First Time Quality,2,First Time QualityTraining Module,Training Objectives 培训目标: To Understand 理解 What First Time Quality Is 什么是一次下线合格率? Why It Is Important 一次下线合格率的重要性 Why We Need to Measure It 为什么需要对一次下线合格率进行测量? How to Calculate It 如何计算? What the FTQ Deployment Process is 怎样进行FTQ? What the Basic Quality Tools Are 基本质量工具是什么? How to Apply the Quality Tools 怎样运用基本质量工具? What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 每个工厂应该监控和汇报什么?,3,First Time QualityTraining Module,What is First Time Quality? 什么是一次下线合格率? First Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted 一次下线合格率是测量制造过程中不合格品数与总产品数的比值.,REJECTS,4,First Time QualityTraining Module,Why is FTQ important? 一次下线合格率的重要性 Because if we dont make good parts the first time, we have to inspect in quality 因为如果我们第一次没有生产出好的产品,我们就必须进行检验. We know inspection is at best 85% effective 我们知道检验最多只有85%的有效性. Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer 因而,如果任何时候一次下线合格率大于0,我们都需要依赖检验来保护客户. To reduce manufacturing costs 降低制造成本 To eliminate waste through the value stream and meet customer requirements (take time) 通过价值流和满足客户要求来消除浪费.,5,Catch Defects,Filter,Inspection misses some defects 检验会遗漏一些缺陷,Defects not caught 漏网缺陷,Voice of the Customer 客户的声音,Problem问题,D,D,The Role of Inspection,D,Inspection is like a filter 检验好比一个筛子,6,1,2,Catch & Count defects 抓住并计算缺陷,React to ALARM LIMITS 超过警戒线的反应,Follow Reaction Plan 执行反应计划,Voice of the Customer客户的声音,The Role of First Time Quality Process,Reaction Plan,ZERO Defects Forward,7,Analyze Data分析数据 Understand Defects and Decide the Order of Priority: 理解缺陷并决定优先次序 Assign problems to Cross-Functional Group: 向跨功能小组提出问题 Select and Plan the Improvement: 1.Right Information 2.Right Cause 3.Right Timing 选择并计划改善问题 正确的信息 正确的原因 正确的时间选择 Fix the Biggest Problems First: 首先找到最大的问题所在,Responsible Team Works Problems 相关团队负责解决问题,DEFECT 1. - 2. - 3. -,Hour Glass,The Role of First Time Quality Process,4,3,2,3,2,2,1,1,1,1,8,Inspection Exercise,THE NECESSITY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT.,Count the Number of Fs contained in the paragraph below (60sec) 数一下下面总共出现了几个“F”（60秒）,9,Inspection Exercise,THE NECESSITY OF TRAINING FARMHANDS FOR FIRST CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK IS FOREMOST IN THE MINDS OF FARM OWNERS. SINCE THE FOREFATHERS OF THE FARM OWNERS TRAINED THE FARMHANDS FOR THE FIRST- CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK. THE FARMS OWNERS FEEL THEY SHOULD CARRY ON WITH THE FAMILY TRADITION OF TRAINING FARMHANDS OF FIRST-CLASS FARMS IN THE FATHERLY HANDLING OF FARM LIVESTOCK BECAUSE THEY BELIEVE IT IS THE BASIS OF GOOD FUNDAMENTAL FARM MANAGEMENT.,Total of 36 Fs,10,First Time QualityTraining Module,Why does FTQ need to be measured? 为什么需要测量FTQ Main Reasons 主要原因: It is the first signal that a process is out of control 它是过程失控最先发出的信号 It allows us to respond to problems internally before they reach our customers 它使我们能够在问题到达客户之前先在内部作出反应. It measures improvement from corrective actions implemented 通过执行纠正措施后来衡量问题改善的情况. If we dont fix our quality problems internally, we will never be able to fix our external customer issues 如果我们不能在内部找到质量问题,我们就不能确定外部客户的问题.,11,First Time QualityTraining Module,How is First Time Quality calculated? 如何计算FTQ FTQ is reported in parts per million (PPM) defective FTQ反映每一百万个产品中的缺陷产品数. It can be measured at any step in the manufacturing process where parts are rejected 可以在有拒收产生的制造过程的任何一步测量FTQ. It is calculated by counting the number of pieces rejected versus the total number of pieces attempted 通过以不合格品数除以总数来计算. The total number of pieces attempted includes all good pieces produced plus all pieces rejected 总的产品数包括生产出来的所有合格品数和不合格品数之和. Pieces rejected are all parts scrapped or reworked prior to usage by subsequent processes. The actual calculation looks like this: 不合格品数包括所有报废和经过返工后合格的产品数. 公式: Number of Pcs. Rejected不合格品数 Total Number of Pcs. Attempted总产品数,X 1,000,000 = FTQ PPM,12,First Time QualityTraining Module,How is First Time Quality calculated?如何计算FTQ? An example at the cell level: Cell “A” has six operations A单元有6个操作工序 Reject data is collected at operations 3 and 6 在第三和第六工序收集到不合格品数据 Cell “A” produced 1040 good pieces during the first hour of production. 第一个小时A