七顆鉆石流程

17DiamondProcess

七顆鉆石流程2Whatisthe7DiamondProcess?

七顆鉆石的流程是什么？The7DiamondProcessisoneofmanytoolsthatcanbeusedintheproblemsolvingprocess.七顆鉆石流程是可以用來(lái)解決質(zhì)量問(wèn)題的工具之一。Thistoolisusedtoinvestigatediscrepanciesdiscoveredbythefollowing:它可以用來(lái)調(diào)查以下方面發(fā)現(xiàn)的差異

GlobalCustomerAuditSystem(GCAS)全球顧客評(píng)審

YardWalkAudits生產(chǎn)線上巡檢

VerificationStations檢驗(yàn)工位3

Purposeofthe7DiamondProcess

7顆鉆石流程的目的

The7DiamondProcess

isastructuredwayofassessingourmanufacturingprocesstodeterminewhetherofnotithasfailedtomeetthequalitystandarddemandedbyourcustomers.7顆鉆石流程是一個(gè)構(gòu)建好的評(píng)價(jià)我們的制造流程是否滿足了顧客所要求的質(zhì)量標(biāo)準(zhǔn)的一個(gè)方法

47Diamond

Process流程Responsibility責(zé)任Production第一步

¨1Production第二步¨2Production第三步¨3Rel.Engineer/SQA/Supplier負(fù)責(zé)的SQDE工程師/供應(yīng)商

¨4CorrectProcess?正確的工藝CorrectTool?正確的工具CorrectPart?正確的零件PartsQuality?零件質(zhì)量Responsibility責(zé)任ProcessControlManagers工藝控制負(fù)責(zé)人¨5aIsEngineeringsupportrequired?是否需要工程方面的支持ProblemIdentifiedBeginInterrogation問(wèn)題定義(開(kāi)始調(diào)查)Responsibility責(zé)任QETPST(Lead)¨5bSMTRGM(Lead)¨6StatisticalEngineering(RedXStrategies)統(tǒng)計(jì)工程(紅-X方法)¨7WillProcessChangeResolve?工藝更改能解決問(wèn)題嗎ProductChangeRequired?產(chǎn)品更改需要嗎？HardyPerennialorExtremelyComplexProblem非常復(fù)雜的問(wèn)題SQA -SupplierQualityAssuranceQET -QualityEngineeringTeamPST -PlantSupportTeamSMT -SystemsManagementTeamRGM-ReliabilityGrowthManagement5ReviewofResponsibility

職責(zé)回顧

Diamonds1-4 Production&Reliability鉆石1-4生產(chǎn)&可靠性

Filter5a ProcessControlManager(PCM)5a過(guò)濾工藝控制負(fù)責(zé)人

Diamond5b-7 ProductEngineering鉆石5b-7產(chǎn)品工程6InsertSampleCountermeasureCardHere此處插入對(duì)策卡樣卡77DiamondProcessStages

流程的各步驟Stages1&2oftheprocessareusedtodetermineiftheProductionorganizationisrunningtheassemblyprocesstodesignintent.1、2步是用來(lái)確定生產(chǎn)部門(mén)運(yùn)行的裝配流程滿足設(shè)計(jì)內(nèi)容。

Theinitialinvestigation(Stage1)isdonewherethedefectwasidentified.最初的調(diào)查(第一步)應(yīng)在發(fā)現(xiàn)缺陷的地方開(kāi)始Stage2isonlyusedwhentheinvestigationinStage1determinedthatthecauseoftheproblemwasfromanupstreamsource.第2步只能當(dāng)?shù)谝徊降恼{(diào)查,確定問(wèn)題是來(lái)源其他方面時(shí),才可開(kāi)始Iftheprocessisn’tbeingmanagedtodesignintent,thenitmustbecorrectedandvalidated,priortoaskingforEngineeringassistance.如果工藝沒(méi)有滿足設(shè)計(jì)內(nèi)容，當(dāng)需要工程方面的協(xié)助前，必須進(jìn)行糾正并要有效。Engineeringreferral(Stage3)occurswhenthemanufacturingprocessdoesmeetdesignintentandtheproblemstillexists.當(dāng)制造過(guò)程滿足設(shè)計(jì)內(nèi)容并且問(wèn)題依然存在時(shí)，第3步開(kāi)始。8¨1-CorrectProcess正確的過(guò)程

