QSB-質(zhì)量系統(tǒng)基礎(chǔ)

QualitySystemsBasics質(zhì)量系統(tǒng)基礎(chǔ)KeyStrategies關(guān)鍵戰(zhàn)略QUALITYSYSTEMSBASICS質(zhì)量系統(tǒng)基礎(chǔ)

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Introductions/OpeningComments.

導(dǎo)言/開場注釋·

Whyarewehere?

我們?yōu)槭裁丛谶@里？-6-Panel

6-面板-TopFocus

最應(yīng)關(guān)注點(diǎn)

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GMVideo(BoysofSummer/Paradigm)

GM錄像（夏季男孩/范例）·

QualitySystemsBasics

質(zhì)量系統(tǒng)基礎(chǔ)-FastResponse

快速反應(yīng)-ControlofNon-ConformingProduct

不合格品控制-Risk(RPN)Reduction

RPN的降低-StandardOperatorTraining

操作工標(biāo)準(zhǔn)化培訓(xùn)-StandardizedWork

標(biāo)準(zhǔn)操作-LayeredAudits

分層審核-ErrorProofingVerification

防錯(cuò)（即值）認(rèn)證-C.A.R.E.

C.A.R.E-LessonsLearned

經(jīng)驗(yàn)教訓(xùn)

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DevelopEnhancedQualitySystem

開發(fā)強(qiáng)化質(zhì)量系統(tǒng)·

DocumentChanges

文檔變化·

PresentChanges

現(xiàn)有改變

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EstablishNextSteps

建立下一步驟-AssignFollow-upIssues

分配后續(xù)事項(xiàng)-IdentifyFollow-upDates

識別后續(xù)日期

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Adjourn

休會(huì)QUALITYSYSTEMSBASICS（Continued)質(zhì)量系統(tǒng)基礎(chǔ)（續(xù)）

Name

姓名Organization

組織CurrentPosition

現(xiàn)任職務(wù)Introductions介紹Let’sGetToKnowOneAnother!讓我們相互認(rèn)識一下吧Whyarewehere?

我們?yōu)槭裁丛谶@里？Profit-CostofQualityEquation

質(zhì)量的利潤成本等式QualityOrganization質(zhì)量組織Cost成本Profit利潤MarketPrice市場價(jià)格0Price價(jià)格0CostCompanyinneedofQSB需要QSB的公司Cost成本Profit利潤C(jī)ostofQuality質(zhì)量成本CostofQuality(examples).質(zhì)量成本（案例）

Scrap

廢料Repair

維修Rework

返工Containment

遏制AddedOperations&Operators

增加的操作和操作工

PremiumFreight

額外運(yùn)費(fèi)LossofBusiness,etc.

商業(yè)損失等0SuppliersofTheYear當(dāng)年供應(yīng)商SupplierPerformanceDistribution供應(yīng)商績效分布Poor差ExitStrategy退出戰(zhàn)略TopFocus最應(yīng)關(guān)注Exec.Champions執(zhí)行冠軍5%Maintain/Improve維持/提高90%Excellent優(yōu)5%

NewBusiness新業(yè)務(wù)UseactualSupplierBidListfromWWPPCLWebSite.使用從WWPPCL網(wǎng)站得到的現(xiàn)行的供應(yīng)商投標(biāo)表InsertSupplierslatestQuality6-PanelfromGMWWPPCLWebSite從GMWWPPCL網(wǎng)站填寫供應(yīng)商最近的質(zhì)量6-面板表Whyarewehere?

我們?yōu)槭裁丛谶@里？TointroducethesuppliertoQualitySystemsBasicsandtoidentifyopportunitiesforimprovementandsupportforGMexpectations.(QS-9000isthefoundation,theseQSBtoolsareasupplement)

為了向供應(yīng)商介紹質(zhì)量系統(tǒng)基礎(chǔ)，以及識別出能夠提高和支持GM（對產(chǎn)品）期望的機(jī)會(huì)（QS-9000是基礎(chǔ)，而QSB工具是補(bǔ)充）。Toestablishavision

ofwhatcanbeaccomplishedthroughutilizationofQSBtechniques.

為了建立應(yīng)用QSB技術(shù)后所形成的遠(yuǎn)景。ToobtainsuppliermanagementsupportofQSBtrainingactivity.

為了得到供應(yīng)商有關(guān)QSB培訓(xùn)活動(dòng)的管理方面的支持。ConducttrainingofQualitySystemsBasicsKeyInitiatives.

對QSB的關(guān)鍵初始點(diǎn)進(jìn)行培訓(xùn)。?

FastResponse快速反應(yīng)

FirstReactiontoanIssue對問題進(jìn)行第一時(shí)間的反應(yīng)?

ControlofNon-ConformingProduct(Labeling)不合格產(chǎn)品的控制（標(biāo)簽）

Containment遏制?

Risk(RPN)Reduction風(fēng)險(xiǎn)(RPN)降低

Didweknowtheriskexisted?ErrorProofed?我們是否知道已存在的風(fēng)險(xiǎn)？錯(cuò)誤被防止了么？?

StandardOperatorTraining操作工標(biāo)準(zhǔn)化培訓(xùn)

Wastheoperatortrained?操作工是否已被培訓(xùn)？?

StandardizedWork標(biāo)準(zhǔn)化作業(yè)

Didtheoperatorfollowstandardizedwork?操作工是否遵循了標(biāo)準(zhǔn)化作業(yè)？?

LayeredAudits分層審核

Wereleadershiplayeredauditsperformed?是否對領(lǐng)導(dǎo)層進(jìn)行了分層審核??

ErrorProofingVerification防錯(cuò)認(rèn)證

WastheErrorProofingverified?防錯(cuò)（機(jī)制）進(jìn)行認(rèn)證了么??

C.A.R.E.

