品质成本（中英文版）

COQTrainingCOSTOFUALITY品質成本COQTrainingPoorQuality…PoorBusiness!品質差，生意差!ItisatimebombwaitingtoExplode!COQ高，是一顆等待爆炸的定時炸彈！IFCOQhigh,如果COQ高COQTrainingHiddenfailurecost隱藏的失效成本Commonlymeasuredfailurecost通常量度的失效成本TrueFailureCosts真正的失效成本•Scrap報廢•Rework翻工•Warranty保證•Engineeringtime工程設計時間•Managementtime管理時間•Shopandfielddowntime工場壞機時間•Increasedinventory增加存貨•Decreasedcapacity削弱生產能力•Deliveryproblems交貨問題•Lostorders訂單減損CommonlymeasuredfailurecostisonlythetipoftheTrueFailureCosts.通常量度的失效成本只是真正失效成本中的冰山一角。Qualitycostisameasureoftheachievementandnonachievementofproductquality.TipoftheIceBerg冰山一角COQTrainingBasicPremisesforQualityCost:品质成本基本前提:1.Itislessexpensivetopreventratherthandetectnonconformity预防比检测更省钱。2.Processandproductperformancecanbeappraised(measured)工序和产品性能可以评估(量度)3.Thecausesfornonconformancecanbeidentifiedandtheireffectscanbereducedoreliminated产品不符的原因可以确认，其影响可以减小或消除COQTrainingWhyExaminetheCostofQuality?为何要审视品质成本?1.Getmanagementattention引起管理层的关注2.Changethewayemployeethinkabouterrors改变雇员看待错误的方法3.Providebetterreturnonthequalityimprovementprogram提供更好的回报4.Provideatooltomeasureimpactofcorrectiveactions为改正行动提供量度的工具5.Provideatooltomeasuretheimpactofpoor-qualityonprofits为恶劣品质对利润的影响提供量度的工具PreventionScrap预防报废COQTrainingTheCostPyramid成本金字塔ProcessControl工藝控制Inspection檢查FieldService服務Design設計CostofQualityQFDSPCDOEMoneyspendtofixanissueatdifferentstages:不同階段修正某個問題所花的金錢：Design:1$設計:1$Production:100$生產:100$Customer:1000$到客戶手中:1000$COQTrainingResultantCost結果成本=FailureCost失效成本，DefectCost次品成本.ControllableCost可控成本=PreventionandAppraisalCost.預防和評估成本.PoorQualityisPoorBusiness品質差即是生意差0102030405060ControllableEffortCostTotalCost總成本ControllableCost可控成本ResultantCost結果成本ALowHighCOQTrainingEffectofGoodPreventiveActivities良好的預防活動產生的效果0102030405060ControllableEffortCostABOldTotal舊的總成本ControllableCost可控成本ResultantCost結果成本LowHighNewTota新的總成本lGoodPreventiveactivitiesusuallybeginatfrontendofprocesswithbettereffectonresultantcost.良好的預防活動通常開始于工序前沿，對結果成本產生較好的影響。在报废和预防维护/检测之间寻求一平衡点COQTrainingTaguchiQualityLossFunction(QLF)Taguchi品质损失函数(QLF)Qualitycostareusuallyquantifiedintermsoftangiblecostsuchasreworkandscrapcost,andcustomerwarranty.Theselossesconstituteonlythetipoftheiceberg.品质成本通常以有形成本如翻工，报废，给客户提供担保等等而被量化，这些损失只是冰山一角。Whatabouttheintangiblecostssuchasmanagement/engineeringtime,inventory,customerdissatisfaction,andlossmarketshare?那些无形的成本代价如管理/设计时间，存货，客户的失望，市场份额损失等，又怎样呢？QLFisamethodusedtoapproximatethesehiddenandlongtermlosses.QLF是用于估算这些隐藏的而且是长期损失的方法。