ArethecorrectBestPeoplePracticesheetsposted?是否有正確的操作指導(dǎo)文件？

AretheBestPeoplePracticesbeingfollowed?是否執(zhí)行操作文件？

IstheoperatorsKeyPointChartbeingfollowed?是否滿足關(guān)鍵操作點(diǎn)控制圖

Arethecorrectdocumentspostedontheoperationcertificationboard?是否在操作示板上有正確的文件

IsthejobbeingperformedtothePAD’s?是否按照PAD操作

Cananyofthesecausetheproblem?以下的問(wèn)題有可能產(chǎn)生問(wèn)題嗎？Stages1&2ProductionCorrects正確的生產(chǎn)Production¨2Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正確的工藝過(guò)程CorrectTool?正確的工具CorrectPart?正確的零件PartsQuality?零件的質(zhì)量8¨1-CorrectProcess正確的過(guò)程

Hasamandatorysequencebeenidentified?Isitbeingfollowed?是否強(qiáng)制的操作序列號(hào)已識(shí)別，是否執(zhí)行了

Isthejobbeingdonethesameonbothshifts?在各班次中操作工作是否一致

Doestheoperatorunderstandwhattheproductstandardsare?操作者是否理解產(chǎn)品標(biāo)準(zhǔn)

Isittheregularoperator?Hastherebeenalotofturnoveronthejob?是否為固定操作工？是否此操作有很多輪換人員

Hastheoperatorbeenproperlytrained?操作者是否正確培訓(xùn)過(guò)

Arethevisualaidscurrent?目前是否有目視化的輔助措施

Doestheoperatorunderstandthequalityoutcomesofher/hisjob?操作者是否知道他/她的崗位的產(chǎn)品的輸出質(zhì)量

Doestheoperatorknowhowtocommunicatewhenhe/shehasaproblem?操作者是否知道當(dāng)他/她的崗位出現(xiàn)質(zhì)量問(wèn)題時(shí)如何傳遞溝通信息？Cananyofthesecausetheproblem?以下的問(wèn)題有可能產(chǎn)生問(wèn)題嗎？Stages1&2ProductionCorrects正確的生產(chǎn)Production¨2Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正確的工藝過(guò)程CorrectTool?正確的工具CorrectPart?正確的零件PartsQuality?零件質(zhì)量9

Arethecorrecttools&fixturesbeingused?(bothshifts)

是否使用正確的工具/夾具(各班次)

Arethetoolssettothespecifiedtorque?

工具是否設(shè)置成規(guī)定的扭矩

Aretheyproperlycalibrated?是否進(jìn)行適當(dāng)?shù)男?zhǔn)

Arebothshiftsusingthesametool?

是否各班次用同樣的工具

Arethebitsorsocketsworn?是否螺絲刀或套筒已磨損

Hasanextraairhosebeenattachedtothetool?

是否在工具上有多余的空氣管

IsthetooltiedtotheAndonsystem?工具是否與暗燈相連

HasthetoolbeenputonBypass?是否工具被旁路

Dothetools&fixtureshavemutilationprotection?是否工具/夾具有損毀保護(hù)

Hastheworkstationbeenerrorproofed?

工位是否有防錯(cuò)設(shè)施

Doestheworkstationlayoutallowtheoperatortoworkeffectively?

是否工位的布置適合操作者有效的工作

HasthePreventiveMaintenancebeendone?(checklog)

是否進(jìn)行了預(yù)防性維修(檢查表)

Aretoolsfunctioningcorrectly?

工具功能是否正確Stages1&2ProductionCorrectsProduction¨1Production¨3Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正確的工藝過(guò)程CorrectTool?正確的工具CorrectPart?正確的零件PartsQuality?零件質(zhì)量¨2-CorrectTool正確的工具Cananyofthesecausetheproblem?10IsthePartsRoutingcurrent?零件的的路徑徑是否否正確確Arethecorrectpartnumbersidentifiedonthematerialracks?是否在料架上上標(biāo)識(shí)有正確確的零件號(hào)Arepartsstockedincorrectlocationontherack?在料架上擺放放位置是否正正確Dothepartnumbersontheboxesagreewiththerack?包裝盒上零件件號(hào)與料架上上是否一致Areallpullcardsavailable?拉動(dòng)卡是否有有效HasaPAAbeenissuedchangingpartusage?是否有零件用用途改變的PAAHasthePAAexpired?PAA是否過(guò)期Iserrorproofingneeded?是否需要防錯(cuò)錯(cuò)措施Isexistingerrorproofingdeviceworkingcorrectly?是否已有的防防錯(cuò)設(shè)備運(yùn)行行正確Stages1&2Production¨1Rel.Engineer/SQA/Supplier

