeaders NSAMPLEPROJECTWAFERCRYSTALIZATIONCOQREDUCTIONPROJECT

How?質(zhì)量成本改進范例SAMPLEPROJECTHow?質(zhì)量成本改進范例TrackingonWeekly/MonthlyBasisMeasureBUName:COQDetails:PlanPlanPlanPlanPlanPlanDollars%%Dollars%%Dollars%%Dollars%%Dollars%%Dollars%%QualityadministrationQualitytrainingQualityassurancesystemProductandprocessqualificationQualityrequirementplanningSupplierevaluation&certificationTTLPreventivecostIncominginspectionTestequipmentcalibration&repairIn-processinspectionFinalinspectionProcessevaluationIn-processtestingQualityassurancetestingUtilities,supplies,products,etcQualityauditsTTLAppraisalcostScrapReworkSortingIncomingmaterialdispositionRejectdispositionCorrectiveactionevaluationRe-inspectionTTLinternalfailurecostCustomercomplaintevaluationReturnedgoodsrework&sortingReturnedgoodsreplacementReturnedgoodprocessingLegal/settlementcostTTLexternalcostTTLQualityCostMayJunActualActualActualActualActualActualJanFebMarApr按周/月/跟蹤數(shù)據(jù)TrackingonWeekly/MonthlyBasCrystalCOQMatrixTrendScrap$rate-Crystal0.1310.0700.1590.2000.1270.1750.0000.0300.0600.0900.1200.1500.1800.2100.240MarAprMayJunJulAugSeptOctNovDecScrap$rateGoal$40%50%60%70%80%90%100%JanFebMarAprMayJunJulAugSeptOctNovDecTotalYieldGoalYield-Crystal0.00%1.00%2.00%3.00%4.00%5.00%MarAprMayJunJulAugSeptOctNovDec020000040000060000080000010000001200000Scrap$TotalCOQ%COQ%GoalTotalCOQ%&Scrap-CrystalCrystalCOQMatrixTrendScrap0.00%0.1%0.2%0.3%0.4%0.5%0.6%MarAprMayJunJulAugSeptOctNovDecPrevention1.00%2.00%3.00%4.00%5.00%MarAprMayJunJulAugSeptOctNovDecInternalscrap%InternalGoalInternal&Scrap%-Crystal0.00%0.05%0.10%0.15%0.20%0.25%MarAprMayJunJulAugSeptOctNovDecExternalExternal%-Crystal0.00%0.1%0.2%0.3%0.4%0.5%0.6%MarAprMayJunJulAugSeptOctNovDecAppraisalPrevention%-CrystalAppraisal%-CrystalCOQ%Trend---Crystal0.00%0.1%0.2%0.3%0.4%0.5%0.6%MIFRFDefectTrendByProcess0.000.020.040.060.080.100.12B/PMOUNTF/PWELDT/CF/T1F/T2VisualPackageMarAprMayJunJulAUGGoalIFRFDefectTrendByProcess0.IFRFDefectModePareto0.000.020.040.060.080.10DLD/HRBrokenDeadLossH/LFreqH/LAngleH/LDeltRotationDirtyLeackageOthersMarAprMayJunJulAugGoalIFRFDefectModePareto0.000.0品質(zhì)成本（中英文版）課件COQTop-4Scrap--Crystal22.84%9.87%7.87%4.65%54.77%0.0%20.0%40.0%60.0%80.0%100.0%ASSYDLDBASICBrokenBlankASSYDead/BrokenBASICRoundingOthersScrap%Cumulative%COQTop-4Scrap--Crystal22.84%0%10%20%30%40%50%60%70%80%90%100%ContaminationRoughnessScratchInvisibleParetoofDLDFailureAnalysis0%2%4%6%8%10%12%AbrasiveMetalFlakeOilAdhesiveParticleAl0%10%20%30%40%50%60%70%80%90%1ManpowerMaterialMethodMachineHighRoughnessCementContamination(adhesivedotonblank)DLDElectrodehandlingscrapNotwellfollowcleanroomWIWelderfixturecreatesAlparticleDirtyBPchamberWrongcalibrationmethodBuginFTsoftwareBubbleintheadhesiveDirtyblanketchingmarkBPframeBP/FPmaskscleanlinessFishBoneDiagramOilleakfrompumpAdhesivethawtimetooshortBlankcleaningnoteffectiveBlanklappingovertargetChip/TwinblankPatternmis-alignmentBlankwithLow-Q/WrongflatEquipmentvarianceMetalparticleinlidImpurityinN2gasEnvironmentLowairflowAu/Au/CrimpurityPeopleintroducedparticleLongWIPtimebeforeFP/weldManpowerMaterialMethodMachineHDLDActionUpdate-AugAction/StudyStatusTDU%ImpactTop-1Driver:IFRF--DLD(DR/DF/Rs/R):Champion:Lisa/RenaCoach:Jim/WandaAddvalveforweldingovenDone0.25%ParticlecountUSL<7KCBMupgradeblankwashprocessImplementupdatedtoolingPMplanDoneDoneTBD0.5%QCEconverttoFO4000abrasiveQCEaddlightboxcheckforetchingmark9/50.1%ConverttostainlesssteelweldingfixtureParticlecountUSL<5K-FPnon-paperreportsystemsetup-Cleanroomuselintfreepaper10/611/5TBD12/10.05%TBDDLDActionUpdate-AugAction/St0%10%20%30%40%50%60%BrokenFreq.OutRangeScratchLessadhesiveShortBPlowMixMis-alignmentRotationParetoofBroken/DeadFailureAnalysis0%10%20%30%40%50%BrokenatConnerBrokenatmiddleHandlingBrokenDead0%10%20%30%40%50%60%BrokenFreqMachineManpowerDroptothegroundTransportationShockMaterialChippedBlankWrongHandlingHardnessofBaseTabsPoorSlotroughnessofbaseLeadCutterShockUltrasonicLevelofBlankWasherHandlingbrokenLargeWeldingPressureStampingShockMethodUnsafePackageCementVolumeMountRotationLowviscosityofAdhesiveDead/BrokenFishBoneDiagramDead/BrokenProductmixPatternalignmentinsufficientepoxyamountAdhesivecontaminationBubbleinepoxySlutknifeofleadcutter/formerB/PplatedeadLargespotsizeforsomemodelUM5shieldwithpooredgeNotoptimizedBPmaskdesignforMSmodelMachineManpowerDroptothegroHandlingrelatedscrapreductionDead/BrokenActionUpdate-AugTop-3Driver:IFRF--Dead/Broken:Champion:Bacon/YKCoach:Pieter/WXAction/StudyStatusTDUImpactB/PmaskredesignforMSmodels-Incentiveprogram-ProcessmappingforerroropportunityreductionShieldconverttoSunshowA01baseredesign9/200.6%10/1TBD11/59/300.1%TBDHandlingrelatedscrapreductiCBMDPUTrendbyProcess0.0%2.0%4.0%6.0%8.0%10.0%12.0%Rounding16B4S14S2PinlapPolishEpoxyEtch1Etch2Rounding2FinalAprMayJunJulAugCBMDPUTrendbyProcess0.0%2.CBMDUPTrendbyDefectMode0.0%2.0%4.0%6.0%8.0%10.0%RoundingScrapchipdistortionfracturehhighhighBroken&Lostm.bandscratwinsAprilMayJuneJulyAugestCBMDUPTrendbyDefectMode0.CBMBroken/LostTrendbyProcess0.0%1.0%2.0%3.0%4.0%4S1Pinlap6B4S2PolishEpoxyEtch1Etch2Finalwk27wk28wk29wk30wk31wk32CBMBroken/LostTrendbyProceMan