COQTrainingTaguchiQualityLossFunction(QLF)Taguchi品質損失函数(QLF)•Wecannotreducecostwithoutaffectingquality.我們不能削減成本而不影響品質•Wecanimprovequalitywithoutincreasingcost.我們可以不增加成本而改善品質.Wecanreducecostbyimprovingquality.我們可以通過改善品質而降低成本.•Wecanreducecostbyreducingvariations.我們可以通過減少差異而降低成本.TaguchiQLFstriveforminimalvariationaroundtargetvalueswithoutaddingcost.Hedefineslossas“…thelostimpartedtosocietyfromthetimetheproductisshipped”,thislossincludesTaguchiQLF努力达致接近目标值的最小差异而不增加成本。他将损失定为：“从产品装运时流失的那部分损失“这种损失包括：customerdissatisfaction,客戶不滿意addedwarrantycosttotheproducer,生产商增加担保成本lossduethecompany’sbadreputation,公司信譽恶劣引致的损失whichwouldleadtoeventuallossofmarketshare.这种损失终將导致市场份额的丧失。COQTrainingTaguchiQualityLossFunction(QLF)Taguchi品质损失函数(QLF)ThewayQLFisestablisheddependsonthetypeofqualitycharacteristicsinvolved.Aqualitycharacteristicsiswhateverwemeasuretojudgeperformance(quality).QLF的建立有赖于有关的品质特性。品质特性是用来判断性能(品质)而进行的一切量度。Therearefivetypesofqualitycharacteristics.有五种品质特性.Nominalthebest.Achievingadesiredtargetvaluewithminimalvariations,suchasdimensions&outputvoltage.名义上的最好达致理想的目标值，差异最小，如尺寸和输出电压。Smallerthebetter.Minimizingaresponse,suchasshrinkageandwear.越小越好如收缩和磨损Largerthebetter.Maximizingaresponse,suchaspulloffforceandtensilestrength.越大越好如拉力和张力Attribute.Classifyingand/orcountingdata,suchasappearance.属性澄清并且/或者清点数据，如外观Dynamic.Responsevariesdependingoninput,suchasafandrivespeedshouldvarywithenginetemperature.动态回复有賴於輸入，如風扇的變速必須根据引擎溫度而變化。COQTrainingTaguchiQualityLossFunction(QLF)Taguchi品质损失函数(QLF)Valueofqualitycharacteristics品质特性值Loss$yL=k(y-T)²L=Lossin$’s以美元计的损失k=Costcoefficient成本系数y=Valueofqualitycharacteristics品质特性值T=Targetvalue.目标值LSLUSLCOQTraining1.PreventionCost預防成本-Costofallactivitiesspecificallydesignedtopreventpoorqualityinproducts.專門設計用于防止產品惡劣品質的一切活動成本。2.AppraisalCosts..評估成本-Costassociatedwithmeasuring,evaluatingorauditingproductstoensureconformancetoqualitystandards.為確保符合品質標準所進行的與產品量度、評估或審核等有關的成本。3.InternalFailureCosts.內部失效成本-Failurecostsoccurringpriortodeliveryorshipmentoftheproduct.在產品交運前發生的失效成本4.ExternalFailureCosts.外部失效成本-Failurecostsoccurringafterdeliveryorshipmentoftheproduct.產品交運之後發生的失效成本ElementsofCOQ.COQ的要素COQTrainingCostofConformance:•Prevention-Costassociatedwithdesign,implementationandmaintainingaqualitysystem預防---與設計，實施和維護品質系統有關的成本。•Appraisal-Costassociatedwithmeasuringconformance評估---與符合標準量度有關的成本。符合標準的成本:COQTrainingCostofNon-conformance:與標準不符的成本:•InternalFailure-Costassociatedwithinternalnon-conformance(detectedpriortodeliveryofaproductorservice)內部失效---與內部標準不符有關的成本(產品或服務提供給客戶之前檢測發現)•Appraisal-Costassociatedwithex