七颗钻石流程（PPT 38页）

17DiamondProcess七颗钻石流程Developedby:GMTG-ArlingtonL.O’Neal/C.KesslerAug2000Revised:8Aug20002Whatisthe7DiamondProcess?七颗钻石的流程是什么？The7DiamondProcessisoneofmanytoolsthatcanbeusedintheproblemsolvingprocess.七颗钻石流程是可以用来解决质量问题的工具之一。Thistoolisusedtoinvestigatediscrepanciesdiscoveredbythefollowing:它可以用来调查以下方面发现的差异•GlobalCustomerAuditSystem(GCAS)全球顾客评审•YardWalkAudits生产线上巡检•VerificationStations检验工位3Purposeofthe7DiamondProcess7颗钻石流程的目的•The7DiamondProcessisastructuredwayofassessingourmanufacturingprocesstodeterminewhetherofnotithasfailedtomeetthequalitystandarddemandedbyourcustomers.•7颗钻石流程是一个构建好的评价我们的制造流程是否满足了顾客所要求的质量标准的一个方法47DiamondProcess流程Responsibility责任Production第一步¨1Production第二步¨2Production第三步¨3Rel.Engineer/SQA/Supplier负责的SQDE工程师/供应商¨4CorrectProcess?正确的工艺CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量Responsibility责任ProcessControlManagers工艺控制负责人¨5aIsEngineeringsupportrequired?是否需要工程方面的支持ProblemIdentifiedBeginInterrogation问题定义(开始调查)Responsibility责任QETPST(Lead)¨5bSMTRGM(Lead)¨6StatisticalEngineering(RedXStrategies)统计工程(红-X方法)¨7WillProcessChangeResolve?工艺更改能解决问题吗ProductChangeRequired?产品更改需要吗？HardyPerennialorExtremelyComplexProblem非常复杂的问题SQA-SupplierQualityAssuranceQET-QualityEngineeringTeamPST-PlantSupportTeamSMT-SystemsManagementTeamRGM-ReliabilityGrowthManagement5ReviewofResponsibility职责回顾•Diamonds1-4Production&Reliability•钻石1-4生产&可靠性•Filter5aProcessControlManager(PCM)•5a过滤工艺控制负责人•Diamond5b-7ProductEngineering•钻石5b-7产品工程6InsertSampleCountermeasureCardHere此处插入对策卡样卡77DiamondProcessStages流程的各步骤Stages1&2oftheprocessareusedtodetermineiftheProductionorganizationisrunningtheassemblyprocesstodesignintent.1、2步是用来确定生产部门运行的装配流程满足设计内容。Theinitialinvestigation(Stage1)isdonewherethedefectwasidentified.最初的调查(第一步)应在发现缺陷的地方开始Stage2isonlyusedwhentheinvestigationinStage1determinedthatthecauseoftheproblemwasfromanupstreamsource.第2步只能当第一步的调查,确定问题是来源其他方面时,才可开始Iftheprocessisn’tbeingmanagedtodesignintent,thenitmustbecorrectedandvalidated,priortoaskingforEngineeringassistance.如果工艺没有满足设计内容，当需要工程方面的协助前，必须进行纠正并要有效。Engineeringreferral(Stage3)occurswhenthemanufacturingprocessdoesmeetdesignintentandtheproblemstillexists.当制造过程满足设计内容并且问题依然存在时，第3步开始。8¨1-CorrectProcess正确的过程•ArethecorrectBestPeoplePracticesheetsposted?•是否有正确的操作指导文件？•AretheBestPeoplePracticesbeingfollowed?•是否执行操作文件？•IstheoperatorsKeyPointChartbeingfollowed?•是否满足关键操作点控制图•Arethecorrectdocumentspostedontheoperationcertificationboard?•是否在操作示板上有正确的文件•IsthejobbeingperformedtothePAD’s?•是否按照PAD操作•Cananyofthesecausetheproblem?