Method

Machine

Cause-and-EffectChartEnvironmentBroken&LostMaterialHandlingerrorNewplateThickblankmixCarrierbrokenPlateflatnessStaticelectricityHumidityCarrierqualityAbrasivegritSlurrysystemPlateconditionStretchringSkillOvertimeBlankfrequencySpeedstabilityPlatebearingLoadsizeWCA#3/FO4000#WashbasketGearheightWheelconditionStackedblanksOwnershipManMethodMachineRoundingScrapParetoRoundingScrapPareto

Employees

Methods

Equipment

Cause-and-EffectChartEnvironmentRoundingScrapMaterialWronghandlingDiamondwheelStackAlignmentWheelvibrationCompressionairTemperature

Slurryfeeder

FracturediceSkillOvertimeBlankfrequency

FeedwayalignmentOrientationfixtureFinewheelRemovalCoolantcompositionStackSpeedLoadfixtureDe-waxtimeBlanktypeOwnershipBubbleinstackStacklengthPinpressureLivecenterRoundingspeed-F3Flatspeed-F7Fine/RoughwheelcoolantEmployeesMethodsEquipTop-2driver:CBM--BlankBroken/Lost:Champion:John/PhilipCoach:Jim/PieterRoundingDOEforsuitableremovalamountCBMCOQActionUpdate-AugAction/StudyStatusTDUImpactTop-4driver:CBM--Roundingscrap:Champion:Digal/MonicaCoach:JHLi/WXDefinepin-lapcarrierlifetime/criteriaAction/StudyStatusTDUImpactDone*DifficultTDBL/HAPYyieldimprovement(22%costreduction)LappingPlateConditiontimeextendto3HrsDoneUpgradeslurryoutletsystem9/30Setincomingbrokenratespec.forcontractorDone10/240.4%1.4%0.4%1%0.5%Top-2driver:CBM--BlankBrokCOSTOFUALITY

品質(zhì)成本QCOSTOFUALITYQ

PoorQuality… PoorBusiness!