¨4CorrectProcess?正確的工藝過(guò)程ProductionCorrectsCorrectPart?正確的零件Production¨2CorrectTool?正確的工具PartsQuality?零件質(zhì)量¨3-CorrectPart正確的零件Cananyofthesecausetheproblem?11TheReliabilityEngineerisresponsiblefordeterminingifpartshavechangedandoverallpartquality.Ifpartsquality(outofspecification)isdeterminedtobetheproblem’’srootcause,thentheREwill:writePR&R’’stonotifythesupplierthatthereisaproblem.可靠性工程師師確定零件是是否更改過(guò)并并對(duì)產(chǎn)品全部部質(zhì)量負(fù)責(zé)。。如果由于零零件質(zhì)量(超超差)是根本本原因，那么么應(yīng)：填寫(xiě)PR&R通知供應(yīng)商：：workwithSupplierQualitytovalidatethecorrections.同供應(yīng)商共同同確認(rèn)糾正措措施setupsortingoperationsandproductionwillsupportsortingofmaterialattheoperation.采取篩選措施施，制造應(yīng)支支持在工位上上的物料篩選選workwithGroupLeaderstovalidatecountermeasuresorcontainment.同工段長(zhǎng)共同同確認(rèn)對(duì)策和和遏制措施Ifpartvariationwithinspecificationistherootcause,thentheREwill:如果果確確認(rèn)認(rèn)零零件件在在規(guī)規(guī)范范內(nèi)內(nèi)，，那那么么RE應(yīng)：：workwiththesupplierandSQAtomovethepartbacktotheneededrangewithinthespecification同供供應(yīng)應(yīng)商商共共同同工工作作，，SQA將零件返返回到規(guī)規(guī)范內(nèi)需需要的范范圍workwithQualityEngineeringtodetermineifanEngineeringChangeisrequiredtoprovideirreversiblecorrectiveaction同質(zhì)量工工程師合合作，確確定是否否需要工工程更改改這種不不能消除除的糾正正措施Stages1&2Production¨1CorrectProcess?正確的工工藝流程程Rel.Engineer/SQA/SupplierPartsQuality?零件質(zhì)量量Production¨2CorrectTool?正確的工工具CorrectPart?正確的零零件Production¨3¨4-PartQuality零件質(zhì)量量12Diamonds1-4inReview鉆石1-4步回顧Diamonds1-4areforevaluatingthestabilityoftheprocess.1-4步用來(lái)評(píng)評(píng)價(jià)工藝藝過(guò)程的的穩(wěn)定性性O(shè)nceaproblemhasbeenidentified,theautomaticresponsemustbetoimmediatelystepthrudiamonds1-4.當(dāng)問(wèn)題被被定義后后，1-4步的的負(fù)責(zé)人人員就自自動(dòng)確定定下來(lái)Itmustbecomeinherentinourproblemsolvingthoughtprocess.這些步驟驟是問(wèn)題題解決過(guò)過(guò)程中固固定的流流程Responsibility職責(zé)ProcessControlManagers過(guò)程控制制負(fù)責(zé)人人¨5aIsEngineeringsupportrequired?是否需要工程的支持13¨5a-EngineeringFilter5a-工程過(guò)濾濾IsEngineeringsupportrequired?需要工程程方面的的支持嗎嗎5aisasteptofilteroutandresolveless-complexissuesbeforeseekinghelpfromQualityEngineering.5a是一步過(guò)過(guò)濾出并并將不復(fù)復(fù)雜的問(wèn)問(wèn)題在尋尋求質(zhì)量量工程幫幫助前解解決TheProcessControlManagerisresponsibleforconductinginitialstudiespriortoescalatingtheissue.