WasC.A.R.E.inplace?(100%inspectionforhighriskitems)[e.g.Customerusedfeatures]C.A.R.E.是恰當(dāng)?shù)拿矗浚▽Ω唢L(fēng)險(xiǎn)項(xiàng)目是否進(jìn)行了100%的檢查）[比如：客戶的習(xí)慣性特點(diǎn)]

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LessonsLearned經(jīng)驗(yàn)教訓(xùn)

KEYSTRATEGIES關(guān)鍵戰(zhàn)略

Capitalizeonoursuccesses,minimizemistakes使我們的成功增值，使我們的錯(cuò)誤最小化Yeah,but....是的，但是

Wehaveconstraintsfromthelargersystem!!

我們在更大的系統(tǒng)中會(huì)遇到障礙!! Wedon’thavetime!!

我們沒有時(shí)間!! Wedon’tknowhow!!

我們不知道如何做!! Wedon’thavethetools!!

我們沒有工具!!(Weallmakeexcusesandsay,ICan’t)（我們所有的人都在制造借口，說：我不能）Quote:“Thosewhosaywecan’t,shouldgetoutofthewayofthosewhoaregettingitdone.”引用：“說‘做不了’的人應(yīng)該閃開，讓那些能夠做的人來”

JoelBarker

BusinessofParadigms

Ican’t…我不能…

butWEcan!!

但是我們能!!“GMCan’tdoitalone,andwecan’texpectourSupplierstodoitaloneeither”“GM不會(huì)單獨(dú)行動(dòng)，我們也不能期望供應(yīng)商單獨(dú)行動(dòng)Suppliers供應(yīng)商WorkingTogetherToProvideHigherQualityforourCustomer一起努力以高質(zhì)量回報(bào)我們的客戶通用汽車?

FastResponse快速反應(yīng)?

ControlofNon-Conforming不合格品控制

Product(Labeling)產(chǎn)品（標(biāo)簽）?

Risk(RPN)Reduction風(fēng)險(xiǎn)（RPN）降低?

StandardOperatorTraining操作工標(biāo)準(zhǔn)化培訓(xùn)?

StandardizedWork標(biāo)準(zhǔn)化作業(yè)?

LayeredAudits分層審核?

ErrorProofingVerification防錯(cuò)驗(yàn)證?

C.A.R.E.?

LessonsLearned經(jīng)驗(yàn)教訓(xùn)KEYSTRATEGIES關(guān)鍵戰(zhàn)略

NoMajorDisruptions無重要中斷

NoPRR’S無PRR’S+0PPM’S0PPM’S=WorldClassQuality

世界級的質(zhì)量2001vs.2002J.D.PowerIQS22001vs.2002J.D.PowerIQS2Problemsper100VehiclesbyManufacturerProblemsper100VehiclesbyManufacturerPowertrainSummaryPowertrainSummaryLegend圖例20012002*TotalPowertrainincludesEngineandAutomaticTransmission全部動(dòng)力總成包括發(fā)動(dòng)機(jī)和自動(dòng)變速器*TotalPowertrainincludesEngineandAutomaticTransmissionEngine發(fā)動(dòng)機(jī)18.713.413.015.210.116.216.111.110.59.202468101214161820FordDCHondaGMPTToyotaProblemsPer100VehiclesAutoTransmission自動(dòng)變速器6.12.25.95.43.95.95.15.03.63.202468101214161820FordToyotaDCHondaGMPTProblemsPer100VehiclesPassengerCarPowertrain*客車動(dòng)力總成24.819.318.412.219.122.121.014.814.313.6051015202530FordDCHondaToyotaGMPTProblemsPer100Vehicles生產(chǎn)商每百輛車中動(dòng)力總成問題概攬2001vs.2002J.D.PowerIQS22001vs.2002J.D.PowerIQS2Problemsper100VehiclesbyManufacturerProblemsper100VehiclesbyManufacturerPowertrainSummaryPowertrainSummaryLegend圖例20012002*TotalPowertrainincludesEngineandAutomaticTransmission

全部動(dòng)力總成包括發(fā)動(dòng)機(jī)和自動(dòng)變速器Engine

發(fā)動(dòng)機(jī)20.921.717.614.219.618.616.210.60510152025DCFordGMPTToyotaProblemsPer100VehiclesAutoTransmission自動(dòng)變速器15.99.37.47.013.29.78.15.40510152025DCFordGMPTToyotaPassengerCarAutomaticTransmissions10.86.24.94.54.44.43.62.92.60246810124L30-EML44L60-EM304T80-EMH14T65-EMN73T40MD94T40-EMN44T65-EMN34T65-EM154T45-EMN5LightDutyTruckPowertrain*輕卡動(dòng)力總成36.831.124.921.232.828.324.316.00510152025303540DCFordGMPTToyota生產(chǎn)商每百輛車中動(dòng)力總成問題概攬我們與他人討論得到的占到45%EducatorsTellUsWeLearn&Understand教育專家告訴我們?nèi)绾螌W(xué)習(xí)并理解10%ofwhatwehear15%ofwhatwesee20%ofwhatwebothsee&hear40%ofwhatwediscuss

withothers80%ofwhatweexperience

directlyorpractice90%ofwhatweattempttoteachothers我們聽到的占10%我們看到的占15%我們既看到又聽到的占20%我們試圖教育別人的時(shí)候所得知識占90%我們通過直接經(jīng)驗(yàn)或?qū)嵺`得到的占80%FASTRESPONSEPROCESS快速反應(yīng)過程PURPOSE:

目的：Toimmediatelyaddressqualityfailures.迅速確定質(zhì)量缺陷SCOPE:范圍：Theseproceduresapplytoallmanufacturing.

