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首页 Faurecia 7QB TRAINING (佛吉亚7QB培训教材).ppt

Faurecia 7QB TRAINING (佛吉亚7QB培训教材).ppt.ppt

Faurecia 7QB TRAINING (佛吉亚7QB培训…

李桂
2019-08-13 0人阅读 举报 0 0 暂无简介

简介:本文档为《Faurecia 7QB TRAINING (佛吉亚7QB培训教材).pptppt》,可适用于工程科技领域

关于Faurecia 7QB TRAINING (佛吉亚7QB培训教材).ppt.ppt文档,极速6合拥有内容丰富的相关文档,站内每天千位行业名人共享最新资料。

TheQBofproductionFAStrainingpresentationVQB:Leveltraining**QB:TARGETSOFTHELEVELTRAININGObjective:TounderstandthebasictoolsofQualityusedbyFaureciaandFASAttheendofthemoduleyouwilldiscoverandbeabletoapplytheQBintheplantTimeframehoursProgram:Introduction:BQPandRelationtoQBOKstPartPokaYokeSelfInspectionFinalInspectionTQWRedBinsReworkundercontrolQRCITrainer(s)levelndashwhocanconductQualificationprocess:ThetraineehasunderstoodalltheQBtoolsandthemindsetbehindthemBreakthroughQualityPlanQBofBQPQBinProductionQBinDevelopmentTheBQPisatopdownapproachsettingpracticalandsimplerulesdesignedtoaddressourmainweaknessesinproductionandindevelopmentBQPindetailAfterobservationandideasfromattendees,presentOURanswertomeetcustomerexpectationsandcompanyrsquostargetsEachtrainermusthaveacopyoftheBQPtoshowit,toexplainitandtocommentitQBinproductiondevelopment=foundationforBQPBQP=actionShowtheBQP!BQP=enginestotakeoffForabestinclasssupplier,glidingisenough!BQP=topdownapproach,withsimpleandpreciseactionrulesBQP#:CapitalizationTransversalizationofDDndashproblemsolvingreportforQualityDDescriptionSketchDRiskonsimilarproductsandprocessesDContainmentIndayDRootcauseofnondetectionDRootcauseofnonconformanceDCountermeasuretonondetectionandnonconformanceInworkingdaysDEffectivenessofactionplanDLessonslearnedInworkingdaysLLStobecreatedduringDFinalcustomerneedsCustomerneedsPastproblemsKeyDimensionsKeyFunctionsSuppliersJobinstructionsDailychecksheetsPokayokechecksStatisticalProcessControlkeycharacteristicsincludingSR!ControlPlanGoodPartsBadPartsActionRulesQUALITYBASICSOFPRODUCTIONBQPAction#:StrictapplicationofcontrolplanSomeofthekeycharacteristicsareSRrequirementsBQPAction##:QuickresponseindailyQRCIPlantProgramQRCI:ContainmentactionmustbetakeninthesamedayshiftascustomerdefecthappenedPlantQRCI:CustomerSupplierissuesTopscrap(covered)internalescalatedissuesUAPQualityProductionQuality!PassonlygoodpartstothenextstageExplainSusingthisslideConsistencybetweenhouseofqualityandFESpyramidQualitystartswithcleanlinessandorder:SZoningOnething,oneplaceOneplace,oneownerSindetailYoucanplaywiththeaudience:whatdoesSmeaninJapaneseFromhere,useRemindthelinkwiththehousetoprightJobInstructionWorkinstructionPrecisedescriptionofalloperationsandinspectionsHowtodothejobwell(atfirstapproach)Important:manufacturingandINSPECTIONOKstpart(FAUSPSG)Scope:Identifypotentialrisksafteratthebeginningoftheshiftoractivitiesinvolvingthestopoftheline(maintenance,changeover,alerts)Assurethecorrectrestartoftheprocessasktomakeabrainstorming:whatneedstobecheckedbeforetheproductioncanstartdisplay:thislistisanexampletobeadapted,improvedaccordingtoyourneedsCaution:thestOKpartisthestparthavinggonethroughallstepsoftheprocessafterstartoftheshiftImportantroleoftheGAPleaderandthesupportfunctionstoguaranteeOKstpartOKstpartDailyChecksheetOKstpartOKCheckbeforehandthatallrequiredconditionsaremettoproducegoodparts,inasafelywayldquoIrsquoamresponsibleofmyworkstationandthesurroundings,soIwillmakesureeverythingisOKtostartproductionrdquoIfanysinglecheckitemisNOK,theproductionshallnotbestartedHSEOKNOKhellipSOKNOKhellipTrainingPolyvalenceOKNOKhellipPokayokersquosOKNOKhellipProcessParametersPreventiveMaintenanceOKNOKhellipOKNOKhellipProductCharacteristicsOKNOKhellipImage:likeaplanepilot,youneedagreenlighttostartproductionOtherwise,youdonotstart(Or,youproduceonlysuspectparts)OKstpartDailyChecksheetOK!stpartOK!GO!Doneateverystartofshift,processchangeover,breakdownBackupmodeclearlyidentified,availableatworkstationKeepanddisplaystpartOKuntilnextchangeshiftIfnextstartupNOKorcustomerconcern=identifyscopeofsuspectpartsforcontainmentHSEOKNOKhellipSOKNOKhellipTrainingPolyvalenceOKNOKhellipPokayokersquosOKNOKhellipProcessParametersPreventiveMaintenanceOKNOKhellipOKNOKhellipProductCharacteristicsOKNOKhellipasktomakeabrainstorming:whatneedstobecheckedbeforetheproductioncanstartdisplay:thislistisanexampletobeadapted,improvedaccordingtoyourneedsCaution:thestOKpartisthestparthavinggonethroughallstepsoftheprocessafterstartoftheshiftImportantroleoftheGAPleaderandthesupportfunctionstoguaranteeOKstpartqualitybasicVisualManagementofOKstPartqualitybasicVisualManagementofOKstPartReactionrulesforNOKstatusOKprocesschecksheetOKproductchecksheetOKNOKCheckpointWhattocheckHowtocheckWhattodoifNOKValidatedbyGLImage:likeaplanepilot,youneedagreenlighttostartproductionOtherwise,youdonotstart(Or,youproduceonlysuspectparts)OKstPartndashMandatoryRulesOKstpartinstructionsandOKstpartchecksheetsarecreatedoutofcontrolplanTheycover:HSE,S,training,pokayokersquos,processparameters,productcharacteristicsTheydescribewhenOKstpartchecksaretobeperformedAlocationisreadyforthestOKpartForeachcheckitem,checkingmethod,OKcriteriaandreactionrulesaredefinedTheGAPLeadervalidatesOKstpartcheck(stOKpartandchecksheets)IfoneitemormoreisnotOK,productionisnotstarteduntiladulyvalidatedbackupmodeisappliedSuspectpartsaremanagedCultureofselfmanagementandthederogationincaseofNOKPokayoke(FAUSPSG)Scope:SystematicallydetectcatchandblockanerrorbeforeitturnsintoadefectFreethemindtofocusonvalueaddedoperationsaskWhatisPokayokedisplaytextweexpectalothellipaskHowmanykindsofPYexistdisplay:PokaYokeProductpokayokeProcesspokayokeFullyconsistentwithFMEAControlplanUse#redrabbit#(masterparts)tocheckpokayokeIfnotOK:stopproduction,thenapplythereactionrulesSimpleerrorproofingdevicestopreventhumanerrorsEachPokayokemustcontain:ClearinstructionwithreferencenumberCheckingmethodandfrequencyWorkingprincipleBackupmodeincaseoffailureExplanationofprocesspokayoke:Whentheairbagiscut,themachinedrillsaholeinthefoiltoindicatethattheoperationturnedoutOKThefoilmustbehangedupbytheholeAsaresult,evenwithoutinspection,onlygoodfoilscanbestoredPokaYoke,followupTypeofPokaYokeCHANGETHEEXAMPLEPokaYokeVisualManagementAllPYpadlockmustbeturntoredtoensurethePYwillbecheckedagainbeforetherestartingoftheproductionPOKAYOKEPokaYokeMRMANDATORYRULESChecksinserialproductionAllPYrsquosarecheckedvalidated,atthefrequencyrequiredinthecontrolplanForSRcharacteristics,atthestartofeveryshift,breakdown,changeoverorqualityissuewhencharacteristicisimpactedPadlocktagsareturnedtogreenorredaccordingresultActionsareinitiatedaccordingreactionrulesBackupmodeifapplicableandonlyifassafeasthenormaloperationieforSRfasteningcharacteristics:manualinspection(egtorquewrench)visualmarkingoncheckedcharacteristicRecordingofpartsproducedinbackupmode(datendashshiftndashoperatorndashquantityndashmarking)SelfinspectionStopatdefect(FAUSPSG)Scope:Preventanydefectivepartstobepassedonthenextstage(internalCustomer)OperatormusthavetheabilitytojudgewhethertheoperationthatisbeingperformediscorrectSelfinspectionTheoperatorknowshowtojudgeiftheoperationisOKorNOK(ieBoundarysamples,defectsamples)TheoperatorcheckshisworkrightawayTheoperatorknowswhattodoifpartisnotOK:scraporrepairTheoperatorisempoweredtostopthelinemachineatdefect,accordingtoreactionrulesThedefecthastobeanalyzedwiththeteamtotakeimmediateactionsOpenalineQRCIaccordingtothereactionrulesEmpoweredmeanslsquomustrsquostoptheline,notlsquocanrsquo!!!!BULLETPOINTS,ANOTHEREXAMPLETALLYRECORDSHEETStopatdefectMainobjectives:EliminateproblemsReducereworksReduceScrapImproveproductivityGetGAPautonomousImproveproductandprocessknowledgehellipIt#samanagementdecisiontodoitTargetmanualoperationsstdefectContinuousprocessessetyourownlimitsfortotalvaluesandconsecutiveparts,Ultimatetarget:Stopatstdefect!!VideoSelfInspectionndashMandatoryRulesItemsCreateandupdatejobinstructionstipulatinghowtocorrectlyperformthejob,inlinewithControlPlanrequirementsTrainoperatorsforStandardizeWorkValidateacquisitionofskillslevelStrictlyfollowselfinspectionDonottopassanydefectiveparttothenextworkstationEnsurestrictrespectofSelfInspectionwithinStandardizedWorkStopthelinewhenaproblemoccursndashatfirstdefectformanualprocessesatthresholdforcontinuousprocessesTakeimmediateactiontosolvetheproblembyusingQRCIlineIncaseofdefectcreatedupstream:immediatefeedbacktooccurrenceprocessandimmediateactiontocontainandimprovedetectionMonitoreffectivenessofselfinspectionbytrackingmisseddefects,operatorbyoperatorResponsibleSupervisorGAPleaderGAPleaderSupervisorOperatorGAPleaderOperatorGAPTeamSupervisorsFinalInspectionandTQW(FAUSPSG)Scope:Performedafinalinspectionintheproductionlineofthefinalproductrsquoscharacteristics(functional,dimensional)tosystematicallydetectcatchadefectbeforetheproductreachesthefinalcustomerFinalinspectionIndividualmonitoringofmisseddefectsFIisthelastworkstationbeforethecustomerTheoperatormustknowthecheckitems(number,inspectionpaths)whichareregularlyupdatedTheoperatorshouldremovedoublechecksTheFIworkstationandoperatorareclosetothelinetoinformtheGAPleaderifadefectisfoundtosendimmediatefeedbacktotheoperatorsWorkInstructionsdedicatedtoFIIndividualmonitoringtomaketheoperatoraccountableCHANGEEXAMPLEManagementofFinalInspectionVideoListofCheckingpointsVisualmanagementofFIIndividualmonitoringtomaketheoperatoraccountableFinalInspectionndashMandatoryrulesITEMCRITERIAOKNOKCOMMENTSCheckitemsinjobinstructionDerivefromcontrolplanTimeforinspectionisstipulatedinStandardizedWorkNumberofcheckitemsclearlyshownNomorethanCheckitemsupdatedaccordingtoCustomerfeedbackForeachcheckitem:whattocheck,howtocheck,checkfrequency,acceptancecriteria,whattodoincaseNOK(scraporrepair)CheckitemsandinspectionpathdisplayedonworkstationBoundaryandordefectsamplesavailableasneededinjobinstruction,validatedbyCustomerorQualityInspectionworkstationCleanandtidyLightingconditionssameasatCustomerrsquosTrainingOperatorformallytrainedtoeachcheckitemGageRRforappearancedefectsPolyvalencelevelURespectofstandardAnauditofthestandardizedworkwasperformedduringthelastweekTimeforinspectionisrespectedDoublechecksAlldoublecheckschallengedfollowingrulesfortemporaryqualitywallFeedbacktooccurrenceprocessImmediatefeedbacktogapleaderandoccurrenceprocessincaseofdefectCONCLUSION(oneconditionNOK=conclusionNOK)TemporaryQualityWallBeforelaunchofnewproductionproductiontransferorbyManagementdecisionTheoperatorreportstotheproductionsupervisorTheoperatorshoulddoublechecksomeofthefinalinspectionpoints,underthesameconditionsasthefinalinspectorTheoperatorisclosetothelineforimmediatefeedbacktothefinalinspectionincaseofdefectdetectionAconvergenceplanissetupforquickremovaloftheTQW,followedbysupervisorUAPmanagerIndividualmonitoringtomaketheoperatoraccountableQUESTIONSOFQWTemporaryQualityWallValidatedFinalInspectionValidationformTrainedInspectorsIndividualtrackingofmisseddefectsInspectionInstructions(StandardizedWork)NoadditionalordifferentcheckitemcomparedtolineDefectTallySheetDailydefecttrackingconvergenceChartAnddefecttallysheetOnePieceFlowwithlittletonobufferStationislocatedveryclosetothelineforquickfeedbackatdefectIndividualmonitoringtomaketheoperatoraccountableTQWMandatoryRulesTemplateREMOVALOFTEMPORAYQUALITYWALLLineProduct:Dateofaudit:Startingdate:FaureciaNanterre:Monthlycost:Plant:#RespectofMandatoryItemsRefertoFAUSPSG)Status(OKNOKNA)Comments(PreventiveTQWinplaceforSOPortransfert)ConvergenceplanTrainedoperators,sameworkinghoursWorskstationdedicatedtoinspectionTQWclosetothelineBufferminimizedCheckitemsextractedfromfinalinspection,samelayoutIndividualtrackingofmisseddefectsImmediatefeedbackstopthelinedefectQRQCreviewforTQWdefects(Validationofremovalbyquality)Compliancerate:ActionsRequestedSampleREMOVALOFTEMPORAYQUALITYWALLLineProduct:XXXStartingdate:JanstMonthlycost:operatorsfulltimeforlineLLLDateofaudit:MarchstFaureciaNanterre:AA,BB,CCPlant:DD,EE,FF#RespectofMandatoryItemsRefertoFAUSPSG)Status(OKNOKNA)Comments(PreventiveTQWinplaceforSOPortransfert)NAConvergenceplanOKTrainedoperators,sameworkinghoursNOKNotsamecycletime(timeslonger)NoformaltrainingprocesstoeachcheckitemWorskstationdedicatedtoinspectionOKTQWclosetothelineNOKExtensivebufferinbetweenSamelayoutasfinalinspectionNOKCheckfrequencyatTQWiswhereasitisonlyminatendofprocess:thismustnotbeconsideredaqualitywallIndividualtrackingofmisseddefectsNOKSince#finalinspection#ismadeonlyminImmediatefeedbacktolineatdefectNOKTallycountonlyQRQCreviewforTQWdefectsNOK(Validationofremovalbyquality)NACompliancerate:ActionsRequested(Mosturgent):Validateboundarysamples(paintingapperancecriteria)withfinalcustomerHaveallTQWoperatorsformallytrainedtoeachcheckitemFirst,ensureremovalofdefectswithlowfrequency(paintingdefects=)Then,bringbackinspectionoperationsfromTQWintotheprocessStep:inspectionStep:decreasefrequencydowntocontrolplan#sinitialvalue(mn)accordingtoprocessstabilizationRespectConvergencePlantowardsremovalIndividualmonitoringtomaketheoperatoraccountableRedbins(FAUSPSG)Scope:SeparateandisolatenonconformingorsuspectproductsfromtheflowProvidesamplesfordefectanalysis,leadingtotheireradicationRedbinsndashkeypointsTheBinsarecontainers(box,hanger,trolley,rack,etc)toputnonconformingmaterialofanypartoftheprocess(boughtoutparts,semifinishedgoodorfinishedgoods)Scrap(Red)andrepair(Yellow)binsfitthepartsizeandshapePreferably,thecontentofthebinsshouldbevisibleRedandyellowbinsshallneverbeusedasgarbagebins!!!Theoperatoridentifiesthedefectonthenonconformingpartusingredsticker,arrow,tape,cloth,etctoeasefurtheranalysisInsiderepairbins,repairpartsandsuspectpartsarelabeleddifferentlySelfInspectionisfundamentalIndividualmonitoringtomaketheoperatoraccountableRedBinsBinsarezonedproperlyieStopDefectPieces!SCRAPSortingrulesFlowmarkingofbinsracksofnonconformingpartsandthereturnintotheline:RED=Partisscrap,forbiddenorimpossibletoreworkYELLOW=REWORKRedbinsarevisible,inzonedareas,easilyaccessiblebyoperatorsEachnonconformingpartisidentifiedwithitsdefect(s)markedRepairsandscrapsarephysicallyseparated(Gapleaderauditsthecontentofscrapbins)Redbinsareemptyattheendofshift(byGAPleader)RedbinsndashMandatoryrulesSortingLabelingRecordingAnalysisofNOKitemsParetoQRCIonmaincontributorsValidateimprovementManagementoftheBinsandQuickReactionIndividualmonitoringtomaketheoperatoraccountableADDTHERECORDINGANALYSISACTIONOFQRCIReworkunderControl(FAUSPSG)Scope:PerformethenecessaryactivitiestomakeanonconformingproductmeetthequalityrequirementsReworkundercontrolGoodzoningsortingarethemostimportantelement!Reworkisanonsystematic,nonvalueaddingoperationperformedonaproductReworkisawaste,weneedtoeliminateitbyattackingtherootcausesMandatoryRuleMostofSRandQualityalertsarecausebybadcomplianceofbasicmanagementrules!CarefulwithSRparts!IndividualmonitoringtomaketheoperatoraccountableRework=repairnonstandardoperationsGoalisZEROREPAIRSRepairsmustbespecifiedintheControlPlanandWorkinstructions,withacceptancecriteria!!NonstandardoperationsRepairedpartsareidentifiedPartflowisorganizedOnlinerepairSimplerepair(missingcomponent,badrivetinghellip)Immediate,byoperatororGAPLeaderOfflinerepairTechnicallyimpossibleonthelineortakestoomuchtimeQuickly,byGAPLeaderordesignatedoperator,ondedicatedrepairstation(includedinthepolyvalencematrix),accordingtorepairinstructionsRepairsarerecordedIndicatorismanagedRepairstationsaresimpleinexpensiveReworkundercontrolSpecificValidationfromGapLeaderorFinalInspectorExamplesofnonstandardoperations:finishing,adjusting,weldingsplattersremoval,steaming,cleaninghellipNonstandardoperationsarenotrecordedQRCI(FAUSLSG)*WhatisQRCIAMANAGEMENTattitudetoimmediatelyrespondtononperformancestpriority:SecuretheCustomerndpriority:AvoidReoccurrenceuickesponseontinuousmprovementForcustomersatisfactionQICR*ContainmentwithinsamedayorsameshiftforcustomerdefectsQRCIManagementQRCIispacedbydailymanagementroutines,calledQRCIreviews,ateachofthethreelevelsofPlantorganizationManagerassignstasksfortopissuesescalatedfromthelinesEnsurecontainmentofeachcustomerdefectwithinsamedayorsameshiftOperatorstakeaconcreteactiontosolveproblemsimmediately!