過(guò)程控制制負(fù)責(zé)人人負(fù)責(zé)在在提升問(wèn)問(wèn)題前指指導(dǎo)初始始研究Thesestudiesmayincludebutarenotlimitedto:這些研究究應(yīng)包括括但不局局限在:ProblemDefinitionTree問(wèn)題定義義樹(shù)5Whys5個(gè)為什么么StatisticalProcessControl統(tǒng)計(jì)過(guò)程程控制DesignofExperiment(DOE)試驗(yàn)設(shè)計(jì)計(jì)ShaininTechniques(quick&dirty)技術(shù)(快快速&臟臟)Ifaftertheinitialstudiesthecauseofvariationhasnotbeendetermined,theissueisreferredtoProductEngineering.TheproblemdefinitiontreeistheminimumexitcriteriatogofromDiamond5ato5b.如果經(jīng)過(guò)過(guò)初始研研究，變變差的產(chǎn)產(chǎn)生原因因還沒(méi)有有確定，，就需要要產(chǎn)品工工程的支支持。問(wèn)問(wèn)題定義義樹(shù)是從從5a-5b的基本方方法。QualityEngineering質(zhì)量工程5aProblemSolvingToolbox問(wèn)題解決工具箱Projecttitle:PooradjustmentofRRdoorpanel805-830Leader:PedroArandaAlfaroSponsor:JuanCarlosLiceaArea:VAETCoach:LeonardoCháávezsalcedoInitialdate:oct-04-2002Finaldate:oct-29-2002Problemdescription:ThismonthitwasreportedbytheshippinglotinUSAaproblemofqualityexistedinthe805/830vehicles.TheproblemisthepooradjustmentinRRdoorpanel.Projectsstatement:FindandimprovetheRedXthatproducethepooradjustmentintheRRdoorpanelforthemodel805/830inSilaoAssemblyplant.Strategy:Weinitiatedthisprojectusingthemodeltomodelstrategy,becausetherewasagoodcontrastandgoodleveragebasedonmulti-variseepag6.Measurementsystem:AsmeasurementsystemaForcegagewasused.ThismeasurementsystempassedtheisoplotwithDR=13.6,DM=1.0lbs,andDP=13.6lbs(seepage4)Cluegeneration:Stage1showsthattheRedXdoesn’tliveintheprocess.Thestage2showsthattheRedXlivesinthedoorpanel.Thepaircomparisonshowsthatthedoormoldingisthepartwiththebestcontrast.Statisticalconfirmation:OncewedetectedtheRedXcandidate,IdecidedtodoaBvsCsixpacktrial,inordertoconfirmthedoormoldingistheinfluencetomakethecustomersatisfaction.Thesixpackpassedwith95%ofconfidenceandendcountof6.Irreversiblecorrectiveaction:Tomodifiedtheflange1.5mminlengthtokeepabetterpositionandavoidthatthedoorpaneltakeoutofposition.Improvements:Reducewarrantycosttorepairthedoorpanelcausedbypoorfit(loose)andeliminatetheconditionin100%invehicles805/830models.Theamountofmoneyfromjul01tojul02was11,084.77USD.Lessonslearned:Welearnedthatisnecessarylookingotheralternativesusingotherstrategywhenisnotpossibleinvestmoneybutalwaysfocustoguaranteethecustomerenthusiasm,thereforethisprojectisanexampleofthis.ExecutiveSummary執(zhí)行總結(jié)項(xiàng)目題目：右后門(mén)板調(diào)調(diào)整不好(805/830車(chē)型)。。