APQP2

PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage1of328-D手法CorrectiveActionsProcedure8-DisciplineApproach矫正措施——8-D手法PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage2of328D：8DISCIPLINES8DisciplinesofProblemSolving解決問題的8個步驟PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage3of32一、Whatis8-D?(什么是8-D？)•是一个用于探索原因、解决问题的系统化流程。Discipline1.UseTeamApproach组建团队Discipline2.DescribeTheProblem描述问题Discipline3.ImmediateCorrectiveActions紧急对策Discipline4.SeekTheRootCause根本原因Discipline5.PermanentCorrectiveActions永久改善措施Discipline6.VerificationOfEffectiveness效果确认Discipline7.PreventiveActions防止复发Discipline8.CongratulateYourTeam,CaseClose祝贺结案PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage4of32二.Whenshall8-Dbeused?何时用8-D？•-----------------------------------------------------------------------------------------------------•Supplier'squalityperformanceconsistentlyexceedstheagreedgoal.当供应商品质持续超出要求的目标时。Suppliermeetstheagreedgoal,butonefailuresymptomconcentratesmorethan2%.当单一不良现象达到2%，即使总体质量水平满足要求。Adefectoccurredthatshouldhavebeencontainedwithinthesupplier'sprocess.供应商制程不良导致品质异常。Thefailingparameterwasnottestedbysupplier.供应商未测试的参数导致不良。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage5of32三.Responsibilities职责•-------------------------------发起人：提出8-D（CAR）的要求。--------供应商1.Shallprovideresponsesin8-Dformat.必须用8-D的报告格式向发起人作出回复。2.Communicate8-Ddetailsinternallyasnecessary.准备8-D报告的详细内容。3.Respondwithimmediate/permanentcorrectiveactionsaspergoals.按照计划要求提出紧急对策及永久改善措施。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage6of324.Provideweeklyupdatestotheoriginatorasperschedule.每周按计划向8-D发起人通报改善措施落实情况。5.Achievegoalsontimescalesforimplementationofimmediate/permanentcorrectiveactions.按时完成紧急对策及永久改善措施以符合目标。6.Whereimmediatecorrectiveactionshasbeenrequested,thesuppliershouldperformariskassessmentoftheexposureintheirfinishedgoods.Thisshouldnormallybebasedonafunctional/visualscreenofstatisticallysignificantsample.当紧急对策必须执行时，供应商一定要采用有效的抽样检验方法来评估全面筛选的风险。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage7of32四.Goals目标•1.紧急对策：2个工作天内提出。5个工作天内落实。•2.永久改善措施：5个工作天内提出。10个工作天落实到位。5.Definitions定义紧急对策；短期的，暂时性的。永久改善措施：长期的，永久性的。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage8of32五.Discipline1:UseTeamApproach8-D–第一条：组建团队1.Selectandrecordinternalandexternalteammembers.选择并记录公司内外的所有成员。2.Selectateamchampion(managementmemberswhowillremoveroadblocksoftheteam选择团队决策支持人（决策支持人要能排除障碍）。3.Selectateamleader(Amemberwhodirectseffortsandtakesresponsibilityforteam选择一个组长（组长代表小组向上级负责）。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage9of32六.Discipline2:DescribeTheProblem8-D–第二条：描述问题•1.Usetermsunderstoodbythecustomer.用客户可完全理解的述语描述问题。2.Describethechangeinconditionorpre-existingcondition,whichcausedtheproblem.描述导致问题存在或发生的条件。3.Expresstheconditioninquantifiableterms,ifavailable.如有可能，量化导致问题存在或发生的条件。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage10of32七.Discipline3:ImmediateCorrectiveActions8-D–第三条：紧急对策•1.Definewho,what,when&howyouwillcaptureandcontainthedefectsnow,andpreventthemfromgettingthecustomer.指明紧急对策的人、事、时及方法，同时防止在客户端再发生。2.Considertheeffectoftheimmediatecorrectiveactions：紧急对策应考虑到：Cost成本Delivery交货期Inducementofothertypesofdefects.不可因而引起其他形式的不良。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage11of32八.Discipline4:SeekTheRootCause8D-第四条根本原因•1.Describewhythechangeinconditionoccurred,oridentifythe“Hole”inthesystemwhichallowedthepre-existingconditiontogoundetected.描述为何发生，并指出该问题流出的原因。2.Categorizetherootcauses,e.g.material,machine,Methods,Manpower,Maintenance,Environment.将根本原因按人、机、料、法、环（4M1E）进行分类。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage12of32九.Discipline5:PermanentCorrectiveAction8D-第五条：永久改善措施•1.Describewho,what,when&howyouwillimplementinmaterial,manpower,methods,etc.Tototallyeliminatetherootcauseoftheproblem.描述排除不良根源的人、事、时以及如何使用这些资源。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage13of32十.Discipline6:VerifyOfEffectiveness8D-第六条：效果确认•1.Describeverificationresultsinquantifiableterms.(E.g.:achievedCpK–1.5ordecreaseddefectoccurrencestozero,etc.)用量化指标来确认对策落实效果（例如CpK达1.5…）2.Continueimmediatecorrectiveactionsuntilpermanentcorrectiveactionsareverifiedasbeingeffective.紧急对策不能停，直到永久改善措施被确认生效PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage14of32十一.Discipline7:PreventRecurrence8D-第七条：防止复发•1.Describetheinternaland/orexternalculturalorsystemicchangesthatmustbemadetopreventtheproblemfromrecurring;描述能预防问题再发生的内部及外部的文化、系统改善条件;2.Theteamchampionisresponsiblefortakingtheserecommendationbacktomanagementanddrivingimplementation.决策支持人负责将改进建议往上级呈报并推动落实.PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage15of32十二.Discipline8:CongratulateToYourTeam,CaseClose8D-第八条：祝贺结案•Championandteamleaderrecognizesteammembersfortheirroleinsolvingtheproblem.决策支持人和组长肯定小组成员对解决问题的贡献。PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage16of32問題分析PreparedbyEricChen.Notcopywithoutpermission.A-PLUSPage17of32掌握“問題”之要領1)“問題”?實際與理想之間的差距(Gap).2)問題的型態?A.異常性問題(s太大)B.結構性問題(Xbar太低)3)發掘問題?把問題視作一座冰山(使用工具:5Why,親和圖法,關連圖法..)PreparedbyEricChen.Notcopywithoutpermission.先提昇製程水準(Xbar)還是降低異常(s