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15C培訓PreparedbyFrikLv2011/12/282MQIR#機種:IssueTitle問題:Date日期:Description描述Champion組員:Containment防堵措施:RootCauses根本原因:CorrectiveActions:糾正措施PreventiveAction預防措施Verification驗證:Reviewer審核:ReviewResults審核結果:Characterize問題定性Contain防堵措施Cause成因CorrectiveAction糾正措施Closure結論3•Whendidtheproblemhappen?問題何時發生？•Whatistheissuedescription?問題如何描述？•whichstationwasdefectdetected?不良出現在哪裡？•Whodetecttheissue?誰發現問題？•Whatisthedefectivepicture?不良圖片是什麼？Description描述4•whatisthefailurerate?不良率是多少？•Whatisthelot#?批號是多少？•WhatistheDateCode?日期編碼是什麼？•Whatisthedefectpattern?不良樣式是什麼？•Howwasthedefectdetected?不良是怎麼被探測出來的？•Whatisthetotalinspectionsize?總檢測比例是多少？Description描述5•Whoistheownertoanalysis?誰負責分析？•IstheirFAreportdone?不良分析報告是否完成？•Istheproblemcausingproductionlinedownordeliveryissue?此問題是否會造成生產下降或者交貨延遲?Description描述6•Wasprocessflowanalyzedtopinpointandfindwherethedefectsoccurredandwheretheprocesscontrolpointsareforinvestigationintotheeffectiveness?加工過程分析是否會找出不良發生和制成控制點位置，從而使調查生效？•Istheiranyinternalproductionrecordforprocessabnormality?是否有關於制成不良的內部產品紀錄？Description描述7•Hadweinformedtheproductionpersonnelorsupplier,ifapplicable,abouttheincident?如果對事件采取防堵措施，我們是否已經將此通知到生產人員和供應商？•Aretheaffectedmaterialsidentified,segregatedandquarantinedcorrectlyatallthesupplychain,namelyproductionline,WIP&warehouse&in-transit(fromFlextoMS)?確定在整個供應鏈中受影響的物料是否經過正確地驗明，分離和檢查，即從生產線到WIP,倉庫以及運輸過程。ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍8•Whatisthesuspectquantityonproductionline(includessupplier,ifapplicable)?如果采取防堵措施，生產線上(包括供應商)要檢測數量是多少?•WhatisthesuspectquantityonWIP(includessupplier,ifapplicable)?如果采取防堵措施，在WIP處(包括供應商)要檢測的數量是多少？ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍9•WhatisthesuspectquantityinWarehouse(includessupplier,ifapplicable)?如果采取防堵措施，在倉庫(包括供應商)要檢測的數量是多少？•WhatisthesuspectquantityIn-transit(includessupplier,ifapplicable)如果采取防堵措施，在運輸中(包括供應商)要檢測的數量是多少？ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍10•Whatprocesscontainmentactionscouldbetakenandeffectivenessverified?(Machinesettingetc?Operatorskillsandcertification?DifferentmaterialSupplierwithCpkassessed?DifferentFixture?DifferentOperatingmethod?etc)防堵措施在那個程序實施並且生效？（機器設置等方面，作業員技能和認證？不同物料供應商的Cpk評估？不同治具？不同的操作方法等）ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍11•Whatisescapecontainmentactionscouldbetakenandeffectivenessverified?(VisualCriteriachange?Increasedsamplingsizeorfrequency?etc)不良外流防堵措施在那個程序實施並且生效？（目檢准則變化？增加抽樣比例和頻率等）•HadweassessedSupplyanddeliveryimpact?是否評估過供貨和發貨的影響？ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍12Occur發生•HadwelistedallthepossiblecausestotheproblembaseduponfindingsinProblemDescriptionandContainmentActions?是否依據問題描述和防堵措施列出關於此引起此問題的所有因素？•Hadweinvestigatedwithevidencetoconfirmoreliminatethepossiblecauses?是否通過證據調查確定或排除可能因素？•Hadweperformed`Why-whyanalysis’ontheconfirmedcauses?對已確定的成因是否進行“why-why分析”？ContainmentActionHadweconsideredallthese防堵措施＞考慮范圍13RootcauseanalysisAretheseconsidered?根本原因分析＞考慮范圍Escape外流•HadwelistedallthepossiblecausestotheproblembaseduponfindingsinProblemDescriptionandContainmentActions?是否依據問題描述和防堵措施列出關於此引起此問題的所有因素？•Hadweinvestigatedwithevidencetoconfirmoreliminatethepossiblecauses?是否通過證據調查確定或排除可能因素？•Hadweperformed`Why-whyanalysis’ontheconfirmedcauses?對已確定的成因是否進行“why-why分析”？(要因分析,例如魚骨圖)14Rootcauseanalysis我們是否採用了why-why來確認可能的原因例如:•問題:爲什麽車子無法啟動.•Why?–電池壞了.(第一why)•Why?-交流发电机無法工作.(secondwhy)•Why?–交流發動機的傳動帶壞了.(thirdwhy)•Why?-交流發動機的傳動帶已經超過使用壽命而未及時更換.(fourthwhy)•Why?–我沒有根據建議的服務計畫對車輛進行保養.(fifthwhy,arootcause)•Why?–因為車輛年限較長，更換上的零件不是很匹配.(sixthwhy,optionalfootnote)15CorrectiveactionDowehave矯正措施＞目前實施•Whoismonitoringthe2weekdatatovalidateimprovement?改進後，誰將監控此間二周內的數據？•Isanyonereviewingthevalidationdata?是否有人審核驗證數據？16CorrectiveactionDowehave矯正措施＞目前實施•IsthePermanentCorrectiveActionsverifiedforeffectivenesstoaddresstheRootCauseandcanreplacecontainmentactionsbeforeweselect?在選擇永久矯正措施之前，是否驗證它對問題產生的根本原因有效並能替代防堵措施?•AreCorrectiveActionscomingwithresponsiblepersonnel,DuedateandStatus?矯正措施的實施是否具有相應負責人,執行日期及狀況?17•Whatdocumenthavebeengeneratedafterimprovement?(FMEA,ControlPlan,WI)?改進後產生何種文件(FMEA，管理方案，WI)?•DowehavePokaYokeactionitems?我方是否具有PokaYoke措施項目？(checkinglist)•CansimilarCorrectiveActionsbereplicatedtootherlines/products?類似的矯正措施是否應用輿其它產線或者產品上？PreventiveActionAreactions預防措施＞改善措施POkA18Verification驗證•WhowasMonitoringDatatovalidateeffectivenessofPermanentCorrectiveActionsandPreventiveActions?對永久矯正措施和預防措施有效性的驗證數據，誰負責監控？•Whatisthestatusafterapplyingthecorrectiveaction?矯正措施實施後,情況如何？19TheEnd