*Notjustatechnicaltool,itrsquosamanagementtoolQRCIHandbook*keypointsofQRCIREALPLACEREALPARTSREALDATAQUICKRESPONSELOGICALTHINKINGONJOBCOACHINGLOGICALTHINKINGLogicalthinkingreferstotheabilitytoexplainsimplythelogicalsequenceofanalysesandactionsTheproblemishellipTherootcauseishellipTherefore,thecorrectivepreventiveactionsarehellipAndthewaywewillpreventrecurrence(LLS)ishellip*Timing:Process:Keymessages:Definitions:wordbywordtranslationNeedtoUnderstandwhatisbehindComments:KKldquoWhatdoesSanGenShugimeantoaudienceHaveyouheardofSanGenShugiYesGood!SowhatisitWhydidn#tThierrywanttotranslateitintoAmericanEnglishWhyishestillsayinggenba,genbutsu,genjitsuBecauseevenifwetranslateintorealplace,realpartsandreality,youwon#tunderstandthemeaningbehinditIt#sthesameIt#snotalanguageissueWeneedtounderstandthebackgroundbehindthesewordsldquoCapitalizationandTransversalizationWHextractedfromDreport(AddPictures,Sketchestoclearlyshowdefect,adaptsizeifneeded)ONERootcauseextractedfromDreportLinktotheupdatedtemplatewithcompletefillinginstructionsandexamples*Check:whichisimportantfactorlearningduringanalysisWasalearningpointidentifiedWasthisknowledgeusedtoimprovenewproductsWasanewstandardcreatedHasFMEAbeenupdatedThisisarepetitionofD,canbeextractedfromQRCIboardObjective:summarizeforotherplantsprojectsWhatwelearnedthatcanbeappliedinotherplantsprojects*QRCIVisualManagementZoneforQRCIfollowupQRCIboardEvidenceofNOKpartsResumeOKstPartCheckthateverythingisreadytostartproductionandproduceonlygoodpartsPokaYokeSimple,reliabledevicesthatkeepahumanerrorfrombecomingadefectEnabletheoperatortoconcentrateonworkwithoearingmistakesSelfInspectionEachoperatorcanjudgewhetherhisherownoperationisgoodandpassesonlygoodpartsOnthefirstdefect,theoperatorstopsthelineandwarnstheGAPleaderFinalInspectionTQWFullyunderstandthenumber,locationandsequenceofinspectionpointsRedBinsIdentifythedefectonthepart,isolatenonconforms,reworksandscrapareseparatedReworkundercontrolReworkisNonqualityTheGAPleadermustvalidatethereworkQRCILineQRCI:StopproductionandanalyzeatdefectOperatorstakeconcreteactionstoimproveUAPQRCI:ProblemsescalatedfromthelinesPlantQRCI:Customerdefectscontainedwithinhours,taskassignment,logicalthinking,goandseetheshopfloorThankyouforyourattention!**Afterobservationandideasfromattendees,presentOURanswertomeetcustomerexpectationsandcompanyrsquostargetsEachtrainermusthaveacopyoftheBQPtoshowit,toexplainitandtocommentitQBinproductiondevelopment=foundationforBQPBQP=actionShowtheBQP!BQP=enginestotakeoffForabestinclasssupplier,glidingisenough!BQP=topdownapproach,withsimpleandpreciseactionrulesLLStobecreatedduringDSomeofthekeycharacteristicsareSRrequirementsExplainSusingthisslideConsistencybetweenhouseofqualityandFES

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