品質(zhì)差，生意差!ItisatimebombwaitingtoExplode!COQ高，是一顆等待爆炸的定時炸彈！IFCOQhigh,如果COQ高Why?PoorQuality…Itisatimeb

Hiddenfailurecost隱藏的失效成本Commonlymeasuredfailurecost通常量度的失效成本TrueFailureCosts真正的失效成本

Scrap報廢Rework翻工

Warranty保證

Engineeringtime工程設(shè)計時間Managementtime管理時間Shopandfielddowntime工場壞機時間Increasedinventory增加存貨Decreasedcapacity削弱生產(chǎn)能力Deliveryproblems交貨問題Lostorders訂單減損CommonlymeasuredfailurecostisonlythetipoftheTrueFailureCosts.通常量度的失效成本只是真正失效成本中的冰山一角。Qualitycostisameasureoftheachievementandnonachievementofproductquality.TipoftheIceBerg

冰山一角Why?HiddenfailurecostCommonlymBasicPremisesforQualityCost:品質(zhì)成本基本前提:1.Itislessexpensivetopreventratherthandetectnonconformity預(yù)防比檢測更省錢。2.Processandproductperformancecanbeappraised(measured)工序和產(chǎn)品性能可以評估(量度)3.Thecausesfornonconformancecanbeidentifiedandtheireffectscanbereducedoreliminated產(chǎn)品不符的原因可以確認，其影響可以減小或消除Why?BasicPremisesforQualityCosWhyExaminetheCostofQuality?為何要審視品質(zhì)成本?1.Getmanagementattention引起管理層的關(guān)注2.Changethewayemployeethinkabouterrors改變雇員看待錯誤的方法3.Providebetterreturnonthequalityimprovementprogram提供更好的回報4.Provideatooltomeasureimpactofcorrectiveactions為改正行動提供量度的工具5.Provideatooltomeasuretheimpactofpoor-qualityonprofits為惡劣品質(zhì)對利潤的影響提供量度的工具Why?PreventionScrap預(yù)防報廢WhyExaminetheCostofQualitTheCostPyramid成本金字塔ProcessControl工藝控制Inspection檢查FieldService服務(wù)Design設(shè)計CostofQualityQFDSPCDOEWhy?Moneyspendtofixanissueatdifferentstages:不同階段修正某個問題所花的金錢：Design:1$設(shè)計:1$Production:100$生產(chǎn):100$Customer:1000$

到客戶手中:1000$TheCostPyramid成本金字塔ProcessResultantCost結(jié)果成本=FailureCost失效成本，DefectCost次品成本.ControllableCost可控成本=PreventionandAppraisalCost.預(yù)防和評估成本.PoorQualityisPoorBusiness品質(zhì)差即是生意差0102030405060ControllableEffort

CostTotalCost總成本ControllableCost可控成本ResultantCost結(jié)果成本ALowHighWhy?ResultantCost結(jié)果成本=FailureEffectofGoodPreventiveActivities良好的預(yù)防活動產(chǎn)生的效果0102030405060ControllableEffortCostABOldTotal舊的總成本ControllableCost可控成本ResultantCost結(jié)果成本LowHighNewTota新的總成本lGoodPreventiveactivitiesusuallybeginatfrontendofprocesswithbettereffectonresultantcost.良好的預(yù)防活動通常開始于工序前沿，對結(jié)果成本產(chǎn)生較好的影響。Why?在報廢和預(yù)防維護/檢測之間尋求一平衡點EffectofGoodPreventiveActiTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)Qualitycostareusuallyquantifiedintermsoftangiblecostsuchasreworkandscrapcost,andcustomerwarranty.Theselossesconstituteonlythetipoftheiceberg.品質(zhì)成本通常以有形成本如翻工，報廢，給客戶提供擔(dān)保等等而被量化，這些損失只是冰山一角。Whatabouttheintangiblecostssuchasmanagement/engineeringtime,inventory,customerdissatisfaction,andlossmarketshare?那些無形的成本代價如管理/設(shè)計時間，存貨，客戶的失望，市場份額損失等，又怎樣呢？QLFisamethodusedtoapproximatethesehiddenandlongtermlosses.QLF是用于估算這些隱藏的而且是長期損失的方法。Why?TaguchiQualityLossFunctionTaguchiQualityLossFunction(QLF)Taguchi品質(zhì)損失函數(shù)(QLF)Wecannotreducecostwithoutaffectingquality.我們不能削減成本而不影響品質(zhì)Wecanimprovequalitywithoutincreasingcost.我們可以不增加成本而改善品質(zhì).

Wecanreducecostbyimprovingquality.我們可以通過改善品質(zhì)而降低成本.Wecanreducecostbyreducingvariations.我們可以通過減少差異而降低成本.

TaguchiQLFstriveforminimalvariationaroundtargetvalueswithoutaddingcost.Hedefineslossas“…thelostimpartedtosocietyfromthetimetheproductisshipped”,thislossincludes TaguchiQLF努力達致接近目標值的最小差異而不增加成本。他將損失定為：“從產(chǎn)品裝運時流失的那部分損失“這種損失包括

：customerdissatisfaction,客戶不滿意addedwarrantycosttotheproducer,生產(chǎn)商增加擔(dān)保成本lossduethecompany’sbadreputation,公司信譽惡劣引致的損失

whichwouldleadtoeventualloss