CHN gb_mod9_analyze_3_6_1

1©VisteonCorporationGB-Mod#9Rev3.610/03AnalysisPhaseGBModule#92©VisteonCorporationGB-Mod#9Rev3.610/03ContinuousImprovementRoadMap持续改进路线图ImproveControl•DefineCTQ定义关键质量特性•DetermineCurrentState确定当前水平•DetermineKeyInput/OutputVariables确定关键输入,输出变量•PerformMSA进行MSA•Calculateinitialprocesscapabilities计算初试过程能力Measure测量•VerifyEffectssofKeyinputswithDOE’s用DOE验证关键输入的影响•DetermineOptimumSettings确定优化设置•UpdateControlPlan更新控制计划•VerifyImprovements验证改进效果Analyze•EvaluateExistingControlPlan评估当前的控制计划•Usingstatisticalmethodstodeterminepotentialkeyinputs使用统计方法确定潜在的关键输入•Prioritizekeyinputvariables排列关键输入变量NDefine定义3©VisteonCorporationGB-Mod#9Rev3.610/03AnalysisPhase分析阶段•EvaluateExistingControlPlan评估当前的控制计划•Beginto“Funnel”DowntheListofInputVariables准备筛选输入的清单•BegintoStatisticallyDetermineKEYInputs准备用统计工具确定关键的输入•GainanUnderstandingofCycleTime理解节拍4©VisteonCorporationGB-Mod#9Rev3.610/03分析阶段–工具箱•C-E矩阵•FMEAFMEA•图法•假设检验5©VisteonCorporationGB-Mod#9Rev3.610/03课程目标•能够完成因果矩阵•回顾失效模式和效果分析•理解从图法当中能获得什么信息•理解“TaktTime”概念6©VisteonCorporationGB-Mod#9Rev3.610/03因果矩阵7©VisteonCorporationGB-Mod#9Rev3.610/03筛选XS•即使最简单的过程X的数量也可能很大.•尽管我们需要确保我们收集到准确的数据.但是因为时间和成本的关系，我们不可能收集到所有的数据.•筛选意味着用一个系统的方法来减少X的数量.•筛选的关键工具是因果矩阵•我们用它来确定X的优先级,并关注于那些我们认为对Y影响最大的X.8©VisteonCorporationGB-Mod#9Rev3.610/03因果矩阵表•过程流程图是因果矩阵的输入，因果矩阵用于将X与顾客的Y对应，并通过打分对X排序的。•Y’sarescoredastoimportancetothecustomerY根据对客户的影响被打分.•X’sarescoredastorelationshiptooutputs对X打分的依据是它对输出的影响.•Result:ParetoofX’swhichcanbeusedasastartingpointintheevaluationofthecontrolplansandbuildingthedatacollectionplan.结果:用帕雷托图来排列X,并据此评估控制计划。建立数据收集计划.9©VisteonCorporationGB-Mod#9Rev3.610/03TheMethod方法STEP1Listtheoutputvariables(Y's)alongthetopsectionofthematrix.Theseareoutputswhichtheteamand/orthecustomerdeemtobeimportant.ThesemaybeasubsetofthelistofY'sidentifiedontheprocessmap.列出输出变量在矩阵的上部。这些输出是团队或/和客户认为是重要的。这些可以是过程流程图识别出来的输出的一个子集。STEP2Rankeachoutputnumericallyusinganarbitraryscale(possibly1-10).Themostimportantoutputreceivesthehighestnumber.给每一个输出打分(可以是1-10)。最重要的输出得分最高。10©VisteonCorporationGB-Mod#9Rev3.610/03TheMethodSTEP3Identifyallpotentialinputsorcauses(X's)thatcanimpactthevariousY'sandlistthesealongthelefthandsideofthematrix.识别所有的潜在的可能会影响各个输出的Y的输入或原因，在矩阵的左侧排列这些原因。STEP4Numericallyrate(correlate)theEffectsofeachXoneachYwithinthebodyofthematrix.Thisisbasedontheexperienceoftheteam.给这些输入对输出的影响打分.这是基于团队的经验.STEP5Usethetotalscolumntoanalyzeandprioritizewheretofocusyoureffortwhencreatingthedatacollectionplan.用TOTALCOLUMN来分析和排列当我们制定数据收集计划的时候需要关注的项目。