WCM精华之QC-Workshop.ppt

1 1QCWorkshopDr.H.YamashinaProfessorEmeritus,KyotoUniversityFellowofRCA(TheU.K.)MemberofRoyalSwedishAcademyofEngineeringSciences19thJuly,20072 2Contents1.JapansQCHistory2.WhatIstheQCProblemSolvingApproach?3.TheQCViewpointVitalforQC-TypeProblemSolving4.QualitySpecificationandProcessCapability5.HowtoImproveProcessCapability6.QualityAssuranceofEveryQualityItem7.TheQCSevenStepFormulaSolvingProblemstheQCWay8.TheFourMajorFactorsInfluencingProcessCapability9.ProcessingPointAnalysis10.DiagnosticTabletoCheckQualityControlKeyQuestions3 3CHAPTERCHAPTER 1JapanJapan sQCHistorysQCHistory4 4TheDevelopmentofJapansQualityControl:aLongJourneyVision,strategySatisfactionsofstakeholdersManagementR&DMarketingProductplanningDesignProductionpreparationBusinessManufacturingtechniquesPurchasingManufacturingQualitycontrolInspectioncontrolInspection QC Process QC Total Quality Control TQM 5 5Majorconceptaboutqualityassurance(ingeneral)1Inspection-orientedqualityassuranceThefirststageofqualityassurance,whichfocusesmainlyoninspectionoffinalproducts,involvesonlytheinspectiondepartmentandthequalitydepartment.Theirmainfunctionsaretopreventdefectiveproductsfrombeingreleasedfromthecompany.Limitations(a)Inspectorsdonotbuildinquality.Theyareextrapeople,whichreduceslaborproductivity.(b)Theresponsibilityofqualityassurancedoesnotbelongtotheinspectiondivision,buttothedesignandproductiondivisions.6 6(c)Itisliabletotaketoomuchtimetofeedbackinformationfromtheinspectiondivisiontotheproductiondivision.(d)Astheproductionspeedisincreased,itbecomesimpossibletomakeinspectionbyhumanbeingproperly.(e)Inordertocarryoutqualitycontrolintermsofppm,thestatisticalsamplingmethodforAQLdoesnotwork.(f)Therearealotofitemswhichcannotbeguaranteedbyinspection.(g)Ifdefectivesareproducedoneafteranotheratprocesses,itisnousecarryingoutstrictinspection.7 72Process-orientedqualityassuranceThesecondstageofqualityassurance,whichfocusesonprocesscontrol,involvestheworkshops,subcontractors,thepurchasingdepartment,theproductionengineeringdepartmentandeventhebusinessdepartment.“100%goodqualityispursuedbyinvestigatingprocesscapabilitycarefullyandcontrollingtheproductionprocessproperly.”“Build-inqualityattheprocess.”We(Toyota)arenotinterestedinbuyingproductsfromthecompanieswhichsellgoodproducts,butinterestedinbuyingproductsfromthecompanieswhichhavegoodproductionprocesses.8 8Thebasicprincipleofqualityassurance:Buildinqualityattheprocess.Theinvestigationanddeterminationofinspectionmethods,measuringequipment,orinspectionfacilitiesatprocessesbecomemajorissues.1.Fromthestageofdesigning,qualityproblemsmustbeinvestigated.2.Throughtrials,hiddenproblemsmustbediscovered.3.Theknowledgeaboutqualityandmaintenanceproblemsatexistingprocessesmustbeusedwhenestablishingnewproductionlines.9 94.100%assuranceoftheprocesscapabilityforqualitymustbemade.5.Themethodofinspectingtheinitialproduct(try-out)anditsfeedbacktoimprovetheprocessesmustbeclarified.6.Developmentofinspectionequipmentattheprocessisvital.7.Introductionoffoolproofdevicestopreventhumanmistakesmustbemade.Limitation(a)Theproblemswhichcamefrombaddevelopmentanddesigncannotbesolvedbytheproductionandinspectiondivisions.(b)Themis-selectionofmaterialcannotbesolvedbyprocesscontrol.10103QualityassuranceinnewproductintroductionThethirdstageofqualityassurance,whichstartsfromdevelopinganewproduct,requirescompany-wideactivitiesfromplanningofthenewproducttoreleasingtheproducttocustomers.Qualityguaranteeatthisstageofdevelopingthenewproducteventuallymeansthatqualitycontrolmustbedonewiththeparticipationofallthedivisionsandalltheemployeesincludingsubcontractors.“Build-inqualityatthedesignandtheprocess.”1111Reasons(a)IfQCisnotpursuedproperlyinnewproductintroduction,satisfactoryqualityguaranteecannotbemade.(b)Ifthecompanymakesafailureinnewproductintroduction,itbecomesamatterofsurvivalordeathforthecompany.