領(lǐng)導(dǎo)；PedroAdrandaAlfaro發(fā)起人：JuanCarlosLicea區(qū)域：VAET教練：LeonardoChavezsalcedo起使日：2002年10月4日截止日：2002年年10月29日問(wèn)題描述：本月收到報(bào)告告，在美國(guó)有有關(guān)于門(mén)飾板板的質(zhì)量問(wèn)題題，右后門(mén)飾板調(diào)調(diào)整不好。(805/830型)項(xiàng)目綜述：針對(duì)Lilao裝配廠805/830車(chē)車(chē)型的右后門(mén)門(mén)飾板，發(fā)現(xiàn)現(xiàn)并解決其配合不不好的問(wèn)題。。策略：我們起初應(yīng)用用車(chē)型對(duì)車(chē)型型策略，因?yàn)闉槎嘬?chē)之間有有很好的對(duì)比比度和平衡關(guān)關(guān)系。(見(jiàn)見(jiàn)見(jiàn)第6頁(yè))測(cè)量系統(tǒng)：用測(cè)力計(jì)作為為測(cè)量系統(tǒng)。。這種測(cè)量系系統(tǒng)通過(guò)等量量圖。(DR=13.6,M=1.0lbs,P=13.6lbs見(jiàn)第4頁(yè)線索產(chǎn)生：階段1表明紅紅X不在過(guò)程中。。階段2表明明紅X產(chǎn)生在門(mén)飾板板處。成對(duì)比比較表明門(mén)型型是成對(duì)比較較點(diǎn)。統(tǒng)計(jì)確認(rèn)：一旦我們查到到了候選的紅紅X，我們決定做BvsC六組數(shù)據(jù)比較較，這是為了了確認(rèn)門(mén)型影影響客戶滿意意度。用6對(duì)對(duì)數(shù)據(jù)進(jìn)行比比較具有95%的可信度度和最大累加加值為6.不可撤銷(xiāo)的糾糾正措施：為使門(mén)邊緣加加長(zhǎng)1.5mm以保證正確的的位置不偏離離。改進(jìn)措施：減少保修費(fèi)用用來(lái)修復(fù)由于于配合不好產(chǎn)產(chǎn)生的門(mén)飾板板問(wèn)題，并且且100%消消除803/805車(chē)型型的缺陷。學(xué)到的經(jīng)驗(yàn)：我們學(xué)到了當(dāng)當(dāng)投資不會(huì)會(huì)太多的情況況下，用其它它策略以尋求求可選擇的方方法解決問(wèn)題題。但始終要要關(guān)注顧客熱熱忱。此項(xiàng)目目便是一個(gè)這這樣的例子。。ProjectDefinitionTree/項(xiàng)目定義樹(shù)Problemcharacterization問(wèn)題描述Warrantycondition/保修條件Theproblemispresentedonlyinthereardoor問(wèn)題只是在后后側(cè)車(chē)門(mén)出現(xiàn)現(xiàn)BASED:DISTRIBUTONLOTCAMPAINGCURRENT:100%doorpanel805830modelsloose目前狀態(tài)：805/830型車(chē)門(mén)飾飾板100%松動(dòng)。GOAL:eliminate100%thepoorfit.目標(biāo)：100%消除不良良的配合Projectstatement項(xiàng)目綜述Needenergytoreleasethetrimdoorpanel需要用力才能能卸下門(mén)飾板板Customeriscallingtheprobleminbothsides客戶現(xiàn)在對(duì)兩兩側(cè)都在抱怨怨Efforttorelease(lbs)/釋放力(磅)Frequency頻率CURRENT現(xiàn)有DESIRED希望Solutiontree項(xiàng)目解決樹(shù)TARGET:Eliminatecondition100%目標(biāo)：100%消除除現(xiàn)有問(wèn)題PASSEDISOPLOTDR=15.2SEEPAG4通過(guò)等量圖驗(yàn)驗(yàn)證DR=15.2參見(jiàn)第4頁(yè)P(yáng)ASSEDSTAGE1SOTHEREDXDOESN’TLIVEINTHEPROCESSSEEPAG#7.通過(guò)第一階段段驗(yàn)證，因此此紅X不在裝配過(guò)程程中，參見(jiàn)第第7頁(yè)。THECOMPONENTSEARCHSTAGE2SHOWSTHATTHEREDXDOESNOTLIVEINTHETRIMDOORPANELSOLIVESINTHERESTOFTHEDOORPANEL.SEEPAG#7./零部件分析階階段2顯示紅紅X不是由車(chē)門(mén)內(nèi)內(nèi)飾板造成的的,所以應(yīng)是是由車(chē)門(mén)板的的其余部分引引起的,見(jiàn)7頁(yè).PAIRCOMPARISONSHOWSTHATTHEDOORPANELMOLDINGHASTHECHARACTERISTICTHATPRODUCETHEDIFFERENCESEEPAG9/配對(duì)對(duì)比顯示示車(chē)門(mén)飾板飾飾件有造成差差異的特征，，參見(jiàn)第9頁(yè)頁(yè)THISISTHEBESTSTRATEGYBASEDONMULTIVARISEEPAG5.這是基于多多重變換比比較得出的的最佳策略略，參見(jiàn)第第5頁(yè)。