這些程序應(yīng)用于全部生產(chǎn)過程FASTRESPONSE快速反應(yīng)RESPONSIBILITY:

職責(zé)：ThePlantManagerorQualityManagerareresponsibleforimplementationandexecutionofthisprocedure.工廠經(jīng)理和質(zhì)量經(jīng)理對該程序的應(yīng)用和執(zhí)行負(fù)責(zé)REQUIREMENTS:要求：Eachday,thequalityfunctionshallidentifysignificantqualityconcerns(fromthelast24hours)tobereviewedatthatday’sleadershipmeeting.Inputshouldincludecustomerconcerns,supplierconcerns,linestops,teardown,CARE(Buy-off),Dockaudits,auditissuesandotherinternalqualityconcerns.每天（相關(guān)人員）都應(yīng)通過質(zhì)量等式識別出重要質(zhì)量關(guān)注點(diǎn)（最近24小時(shí)之內(nèi)的），以備領(lǐng)導(dǎo)層日常會(huì)議進(jìn)行回顧之用。輸入應(yīng)該包括客戶關(guān)注點(diǎn)、供應(yīng)商關(guān)注點(diǎn)、生產(chǎn)線停工、拆卸、CARE（確認(rèn)）、出貨檢查、審核事項(xiàng)和其它內(nèi)部質(zhì)量關(guān)注點(diǎn)。FASTRESPONSE快速反應(yīng)REQUIREMENTS(continued):要求（繼續(xù)）Atthatday’sleadershipmeeting,siteleadershipshallreviewsignificantqualityconcernsanddesignatetherespectiveowner(s)toreportoutatthefollowingday’sleadershipmeeting.OwnerreportoutshallbeginwiththeFastResponsetrackingsheetandshallincludetheupdated:在領(lǐng)導(dǎo)層日常會(huì)議上，現(xiàn)場領(lǐng)導(dǎo)應(yīng)該對重要質(zhì)量關(guān)注點(diǎn)進(jìn)行評估，并委派相關(guān)人員在第二天的領(lǐng)導(dǎo)層會(huì)議上進(jìn)行匯報(bào)。各匯報(bào)人的報(bào)告應(yīng)該以快速反應(yīng)跟蹤表作為開始，并包括如下更新的內(nèi)容：ProblemSolvingForm問題解決表FMEA失效模式與后果分析ControlPlan控制計(jì)劃StandardizedWork(method&sequence)標(biāo)準(zhǔn)化作業(yè)（方法與順序）LayeredAudit分層審核WorkforceNotification對工作人員通知Manufacturingsiteleadershipmaydisplayavisualqualitystatus(e.g.similartosafety’sgreencross).生產(chǎn)現(xiàn)場領(lǐng)導(dǎo)應(yīng)該展示直觀的質(zhì)量狀態(tài)圖（比如：跟安全綠十字相似的圖）RECORDS:記錄Recordsshallbemaintainedperlocalprocedures.記錄應(yīng)該就地保存FASTRESPONSE快速反應(yīng)NoQualityDisruptions無質(zhì)量中斷InternalQualityDisruption(definedlocally)內(nèi)部質(zhì)量中斷（現(xiàn)場定義）CustomerQualityDisruption(eg.PRR,Pull,Spill)客戶質(zhì)量中斷（比如：PRR、拉力、溢出等）GMPTFLINTV-6DailyQualityChart每日質(zhì)量表LEGEND:圖例Month月份Year年份January一月2002World'sBestPowertrains31292830212223242526271213141516171819202345678910111Green綠色Yellow黃色Red紅色GQP-029a世界上最好的動(dòng)力總成FASTRESPONSETRACKING

(Example)快速反應(yīng)追蹤（案例）EXITCRITERIA退出標(biāo)準(zhǔn)OverallStatus狀態(tài)總攬IssueNumber問題號IssueDescription問題描述DateOpened發(fā)現(xiàn)日期UnitI.D.#單位I.D#Owner責(zé)任人NextDate后續(xù)日期(ofOwnerReportouttoStaff)Containment遏制PFMEA/CPErrorProofing防錯(cuò)StandardWork標(biāo)準(zhǔn)化作業(yè)LayeredAudit分層審核DateClosed關(guān)閉日期Y1Engineoutoftime10/10/00N/AMcGrath11/29/00GGYGYG2Burrsonfrontfaceofblock10/10/00N/AMcIntosh-SmithGGN/AN/AG10/11/00R3Injectorharnessplacement10/10/00N/AMcGrath11/29/00GGRGGY4Reversedthrustbearing10/11/00N/AMcGrath11/29/00GGYGGG5Proudoilgalleryplug10/12/00N/AMcIntosh-SmithGGGN/AG10/13/00Y6Looseoilpumppulleybolts10/16/00N/AMcGrath11/30/00GGGN/AYG7Unfinishedcylinderbores10/16/00N/AMcIntosh-SmithGGN/AGN/A10/17/00Y8MissingUpperBearingShells11/20/00N/AMcGrath11/30/00GGGYGR9Paintdotsfoundonloose&mis-builtparts11/21/20N/AMcGrath11/30/00GN/AN/ARROpenR10Loose7mmboltonfrontcover11/26/00N/AMcGrath12/4/00RRR??ROpenEXITCRITERIASTATUSKEYRRequiredbutnotinitiated需要，但沒有開始YInitiatedbutnotcomplete已開始，但沒有完成GComplete完成N/ANotApplicable不能實(shí)施GQP-029b責(zé)任人匯報(bào)日期FastResponse快速反應(yīng)

QualitySystemsBasics

KeyStrategies質(zhì)量系統(tǒng)基礎(chǔ)關(guān)鍵戰(zhàn)略ApplicabilitytoAIAG

QS9000ManualAIAGGS9000手冊的適用性ApplicabilitytoAIAG

APQPManualFastResponse快速反應(yīng)

Firstreactiontoanissue.對問題的第一反應(yīng)