11©VisteonCorporationGB-Mod#9Rev3.610/03ProcessMaptobeUsedinExample过程流程图示例COMPOUNDINGINPUTSOUTPUTSTechniquesProceduresRawMaterialsReworkEquipmentEnvironmentCleanlinessDicySolutionTempReactivity(Gel)ViscosityCleanlinessColorHomogeneityConsistencyBatchtoBatchDigestionTimeTemperaturePAPERWORKTURNSTEAMONTODICYTANKLOADDMFLOADDICYLOAD2MIBILLOFMATERIALSISOPROCEDURESREWORKSCALEACCURACYPREHEATINGLOADACCURACYCLEANLINESSRAWMATERIALLOADACCURACYENVIRONMENT(HUMIDITY)RAWMATERIALMIXERSPEEDLOADACCURACYENVIRONMENT(HUMIDITY)RAWMATERIALMIXERSPEEDGETPORTABLECLEANIFNECESSARYLOADSOLVENTTOPORTABLELOADDRUMSTOCKTOPORTABLE2PROPERSIZEREWORKCLEANLINESSCROSSCONTAMINATIONLOADACCURACYENVIRONMENTRAWMATERIALLOADACCURACYENVIRONMENTRAWMATERIALMIXERSPEEDLOADBULKMATERIALTOPORTABLE2PUMPDICYSOLUTIONTOPORTABLEDIGESTSTAGEBATCHTOTREATERLOADACCURACYENVIRONMENTRAWMATERIALMIXERSPEEDPUMPRATEMIXERSPEEDFILTERINGTEMPERATURECOMPLETESOLUTIONTIMEMIXSPEEDVENTINGENVIRONMENTTIMEMIXSPEEDVENTINGENVIRONMENTKeyOutputs关键输出KeyInputs关键输入12©VisteonCorporationGB-Mod#9Rev3.610/03Step1)ExampleRatingofImportancetoCustomer123456789101112131415ProcessInputsGelTimeViscosityCleanlinessColorHomogeneityConsistencyTemperatureSolidsTotal10203040506070CauseandEffectMatrix1.Listkeyoutputs(Y’s)列出关键输出ThisinputisfromtheProcessMap因果据政的输入是过程流程图C&EMatrix.xls13©VisteonCorporationGB-Mod#9Rev3.610/03Step2)RatingofImportancetoCustomer99710109326123456789101112131415ProcessInputsGelTimeViscosityCleanlinessColorHomogeneityConsistencyDigetsTimeTemperatureSolidsTotal1020304050607080CauseandEffectMatrixThisstepmayneedtoincludemarketing,productdevelopment,manufacturing,etc.Ifpossible,actualendcustomersshouldbeincludedaswell.Weseethat“color”andhomogeneity”aremostimportanttothecustomer.这一步有可能需要包括市场部,产品开发,制造等部门,如果有可能最终用户也应该包括在内.我们看到颜色和均匀性对客户是最重要的2.Rankoutputsw.r.t.importancetoCustomer根据对客户的重要程度排列输出14©VisteonCorporationGB-Mod#9Rev3.610/03RatingofImportancetoCustomer99710109326123456789101112131415ProcessInputsGelTimeViscosityCleanlinessColorHomogeneityConsistencyDigetsTimeTemperatureSolidsTotal1ScalesAccuracy02PreheatingDICYTK03DMFLoadAccuracy04DMFCleanliness05DMFRawMaterials06DICYLoadAccuracy07DICYEnvir.Factors08DICYRawMaterials09DICYMixerSpeecd03.Listthekeyinputs列出关键输入Thisstepusestheinputsfromtheprocessmap.这一步使用在过程流程图中识别出来的输入Step3)15©VisteonCorporationGB-Mod#9Rev3.610/03Step4)Guidelines•Youarereadyto“correlate”customerrequirementstotheprocessinputvariables现在，你可以建立客户需要和过程输入的关系了•Assignmentofthescoringtakesthemosttime打分花费最多的时间•Toavoidthis,spelloutthecriteriaforeachscore(examples):为了避免这个,讲清楚