PASSEDBvsCWHEREITSHOWSTHATTHEDOORMOLDINGKEEPINPOSITIONTHEDOORPANELSEEPAG10,BUTWECHOICEOTHERCHARACTERISTICTHATKEEPINPOSITIONTHEDOORPANELANDWITOUTINVESTMONEYSEEPAG11&13.通過(guò)BC對(duì)比試驗(yàn)，，顯示車(chē)門(mén)門(mén)飾板飾件件能夠使車(chē)車(chē)門(mén)飾板保保持正確位位置，見(jiàn)第第10頁(yè)。。但是我們們選擇能夠夠保證車(chē)門(mén)門(mén)飾板位置置并且不用用增加投資資的其它特特性，參見(jiàn)見(jiàn)第11和和13頁(yè)。。Frequency頻率GREENYRUNCHARTSEEPAG17/綠Y字流程圖參參見(jiàn)第17頁(yè)。DESIRED希望CURRENT現(xiàn)有BASED:DISTRIBUTONLOTCAMPAINGEfforttorelease(lbs)釋放力(磅磅)DM=1.0lbsDP=13.6lbsDR=13.6PassedIsoplotIsoplotAForcegagewasusedasthemeasurementsystem拉力計(jì)作為為測(cè)量工具具通過(guò)ISOPLOT評(píng)估POINTTOPOINTTherearenocontrastinthisstrategytherearenodifference.Thereisagoodcontrastbuttheleverageisnotenoughbecausewedon’thavetoolstomeasureit.Thisstrategyprovidegoodcontrastandthebestleveragebasedonmulti-varichartseepag6TherearenocontrastthroughthetimeStrategydiagramPLANTTOPLANTMODELTOMODELTRUCKTOTRUCKSIDETOSIDESAMEPANELSAMEPLANTSAMEMODELSAMETRUCKThereisacontrastbetweentrucktotruckandgoodleveragebutthecontrastisnotenoughbasedonmulti-variseepage6.EVENTTOEVENTSAMEPOINTTherearenocontrastinthisstrategytherearenodifferenceeventtoevent.策略略圖圖事件件對(duì)事件件同一一個(gè)個(gè)點(diǎn)點(diǎn)點(diǎn)對(duì)點(diǎn)同一一塊塊扳扳同一一側(cè)側(cè)對(duì)同一一側(cè)側(cè)同一一臺(tái)臺(tái)車(chē)車(chē)車(chē)對(duì)車(chē)同一一型型號(hào)號(hào)型號(hào)號(hào)對(duì)型號(hào)號(hào)同一一個(gè)個(gè)工工廠廠工廠廠對(duì)工廠廠在這這個(gè)個(gè)對(duì)對(duì)比比中中,無(wú)無(wú)差差異異.在這這個(gè)個(gè)對(duì)對(duì)比比中中,無(wú)無(wú)差差異異.在這這個(gè)個(gè)對(duì)對(duì)比比中中,有有差差異異.但但無(wú)無(wú)測(cè)測(cè)量量工工具具.在車(chē)車(chē)與與車(chē)車(chē)的的對(duì)對(duì)比比中中,有有差差異異.但但不不能能滿滿足足MULTI-VARI的要要求求..在這這個(gè)個(gè)對(duì)對(duì)比比中中,有有差差異異.且且能能滿滿足足MULTI-VARI的要要求求..在這這個(gè)個(gè)對(duì)對(duì)比比中中,無(wú)無(wú)差差異異.Multi-variNOTE:Thisgraphicshowsthatthebestcontrastismodeltomodel.SideTruckEFFORTTOTAKEOFF(lbs)RLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLRLCustomersatisfactionlimitBOBWOWModelCCCCAAAAAAAAAAASSSSSSSSSSSSSSSSNOTE:S:SUBURBAN830MODELA:AVALANCHE805MODELC:CADILLAC806MODEL注:S\A\C三種車(chē)型最好最壞顧客的滿意底底線注:此圖顯示示出在型號(hào)與與型號(hào)的對(duì)比比中有最大的的差異.松脫力(磅)ComponentsearchNOTE:ThisgraphicshowsthattheRedXsuspectdoesnotliveintheprocessbecauseitpassedthestage#1.Thestage2showsthattheRedXsuspectdoesnotliveinthesealwindow.SotheRedXsuspectlivesinthemoldingdoorpanel.Effort(lbs)BOBWOWSTAGE1STAGE2第一階段第二階段最好最壞原狀態(tài)第一次拆裝第二次拆裝第三次拆裝門(mén)窗密封條門(mén)飾板門(mén)飾板飾條鉸鏈注:這個(gè)圖顯顯示因?yàn)橥ㄟ^(guò)過(guò)了第一階段段的試驗(yàn),所所以REDX不是由操作造造成.