FastResponseteachesthesuppliertoimmediatelyaddressqualityfailuresandprovidesasimpleeffectivetooltoorganizeandreporttheseissuesinavisualformat.Thismethodologyutilizesinputstoidentifyconcernseachdayfromtheprior24hours,assignsresponsibilityandprovidesavisualtrackingsystem.FastResponseappliestoelement4.14.2ofQS9000whichcallsforthe

effectivehandlingofcustomercomplaintsandreportsofproductnonconformitiesIntheAIAGAPQPmanualsection1.0PlanandDefineProgram,theinputsfortheplanincludesthevoiceofthecustomer.Thisencompassescomplaints,recommendations,dataandinformationfrominternalandexternalcustomers.Additionallyotheritemswhichcanassistinidentifyingcustomerconcernsare:ThingsGoneWrong(TGW)reports,Warrantyreports,capabilityindicators,Supplierplantinternalqualityreports,Problemresolutionreports,customerplantreturnsandrejections,andfieldreturnproductanalysis.AIAGAPQP手冊的適用性快速反應(yīng)可以使供應(yīng)商迅速確定質(zhì)量缺陷，可以為解決這些問題提供一種簡單有效的工具，并以直觀的模式報(bào)告這些問題。這種方法的思想就是：每天使用輸入數(shù)據(jù)（24小時(shí)內(nèi)的）來識別關(guān)注點(diǎn)，分配職責(zé)并提供直觀的追蹤系統(tǒng)。快速反應(yīng)適用于QS9000的4.14.2要素，而QS9000可以對客戶抱怨進(jìn)行有效處理，并能夠報(bào)告產(chǎn)品的不符合性情況。在AIAGAPQP手冊1節(jié)計(jì)劃與定義項(xiàng)目中，計(jì)劃的輸入包括客戶意見，這包含內(nèi)部和外部客戶的抱怨、建議、數(shù)據(jù)和信息。此外其它可能有助于識別客戶關(guān)注點(diǎn)的項(xiàng)目是：事件錯(cuò)誤報(bào)告、保證報(bào)告、能力指示器、供應(yīng)商工廠內(nèi)部質(zhì)量報(bào)告、問題解決報(bào)告、客戶工廠返回件、拒收件以及現(xiàn)場返回產(chǎn)品分析等CONTROLOFNON-CONFORMINGPRODUCT不合格品的控制PURPOSE:目的：Establishbaserequirementstoensurethatproductthatdoesnotconformtospecifiedrequirementsispreventedfromunintendeduseorinstallation.建立基本要求，以確保那些不能滿足特別要求的產(chǎn)品不被無意使用或安裝。SCOPE:范圍：Thisprocedureappliestoallmanufacturing.該程序應(yīng)用于所有生產(chǎn)過程。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制RESPONSIBILITY:職責(zé)：TheManufacturingPlantManagerisresponsibleforimplementationandexecutionofthisprocedure.生產(chǎn)工廠經(jīng)理負(fù)責(zé)該程序的應(yīng)用和實(shí)施。TheManufacturingQualityManagerisresponsibleforsupportingtheimplementationofthisprocedure生產(chǎn)質(zhì)量經(jīng)理負(fù)責(zé)支持該程序的應(yīng)用。REQUIREMENTS:要求：ManufacturingsitesshalluseVisualManagement-Stoplight.生產(chǎn)現(xiàn)場應(yīng)該實(shí)行可視化管理—停止信號燈Nonconformingproductshouldbesegregated.Areasofsegregation(e.g.scrapbins,reworktables,reworkproductfloat,spillcontainmentareas)shouldbefootprintedorotherwiseclearlyidentified.不合格品應(yīng)該分離開，分離區(qū)域應(yīng)該標(biāo)出范圍軌跡或有清晰的標(biāo)示。UseDepartmentContainmentWorksheettofilloutandidentifytheareasineachdepartmentwhichwillneedtobecheckedfornon-conformingproductintheeventcontainmentactivityisinitiated.填寫部門遏制表單，標(biāo)示出每個(gè)需要對不合格品進(jìn)行檢驗(yàn)的部門的遏制區(qū)域以啟動(dòng)遏制行動(dòng)CONTROLOFNON-CONFORMINGPRODUCT不合格品控制REQUIREMENTS(continued):要求（繼續(xù)）：Forproductcontainmentissues(I.e.whennonconformingproductisbeyondadepartment’sscopeofcontrol),DepartmentContainmentWorksheetsshallbecompletedforeachdepartmentcontainingsuspectproduct(thiswillensureestablishmentofaneffectivebreakpoint).對產(chǎn)品遏制事件（比如當(dāng)不合格品超出部門控制區(qū)域時(shí)），部門遏制表單應(yīng)該由包含可疑產(chǎn)品的各部門完成（這將確保建立有效中斷點(diǎn)）。Forproductcontainmentissues,allproductcontainersshallbeidentifiedinadherencetoaboveprocess.Tomaintainaneffectivebreakpoint,allconformingproductcontainersafterbreakpointshallbeidentifiedwithagreenmark(useofothercolors,exceptredandyellow,isacceptabletoindicateverificationofmultiplefeatures).Suspectandnonconformingproductshallbeidentifiedwithayelloworredpaintmarkwhenfeasible.對于產(chǎn)品遏制事件，所有產(chǎn)品容器(包裝）應(yīng)該根據(jù)以上程序進(jìn)行識別。為了保持有效的中斷點(diǎn)，所有中斷點(diǎn)以后的合格產(chǎn)品都應(yīng)該以綠色進(jìn)行標(biāo)示（除紅、黃外，其它顏色也可以用來標(biāo)示多特性的驗(yàn)證情況）。在可行的情況下，可疑品和不合格品應(yīng)該用黃色或紅色來標(biāo)示。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制REQUIREMENTS(continued):要求（繼續(xù)）：Forproductcontainmentissues,breakpointmaintenanceshallbeverified(via100%inspectionforcontainmentidentification)foradurationspecifiedbythesiteQualityManagerordesignate.對于產(chǎn)品遏制事件，應(yīng)該對現(xiàn)場質(zhì)量經(jīng)理或委派人員指定的對中斷點(diǎn)的維護(hù)期進(jìn)行驗(yàn)證（通過對遏制識別進(jìn)行100%檢查來進(jìn)行）。Productwhichhasbeenremovedfromtheconformingproductprocessflow(e.g.productincontainmentareas,rework/repairareas)shouldbereintroducedintotheprocessstreamatorpriortothepointofremovaltoensureallControlPlaninspectionandtestsareadheredto.從合格產(chǎn)品流中移除的產(chǎn)品（比如：遏制區(qū)域、返工/維修區(qū)域的產(chǎn)品）應(yīng)該在移除點(diǎn)或之前重新引入到過程流中，以確保所有對控制計(jì)劃進(jìn)行檢查和測試。Themanufacturingsiteshallclearlydefinetheprocess&authorityforreleasingproductoutofrework,repairandcontainmentareas.生產(chǎn)現(xiàn)場應(yīng)該對返工、維修和遏制區(qū)域產(chǎn)品的分發(fā)過程和權(quán)限進(jìn)行清晰的定義。Forproductcontainmentissues,localleadershipshallreviewtheresultsofthecontainmentuponcompletion.對于產(chǎn)品遏制事件，相關(guān)領(lǐng)導(dǎo)應(yīng)該對遏制行動(dòng)的完成情況進(jìn)行評估。CONTROLOFNON-CONFORMINGPRODUCT不合格品控制TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產(chǎn)品的標(biāo)簽內(nèi)容應(yīng)該基于現(xiàn)場人員的判斷力TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產(chǎn)品的標(biāo)簽內(nèi)容應(yīng)該基于現(xiàn)場人員的判斷力TAGCONTENTINTHISSECTIONISATLOCALDISCRETION該部分產(chǎn)品的標(biāo)簽內(nèi)容應(yīng)該基于現(xiàn)場人員的判斷力PLT001SUSPECTDONOTUSE可疑產(chǎn)品

