Faurecia7QBTRAINING(佛吉亚7QB培训教材)

The7QBofproductionFAStrainingpresentation2012V17QB:Level1training37QB:TARGETSOFTHELEVEL1TRAININGObjective:TounderstandthebasictoolsofQualityusedbyFaureciaandFAS.Attheendofthemoduleyouwilldiscoverandbeabletoapplythe7QBintheplant.Timeframe1.5hoursProgram:Introduction:BQPandRelationto7QBOK1stPartPokaYokeSelf-InspectionFinalInspection/TQWRedBinsReworkundercontrolQRCITrainer(s)level4–whocanconductQualificationprocess:Thetraineehasunderstoodallthe7QBtoolsandthemindsetbehindthem.BreakthroughQualityPlan7QBofBQP+7QBinProduction+7QBinDevelopmentTheBQPisatop-downapproachsetting7practicalandsimplerulesdesignedtoaddressourmainweaknessesinproductionandindevelopmentBQPindetailBQP#1:Capitalization&Transversalizationof8D8D–problemsolvingreportforQualityD1.Description&Sketch_D2.Riskonsimilarproductsandprocesses_D3.ContainmentIn1dayD4.Rootcauseofnondetection_D5.Rootcauseofnonconformance_D6.CountermeasuretonondetectionandnonconformanceIn10workingdaysD7.Effectivenessofactionplan_D8.LessonslearnedIn60workingdays•Finalcustomerneeds•Customerneeds•Pastproblems•KeyDimensions•KeyFunctions•Suppliers•Jobinstructions•Dailychecksheets•Pokayokechecks•StatisticalProcessControlOK1stpiecePokaYokeSelf-InspectionFinalInspectionkeycharacteristicsincludingS/R!ControlPlanGoodPartsBadParts•ActionRulesRedBinsReworkunderControlQRCI7QUALITYBASICSOFPRODUCTIONBQPAction#2:StrictapplicationofcontrolplanBQPAction#3:QuickresponseindailyQRCIPlant/ProgramQRCI:Containmentactionmustbetakeninthesameday/shiftascustomerdefecthappened.PlantQRCI:Customer+Supplierissues+Top3scrap(80%covered)+internalescalatedissuesUAPQualityProductionQuality!PassonlygoodpartstothenextstageQualitystartswithcleanlinessandorder:5S1SeiriEliminateSeparatewhatyoudoneedfromwhatyoudon’tandthrowoutanythingthatisuseless!ZoningOnething,oneplaceOneplace,oneownerSeiton2StraightenupDefinethemostefficientandsafestwaysofstoringwhatisreallyuseful.Storewhatyouneedwhereyoucangettoit.3SeisoCleanCleanuptheinstallations.Seekoutthecausesofdirtandgetridofthem.4SeiketsuStandardizeEstablish“goodhousekeepingrules.Formalizestorageandcleaningprocedures.5ShitsukeRespectGetintothe“5ShabitinyourGAP.Respecthousekeepingrules.Continuetomakethingsbetter5SindetailJobInstruction/WorkinstructionPrecisedescriptionofalloperationsandinspections.Howtodothejobwell(atfirstapproach).1.OK1stpart(FAU-S-PSG-0630)Scope:Identifypotentialrisksafteratthebeginningoftheshiftoractivitiesinvolvingthestopoftheline(maintenance,changeover,alerts...).Assurethecorrectrestartoftheprocess.OK1stpartHSEOK/NOK…5SOK/NOK…Training/PolyvalenceOK/NOK…Pokayoke’sOK/NOK…ProcessParametersPreventiveMaintenanceOK/NOK…OK/NOK…ProductCharacteristisOK/NOK….DailyChecksheetOK?1stpartOK?1.Checkbeforehandthatallrequiredconditionsaremettoproducegoodparts,inasafelyway.“I’amresponsibleofmyworkstationandthesurroundings,soIwillmakesureeverythingisOKtostartproduction”2.IfanysinglecheckitemisNOK,theproductionshallnotbestarted.OK1stpartDailyCheck-sheetOK!1stpartOK!GO!•Doneateverystartofshift,processchange-over,breakdown•Back-upmodeclearlyidentified,availableatworkstation•Keepanddisplay1stpartOKuntilnextchange/shift•Ifnextstart-upNOKorcustomerconcern=identifyscopeofsuspectpartsforcontainmentHSEOK/NOK…5SOK/NOK…Training/PolyvalenceOK/NOK…Pokayoke’sOK/NOK…ProcessParametersPreventiveMaintenanceOK/NOK…OK/NOK…ProductCharacteristisOK/NOK….7qualitybasicWayofcontrolPartFirstOKPartOK:Start-upinstructioncoverstheredposter=GreensituationNOK:Start-upinstructionscoversthegreenposter=Redsituation:DerogationmandatoryRulesDerogationGreenposterRedposterVisualManagementofOK1stPart7qualitybasicVisualManagementofOK1stPartReactionrulesforNOKstatusOKprocesschecksheetOKproductchecksheetOK/NOK?CheckpointWhattocheck?Howtocheck?WhattodoifNOK?ValidatedbyGLOK1stPart–MandatoryRules1.OK1stpartinstructionsandOK1stpartcheck-sheetsarecreatedoutofcontrolplan.Theycover:HSE,5S,training,pokayoke’s,processparameters,productcharacteristics.TheydescribewhenOK1stpartchecksaretobeperformed.Alocationisreadyforthe1stOKpart.2.Foreachcheckitem,checkingmethod,OKcriteriaandreactionrulesaredefined.3.TheGAPLeadervalidatesOK1stpartcheck(1stOKpartandcheck-sheets)4.IfoneitemormoreisnotOK,productionisnotstarteduntiladulyvalidatedback-upmodeisapplied.Suspectpartsaremanaged.Cultureofself-managementandthederogationincaseofNOK2.Pokayoke(FAU-S-PSG-0650)Scope:Systematicallydetect/catchandblockanerrorbeforeitturnsintoadefect.Freethemindtofocusonvalue-addedoperations.FUERADEFUNCIONAMIENTOPARÁMETRO:MODOBACKUP(óderespaldo)A)100%CHEQUEOMANUALB)100%MARCADOENLASCARACTERISTICASCHEQUEADASC)MATENERREGISTROSDETRAZABILIDADDELASPARTESPRODUCIDASChequeadopor:Firma:Fecha:PKYN°____PokaYokeProductpokayokeProcesspokayoke•FullyconsistentwithFMEA/Controlplan•Use'redrabbit'(masterparts)tocheckpokayoke•IfnotOK:stopproduction,thenapplythereactionrulesSimpleerror-proofingdevicestopreventhumanerrors.EachPoka-yokemustcontain:1.Clearinstructionwithreferencenumber3.Checkingmethodandfrequency2.Workingprinciple4.Backupmodeincaseoffailure.Poka-Yoke,follo