第二階段的試試驗(yàn)顯示門(mén)窗窗密封條不是是REDX,門(mén)飾板飾條是是REDX要素查找規(guī)則Rule1.TherearecompleteseparationbetweentheBOBandWOWvalues.將最好和最壞壞的值完全分分開(kāi)規(guī)則Rule2.DY>V1R設(shè)Where:R=RBOB+RWOW2那么thenRBOB=1.9RWOW=1.2R=1.9+1.2=3.1=1.55.22DY=YBOB-YWOW=46.8-8.1=38.7如果ifDY>V1R那么then38.7>(0.89)(1.55)所以so38.7>1.38所以滿足規(guī)則則1和規(guī)則2的要求sopassedRule1andRule2通過(guò)問(wèn)題為每每個(gè)單元設(shè)定定判定極限Setdecisionlimitsforeachunitbyusingthequestions:DLBOB=YBOB+V2RDLWOW=YWOW+V2R那么Thenudl=48.83DLBOB=46.8+1.31(1.55)=ldl=44.77udl=10.13DLWOW=8.1+1.31(1.55)=ldl=6.07結(jié)果Results~~~~~~~PairedComparison備注NOTE:WeconsiderthatthedoorpanelmoldingistheRedXcandidateinthepaircomparisonbecauseistheonlydifferencebetweenpaneltopanel.In805/830vs806models.我們認(rèn)為門(mén)板板裝飾件是可可能的RedX,因?yàn)樵谠谲?chē)型型805/830和和車(chē)車(chē)型806對(duì)比比后只只有門(mén)門(mén)板有有差異異。WOWBOBDOORMOLDINGREDXCANDIDATEPassedBvsCwith95%ofconfidencethatthemoldingdoorpanelistheRedXwithcompleteseparationandendcountof6.在完完全分分離，，Endcount為5的的情況況下，，以以95%的的置信信度通通過(guò)BvS表明門(mén)板板裝飾件件是RedXBvsCSixpackB=有門(mén)飾件件的車(chē)Vehicleswithdoormolding.C=沒(méi)有飾件件的車(chē)Vehicleswithoutdoormolding.Req:置信度confidence=95%OnceconfirmedthattheREDXislivinginthedoorpanelmolding,wedecidedtochangeourstrategyfrom““modeltomodel”to““trucktotruck”becausethedoorpanelmoldingisuniqueforCadillacmodels.Inotherwords,findonecharacteristicinthesamedoorpanel805/830modelthatmakesthedifference,becausetherearesomedoorpanelsthatrequirealmost20lbstopulledoutofitpositionfromthedoorandthereareotherswithlessthan10lbstopulledoutofitposition;Thecustomerenthusiasmlimitis18lbs.thisisenoughtokeepthedoorpanelinpositionatlowcost.一旦確定定RedX為門(mén)外板板裝飾件件，我們們決定改改變策略略，從從車(chē)型到到車(chē)型變變到卡車(chē)車(chē)到卡車(chē)車(chē)，因?yàn)闉殚T(mén)外板板裝飾件件對(duì)Cadillac車(chē)型來(lái)說(shuō)說(shuō)是唯一一的。換換句話說(shuō)說(shuō)，，同同樣的門(mén)門(mén)板裝在在805/830車(chē)車(chē)型上卻卻產(chǎn)生了了差異，，原因是是一些門(mén)門(mén)板從門(mén)門(mén)上拽出出需要20磅的的力，二二另一些些只需要要小于10磅的的力;顧顧客的的要求是是18磅磅，這已已經(jīng)足夠夠保證門(mén)門(mén)板以較較低的成成本固定定到相應(yīng)應(yīng)的位置置。BOBWOWBIGCONTACTAREASMALLCONTACTAREA大間隙BIGGAP小間隙SMALLGAP門(mén)邊緣DOORFLANGE門(mén)邊緣DOORFLANGEThemaincharacteristicthatcausedifferencebetweenthedoorpanels805/830modelisth