不能使用OKFORUSE可以使用REQ’DFORSCRAPPRODUCT/CONTAINERS(scrapbinspaintedreddonotrequireatag)

對廢品/容器的要求(漆成紅色的廢品箱不需要標(biāo)簽）REQUIREDFORSUSPECT,REWORK,REINSPECTPRODUCT/CONTAINERS對可疑品、返工品和復(fù)查品/容器的要求ANYCOLORTAGFORCONFORMINGPRODUCTISACCEPTABLE(exceptredoryellow)對于合格品，任何顏色的標(biāo)示都是可以的（紅色、黃色除外）REDorYELLOWNONCONFORMINGPRODUCTTAGSSHALLBEUSEDTOIDENTIFYNONCONFORMINGPRODUCT/CONTAINERS.CONFORMINGPRODUCTIDENTIFICATIONWILLBEACCOMPLISHEDTHROUGHAVARIETYOFMETHODS(e.g.IDENTIFICATIONPLATES,SHIPPINGLABELS,PRODUCTCOLORCODING,TAGS).ANYCOLORIDENTIFICATIONISACCEPTABLEFORCONFORMINGPRODUCT(EXCEPTREDORYELLOW)-GREENISPREFERRED.紅色或黃色不合格品標(biāo)簽應(yīng)該被用來標(biāo)示不合格產(chǎn)品或容器。合格品的標(biāo)示應(yīng)該通過不同的方法來完成（比如：標(biāo)示盤、發(fā)貨標(biāo)簽、產(chǎn)品顏色代碼、標(biāo)簽等）。任何顏色的標(biāo)示都可以用來標(biāo)示合格品（紅、黃色除外）—綠色是首選色。6/28/00SCRAP廢料PLT002PLT003ControlOfNonconformingProduct(Labeling)不合格品控制（標(biāo)簽）

RISKREDUCTIONPROCESS風(fēng)險(xiǎn)降低過程PURPOSE:目的:ToreducetheriskofallproductionprocessesbyclosingtheRPNgaptotheIdealState.通過填平RPN與理想狀態(tài)之間的差距，以降低所有生產(chǎn)過程的風(fēng)險(xiǎn)SCOPE:范圍：Thisprocedureappliestoallmanufacturing.該程序適用于所有生產(chǎn)過程POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質(zhì)量缺陷RPN降低過程Part1:(Proactive)RESPONSIBILITY:職責(zé)：ThesiteManufacturingEngineerisresponsibletodrivethePFMEAprocess,facilitatemulti-disciplinaryteamsandtocoordinateRPNreductionactivities.現(xiàn)場生產(chǎn)工程師負(fù)責(zé)：驅(qū)動(dòng)PFMEA過程，推進(jìn)多功能型團(tuán)隊(duì)和管理RPN降低活動(dòng)。DEFINITIONS:定義：PFMEA:PotentialFailureModeandEffectsAnalysis

潛在失效模式與后果分析RPN:(RiskPriorityNumber)isanindicatorofriskbasedonPFMEASeverity,OccurrenceandDetectionrankings.（風(fēng)險(xiǎn)順序數(shù)）是一個(gè)風(fēng)險(xiǎn)指示器，該風(fēng)險(xiǎn)基于PFMEA嚴(yán)重性、發(fā)生的概率

和缺陷程度。IDEALTocalculatetheIdealState#,sumtotalallRPNnumbers,whereas:STATE:RPN’sunder40=actualRPNnumberandRPN’sover40=40

用來計(jì)算理想狀態(tài)的編號，對所有RPN數(shù)求和，但是應(yīng)注意：RPN低于40時(shí)以實(shí)際RPN數(shù)計(jì)，高于40時(shí)以40計(jì)。GAP:DifferencebetweenthetotalsumofRPNandIdealState（實(shí)際）RPN總數(shù)和理想狀態(tài)間的差距。Part1:

(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質(zhì)量缺陷RPN降低過程REQUIREMENTS:要求：PFMEA’sshallbecompletedforallmanufacturingprocessesasrequiredbyQS-9000.所有生產(chǎn)過程的PFMEA都應(yīng)該按照QS9000的要求完成。TheRPNreductionprocessshallbeimplementedforthesemanufacturingprocesses.應(yīng)該針對這些生產(chǎn)過程實(shí)施RPN降低過程。Severity,OccurrenceandDetectionrankingchartsshallbeusedincompletingthePFMEA.在完成PFMEA時(shí)，應(yīng)該使用嚴(yán)重性、發(fā)生的概率和缺陷程度分級圖表。TheRPNReductionFlowDiagramshallbeadheredtointhecategorizationofrisk,establishmentofatop5list,anddevelopmentofimprovementactions.RPN降低流程圖應(yīng)該遵守風(fēng)險(xiǎn)的分類原則，建立RPN的前五位名單并開發(fā)出改進(jìn)行動(dòng)（計(jì)劃）。Part1:(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質(zhì)量缺陷RPN降低過程REQUIREMENTS(continued):要求（繼續(xù)）：TheRPNreductiontrackingchartsshouldbeupdatedmonthlytoreflectthecurrentRPNactualandidealstatenumbers.RPN降低追蹤表應(yīng)該每月更新，以反應(yīng)RPN的實(shí)際狀況和理想狀態(tài)。RPNreductiontrackingchartsshallbereviewedbymanufacturingsiteleadershipatafrequencydefinedlocally.根據(jù)實(shí)際情況，生產(chǎn)現(xiàn)場領(lǐng)導(dǎo)應(yīng)該定期對RPN降低追蹤表進(jìn)行回顧。Part1:(Proactive)POTENTIALQUALITYFAILURERPNREDUCTIONPROCESS潛在質(zhì)量缺陷RPN降低過程

*Thissection(Part1)dealtwithpotentialrisks;Thenextsection(Part2),addressespastqualityfailures(customerandinternal).Asstatedinpart1weshouldhaveanactionplantoreducethetop5RPNnumbersandasyouwillseeinpart2weshouldalsohaveanactionplantoErrorProofallpastqualityfailures.

該節(jié)（第1部分）處理潛在風(fēng)險(xiǎn)問題；后面一節(jié)（第2部分）確定以往的質(zhì)量缺陷（客戶的和內(nèi)部的）。就像第1部分所述，我們應(yīng)該針對降低前5位的RPN來制定計(jì)劃；在第2部分，你將會(huì)看到：對于所有以往質(zhì)量缺陷的防錯(cuò)問題，我們也應(yīng)該制訂行動(dòng)計(jì)劃。Comment:注釋：Severity

嚴(yán)重性Part1:(Proactive)Occurrence

發(fā)生概率Part1:(Proactive)Detection

檢測Part1:(Proactive)RPNREDUCTION

RPN降低PFMEA'SPROCESSPFMEA過程LISTALLRPN'S列出所有PRNPARETO'SOFRPN'SRPN的排列RPNLESSTHAN40RPNBETWEEN

40-100RPNOVER100

FOREACHBUSINESSUNITORPRODUCTFAMILY針對每一個(gè)業(yè)務(wù)單位或產(chǎn)品類別PERIODICREVIEWSTO

ASSURENOCHANGESTOP”5"LIST前5個(gè)列表ACTIONPLANS行動(dòng)計(jì)劃TRACKPROGRESS追蹤程序MANAGEMENTREVIEWS管理回顧PRIORITYACTIONPLANDEVELOPEDBYNATURALOWNER

Part1:(Proactive)RPN小于40RPN介于40-100之間RPN大于100定期回顧以確保不發(fā)生變化由相關(guān)責(zé)任人開發(fā)優(yōu)先行動(dòng)計(jì)劃RPNRANGECHARTRPN范圍表

Part1:(Proactive)Part1:(Proactive)TOP5RPN

前5位RPNPart1:(Proactive)REQUIREMENTS(continued):要求（繼續(xù)）：Multi-disciplinaryteam(s)asidentifiedinRPNReduction

Responsibilityshallalsoidentifyandpareto

past

quality

failures(customerandinternal).應(yīng)該確認(rèn)相應(yīng)的多功能型團(tuán)隊(duì)在RPN降低的過程中的相應(yīng)職責(zé)，并排列出過去的質(zhì)量缺陷（客戶的和內(nèi)部的）Team(s)shalllisttopfailuresanddesignatetruePFMEADetectionRatingforeachRPN.團(tuán)隊(duì)?wèi)?yīng)該列出最嚴(yán)重的缺陷并對每一個(gè)RPN分配準(zhǔn)確的PFMEA檢測等級。Team(s)shalldevelopanactionplantoErrorProoftopfailures(whereE/Pisnotfeasible,aplantoimprovedetectionshallbeestablished).團(tuán)隊(duì)?wèi)?yīng)該制訂出行動(dòng)計(jì)劃以便對最嚴(yán)重的缺陷防錯(cuò)（在E/P不可行時(shí)，應(yīng)該建立計(jì)劃以改善檢測工作）RISKREDUCTIONPROCESSERRORPROOFINGPASTQUALITYFAILURES風(fēng)險(xiǎn)降低過程過去質(zhì)量缺陷的防錯(cuò)

Part2:(Reactive)REQUIREMENTS(continued):要求（繼續(xù)）：ErrorproofingshallbeverifiedpertheErrorProofingVerificationProcess.每一個(gè)防錯(cuò)驗(yàn)證過程都應(yīng)該得到驗(yàn)證Team(s)shallmonitorqualityperformancefortopfailurestoensurenoreoccurrence.對于嚴(yán)重的缺陷，團(tuán)隊(duì)?wèi)?yīng)該監(jiān)視其質(zhì)量（改善）情況以確保不再發(fā)生類似情況Manufacturingsiteleadershipshallscheduleregularprogressreviews.生產(chǎn)現(xiàn)場的領(lǐng)導(dǎo)應(yīng)該針對規(guī)則的過程回顧制訂計(jì)劃RECORDS:記錄：Recordsshallbemaintainedperlocalprocedures.記錄應(yīng)該隨地保存RISKREDUCTIONPROCESSERRORPROOFINGPASTQUALITYFAILURES風(fēng)險(xiǎn)降低過程過去質(zhì)量缺陷的防錯(cuò)