以下的问题有可能产生问题吗？Stages1&2ProductionCorrects正确的生产Production¨2Production¨3Rel.Engineer/SQA/Supplier¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件的质量8¨1-CorrectProcess正确的过程•Hasamandatorysequencebeenidentified?Isitbeingfollowed?•是否强制的操作序列号已识别，是否执行了•Isthejobbeingdonethesameonbothshifts?•在各班次中操作工作是否一致•Doestheoperatorunderstandwhattheproductstandardsare?•操作者是否理解产品标准•Isittheregularoperator?Hastherebeenalotofturnoveronthejob?•是否为固定操作工？是否此操作有很多轮换人员•Hastheoperatorbeenproperlytrained?•操作者是否正确培训过•Arethevisualaidscurrent?•目前是否有目视化的辅助措施•Doestheoperatorunderstandthequalityoutcomesofher/hisjob?•操作者是否知道他/她的岗位的产品的输出质量•Doestheoperatorknowhowtocommunicatewhenhe/shehasaproblem?•操作者是否知道当他/她的岗位出现质量问题时如何传递沟通信息？Cananyofthesecausetheproblem?以下的问题有可能产生问题吗？Stages1&2ProductionCorrects正确的生产Production¨2Production¨3Rel.Engineer/SQA/Supplier¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量9•Arethecorrecttools&fixturesbeingused?(bothshifts)•是否使用正确的工具/夹具(各班次)•Arethetoolssettothespecifiedtorque?•工具是否设置成规定的扭矩•Aretheyproperlycalibrated?•是否进行适当的校准•Arebothshiftsusingthesametool?•是否各班次用同样的工具•Arethebitsorsocketsworn?•是否螺丝刀或套筒已磨损•Hasanextraairhosebeenattachedtothetool?•是否在工具上有多余的空气管•IsthetooltiedtotheAndonsystem?•工具是否与暗灯相连•HasthetoolbeenputonBypass?•是否工具被旁路•Dothetools&fixtureshavemutilationprotection?•是否工具/夹具有损毁保护•Hastheworkstationbeenerrorproofed?•工位是否有防错设施•Doestheworkstationlayoutallowtheoperatortoworkeffectively?•是否工位的布置适合操作者有效的工作•HasthePreventiveMaintenancebeendone?(checklog)•是否进行了预防性维修(检查表)•Aretoolsfunctioningcorrectly?•工具功能是否正确Stages1&2ProductionCorrectsProduction¨1Production¨3Rel.Engineer/SQA/Supplier¨4CorrectProcess?正确的工艺过程CorrectTool?正确的工具CorrectPart?正确的零件PartsQuality?零件质量¨2-CorrectTool正确的工具Cananyofthesecausetheproblem?10•IsthePartsRoutingcurrent?•零件的路径是否正确•Arethecorrectpartnumbersidentifiedonthematerialracks?•是否在料架上标识有正确的零件号•Arepartsstockedincorrectlocationontherack?•在料架上摆放位置是否正确•Dothepartnumbersontheboxesagreewiththerack?•包装盒上零件号与料架上是否一致•Areallpullcardsavailable?•拉动卡是否有效•HasaPAAbeenissuedchangingpartusage?•是否有零件用途改变的PAA•HasthePAAexpired?•PAA是否过期•Iserrorproofingneeded?•是否需要防错措施•Isexistingerrorproofingdeviceworkingcorrectly?•是否已有的防错设备运行正确Stages1&2Production¨1Rel.Engineer/SQA/Supplier¨4CorrectProcess?正确的工艺过程ProductionCorrectsCorrectPart?正确的零件Production¨2CorrectTool?正确的工具PartsQuality?零件质量¨3-CorrectPart正确的零件Cananyofthesecausetheproblem?11TheReliabilityEngineerisresponsiblefordeterminingifpartshavechangedandoverallpartquality.Ifpartsquality(outofspecificati