Part2:(Reactive)Part2:(Reactive)12MonthParetoofCustomerConcerns(Example)Risk(RPN)Reduction

降低風(fēng)險(xiǎn)（RPN）STANDARDIZEDOPERATORTRAINING操作工標(biāo)準(zhǔn)化培訓(xùn)PURPOSE目標(biāo):

Todefinestandardoperatortrainingrequirement.說明操作工標(biāo)準(zhǔn)化培訓(xùn)要求。SCOPE范圍:Thisprocedureappliestoallmanufacturingsites.Itappliestoalloperatorsnewtoanoperationandtooperatorrefreshertraining.該程序適用于所有的生產(chǎn)點(diǎn)，適用于所有新操作工培訓(xùn)和操作工復(fù)習(xí)進(jìn)修培訓(xùn)。STANDARDIZEDOPERATORTRAINING操作工標(biāo)準(zhǔn)化培訓(xùn)RESPONSIBILITY職責(zé):TheProductionManagerisresponsibleforimplementationofthisprocedure.TheManufacturingsiteQualitySystemsandPersonnelstaffsareresponsibletosupportimplementationofthisprocedure.生產(chǎn)經(jīng)理負(fù)責(zé)執(zhí)行這一程序。生產(chǎn)點(diǎn)質(zhì)量系統(tǒng)和人事部門職員負(fù)責(zé)支持這一程序的執(zhí)行。REQUIREMENTS要求:Thefollowingrepresentstheminimumcontentrequirementsforoperatortrainingandshallbeusedintrainingalloperatorsnewtoanoperationandforoperatorrefreshertraining.Operatortrainingrecordsshallbeupdated(seeattachedform)foreachoperatornewtoanoperation.以下是操作工培訓(xùn)的最低內(nèi)容要求，應(yīng)在所有的新操作工培訓(xùn)和操作工復(fù)習(xí)進(jìn)修培訓(xùn)中使用。一有新到崗的操作工，操作工培訓(xùn)記錄都應(yīng)更新（見附表）。Thetrainershallreturnwithintheshift(e.g.withintheoperatorsfirst8hoursofproduction)toverifytheoperatorisadheringtostandardizedworkandtoverifytheproductqualityagain.Thetrainershallreturninapproximately1daytoverifythesameagain.培訓(xùn)人員應(yīng)在班次內(nèi)（例如，在操作工生產(chǎn)的第一個(gè)8小時(shí)內(nèi)）回訪，再次確認(rèn)操作工遵守標(biāo)準(zhǔn)化工作，并檢驗(yàn)產(chǎn)品質(zhì)量。培訓(xùn)人員應(yīng)在1日內(nèi)再次回訪確認(rèn)相同內(nèi)容。STANDARDIZEDOPERATORTRAINING操作工標(biāo)準(zhǔn)化培訓(xùn)REQUIREMENTS(continued)要求（續(xù)）:Thetrainershouldnotifythedownstreamoperationsofpotentialdefects.培訓(xùn)人員應(yīng)事先將潛在缺陷通知后續(xù)操作點(diǎn)。Operatortrainingshallbetrackedonthe“TrainedOperatorTracking”sheet(attached).Thesheetdefinesminimumcontent,electronictrackingattheoperationisacceptable.The“TrainedOperatorTracking”sheetshallbepostedattheoperationandverifiedthroughprocessverification.Schedulingofrefreshertrainingforassignedoperatorsisatlocalsitediscretion.操作工培訓(xùn)將以“已培訓(xùn)操作工跟蹤表”（附）進(jìn)行跟蹤。該表定義了最低要求，操作過程的電子跟蹤也可接受?！耙雅嘤?xùn)操作工跟蹤表”應(yīng)張貼于操作點(diǎn)，并在過程驗(yàn)證時(shí)進(jìn)行核對。指派操作工的復(fù)習(xí)進(jìn)修培訓(xùn)進(jìn)度由本地生產(chǎn)點(diǎn)自行決定。Supplementalemployeesshallnotperformthejobunlesstheyhavebeentrainedwithinthelastthreemonths.候補(bǔ)員工不得參與操作，除非最近三個(gè)月內(nèi)接受過培訓(xùn)。STANDARDIZEDOPERATORTRAINING操作工標(biāo)準(zhǔn)化培訓(xùn)RECORDS記錄:Recordsshallbemaintainedperlocalprocedures.記錄應(yīng)由本地程序進(jìn)行保存。StandardizedOperation-TrainingRecord標(biāo)準(zhǔn)化操作——培訓(xùn)記錄

(Example)（示例）Application

應(yīng)用：:Thefollowingshallbecompletedwithanynewoperator(foranygivenoperation).

（在任何給定操作點(diǎn)）有任何新操作工時(shí)，以下都應(yīng)填寫完整。Review評定

Complete完成Standardizedwork/jobinstructions標(biāo)準(zhǔn)化作業(yè)/工作指示Qualityrecordstobefilledout(eg.Checksheets)應(yīng)填寫的質(zhì)量記錄（如驗(yàn)收單）Part(product)function零件（產(chǎn)品）功能Equipmentoperations/Safety設(shè)備操作/安全Demonstratetheoperationandanswerquestions示范操作及回答問題Demonstrategagingandanswerquestions示范量具及回答問題Havenewemployeerunoperationandanswerquestions讓新員工操作及回答問題Teachpastproblems(eg.FMEA,TopProblemsList)傳授過去的問題（如FMEA，常見問題列表）Verifyfirstunitsproduced,coachasneeded檢驗(yàn)首批產(chǎn)品，根據(jù)需要指導(dǎo)Returnwithintheshift,verifystdwork&productqualityagain班次內(nèi)回訪，檢驗(yàn)標(biāo)準(zhǔn)化操作和產(chǎn)品質(zhì)量Returninapprox.1day,verifystdwork&productqualityagain約一日內(nèi)回訪，再次檢驗(yàn)Notifydownstreamoperationsofpotentialdefects將潛在缺陷通知后續(xù)操作點(diǎn)EmployeeSignature

員工簽名______________TrainerSignature培訓(xùn)員簽名_______________OperationNameand#

操作點(diǎn)名稱和號碼_______________TrainedOperatorTracking已培訓(xùn)操作工跟蹤(Example)（示例）OperationName/#

操作點(diǎn)名稱/號碼___________________DEPT.ASSIGNEDEMPLOYEE部門指派員工SUPPLEMENTALEMPLOYEE候補(bǔ)員工LATESTTRAININGDATEANDTRAINERINITIALS

最近培訓(xùn)日期和培訓(xùn)人員姓名首字母縮寫LatestJobInstructionRev.Date最近工作指示評審日期StandardOperatorTraining

操作工標(biāo)準(zhǔn)化培訓(xùn)STANDARDIZEDWORK

標(biāo)準(zhǔn)化作業(yè)(Methods&Sequence)（方法和順序）PURPOSE目的:

Todevelopstandardworkmethods&sequenceforhighriskoperations.為高風(fēng)險(xiǎn)操作形成標(biāo)準(zhǔn)的作業(yè)方法和順序。SCOPE范圍:Thisprocedureappliestoallmanufacturingsites.該程序適用于所有的生產(chǎn)點(diǎn)。STANDARDIZEDWORK(Method&Sequence)

標(biāo)準(zhǔn)化作業(yè)（方法和順序）RESPONSIBILITY職責(zé):TheManufacturingEngineeringManagerorProductionManagerareresponsibleforimplementationandexecutionofthisprocedure.生產(chǎn)工程經(jīng)理或產(chǎn)品經(jīng)理負(fù)責(zé)執(zhí)行和完成該程序。REQUIREMENTS要求:Siteleadershipshallidentifymulti-disciplinaryteam(s)todrivestandardizedwork.生產(chǎn)點(diǎn)領(lǐng)導(dǎo)應(yīng)確定復(fù)合型小組來進(jìn)行標(biāo)準(zhǔn)化作業(yè)。Multi-disciplinaryteam(s)shallidentifyandlistallassemblyoperationsandallcriticalmanufacturingoperationstoimplementstandardizedworkwithemphasisonoperationswhichexperience:復(fù)合型小組應(yīng)確定并列出所有裝配定點(diǎn)和所有關(guān)鍵生產(chǎn)定點(diǎn)來執(zhí)行標(biāo)準(zhǔn)化作業(yè)，并突出遇到過以下問題的定點(diǎn)：

CustomerQualityConcerns客戶質(zhì)量問題NecessityforaDefinedSequenceorMethodofwork

需要強(qiáng)制順序或作業(yè)方法Off-lineRework線下返工HighRPN高風(fēng)險(xiǎn)順序數(shù)EmployeeFlow-through員工流動(dòng)STANDARDIZEDWORK(Method&Sequence)

標(biāo)準(zhǔn)化作業(yè)（方法和順序）REQUIREMENTS(continued)要求（續(xù)）:Multi-disciplinaryteam(s)shalldevelopstandardizedworkandstandardizedworkprocessesshallbepostedattheoperation.復(fù)合型小組應(yīng)開展標(biāo)準(zhǔn)化作業(yè)，并且標(biāo)準(zhǔn)化作業(yè)過程應(yīng)張貼于操作地點(diǎn)。ImpactedemployeesandnewemployeesshallbetrainedintheuseofStandardizedWork(StandardOperatorTraining).Impacted員工和新員工應(yīng)接受培訓(xùn)來進(jìn)行標(biāo)準(zhǔn)化作業(yè)（標(biāo)準(zhǔn)操作工培訓(xùn)）。StandardizedworkshallbeverifiedthroughLayeredAuditsforanyoperationwhichshippedanon-conformancewithinthelast12monthsduetoafailuretoadheretostandardizedwork.在任何過去12個(gè)月中因未遵循標(biāo)準(zhǔn)化作業(yè)而發(fā)運(yùn)過不合格品的生產(chǎn)點(diǎn)，標(biāo)準(zhǔn)化作業(yè)都應(yīng)通過分層審核來檢驗(yàn)。Multi-disciplinaryteam(s)shallcontinuouslydevelop/improvestandardizedworkbasedonongoingqualityperformance.復(fù)合型小組應(yīng)基于現(xiàn)時(shí)質(zhì)量表現(xiàn)不斷開展/改進(jìn)標(biāo)準(zhǔn)化作業(yè)。STANDARDIZEDWORK(Method&Sequence)

標(biāo)準(zhǔn)化作業(yè)

（方法和順序）StandardizedWork

標(biāo)準(zhǔn)化作業(yè)

LAYEREDAUDITS

分層審核PURPOSE目的:

Toverifycompliancetothedocumentedmanufacturing/assemblyprocess,resultinginmoredisciplinedprocessesandimprovedoverallquality.檢驗(yàn)是否符合文字記錄的生產(chǎn)/裝配過程，以求更多的規(guī)范過程和改進(jìn)整體質(zhì)量。SCOPE范圍:Thisprocedureappliestoallmanufacturing.該程序適用于所有生產(chǎn)。LAYEREDAUDITS分層審核RESPONSIBILITY職責(zé):TheManufacturingPlantManagerisresponsibleforimplementat