(c)Qualityassuranceinnewproductintroductioninvolvesresearch,planning,designing,trialproduction,purchasing,productiontechnology,production,inspection,businessafterservicedepartments.1212procurement10050ThedeterminationcurveoftheproductioncostThegenerationcurveoftheproductioncost0Essential!DevelopmentDesignPrototypeMaterialsManufacturingDeliveryCostweight TheDeterminationCurveandtheGenerationCurveoftheProductionCostFig.1.2:1313IdealTimeforModificationsIdealtimeformodificationsWorsttimeformodificationsPossibilityofqualityandproductivityimprovementCostofmodificationsConceptDevelopmentValidationProductionFig.1.31414PhenomenaSpecsProcessCausesProcessmajoreffectsmediumeffectsminoreffectsDefectmode(custo-mer)DefectiveproductsectionQualitycharacteristicsDefectivemodePrcoesssequenceProcessname123ProcessQAmatrixArticlenameArticlenumberPersonHeadManagerInchargeTable1.1QAMatrix1515 Table1.2QAMatrixA:effectbigB:effectmediumNameofproduct:ABCNameofprocessQAmatrix(Productdevelopmentmanagement)Itemsofproductguaranteeandthedegreeofinfluence(Productdevelopmentmanagement)QualityguaranteeitemsateachprocessGuaranteecharac-teristicsDefectmodeEstimatedcauseThedegreeofinfluenceThedegreeofoccurrenceThedegreeofdetectionChemicalcharac-teristicsElectriccharac-teristicsGuaranteeitemsPhysicalcharac-teristicsPro-cessNo.Spec.valueProblemsatdevelop-mentstage1616*forgotten*overlooked*mistaken*misunderstood*insufficientManContent*manufacturing*handling*manufacturingstandard*lackofaccuracy*wear*breakdown*rawmaterial*auxiliarymaterial*environmentPro-cedureMethodMachineMaterialCauseOperationProcessfunctionDefectivemode1234123Table1.34MAnalysisateachStepofOperationArticlenameArticlenumberDatePersonHeadManagerincharge1717OutlineofequipmentspecificationsProcessFMEA4ManalysisQAmatrixProcesschartEvaluationofequipmentspecifications2ndDR(1)(3)(4)(2)Fig.1.4QualityAssurancebyEquipmentfromEarlyStages1818ExampleTQMActivityofaManufacturingCompany1919100806040200AdministrationClericalworkR&D/DesignTrialMan.ExperimentP.T/F.D.F.ManufactureD.J.ManufactureProductioncontrolProcessing/AssemblyInspectionQ.C./MaintenancetheOthersTotalProductdevelopmentProductionPreparationManufacturing（factory)1086420Numberofpeople(%)ManufacturingQ.C.MaintenanceP.C.ReceivingDeliveryDesignP.T.R&DProductdesignProcessingAssembly/InspectionTheOthersProductionpreparationProductdevelopmentAdministrationSpecialdutyTech.50%ExperimentTrialmanufactureFig.1.5Organization2020Fig.1.6:OrganizationalStructureofaDivisionalHeadQuarterRoles)PromotionofqualityassuranceactivitiesPromotionofqualityassuranceactivitiesfornewproducts,promotionofqualityfornewproducts,promotionofqualitycontrolcontrol ExpeditingcontrolofExpeditingcontrolofnewproducts,newproducts,productioncontrolproductioncontrolProcessplanning,jig,Processplanning,jig,inspectiontoolsinspectiontoolsIncominginspectionIncominginspectionDailymanufacturingDailymanufacturingDivisionalDivisionalheadquarterheadquarterDiv.BDiv.BDiv.ADiv.AQualityassuranceQualityassurancedivisiondivisionPlanningPlanningdivisiondivisionQualitydept.Qualitydept.Inspectiondept.Inspectiondept.Engineeringdiv.Engineeringdiv.Manufacturingdiv.Manufacturingdiv.ProductionProductioncontroldept.controldept.ProductionProductionengineeringdept.engineeringdept.PartinspectionPartinspectiondept.dept.ManufacturingManufacturingdept1dept1ManufacturingManufacturingdept2dept2InspectionoffinalproductsInspectionoffinalproductsAssuranceofdesignqualityAssuranceofdesignquality2121Built-inQualitytoMeetCustomersNeedsPlanningDevelopmentofDesignProductionTechniquesManufactureAfterServiceAssuranceofServiceQualityAssuranceofDesignQualityAssuranceofManufacturingQualityBuild-inOptimalDesignQualityDesignoftheOptimalDesignQualitytoMeetCustomerNeedsFig.1.7:OverviewOfQualityAssuranceActivitiesPromotionofConsistentQualityAssuranceActivitiesQualityControlSystemOfDesignQFDParameterdesignTolerancedesignD.R.FMEA,FTAReliabilitytestingControlofimportantpointsQualityControlSystemofManufactureParameterdesignTolerancedesignInvestigationofprocesscapabilityProcessFMEAAutomaticinspection,foolproofdevicesQAnetworkScreening,DebuggingReliabilitytestingControlofimportantpointsQCcirclesEvaluationofskillsQualityControlEvaluationSystemQCdiagnosisQualityassurancemeetingQualityauditingimprovementmeeting2222ToproduceToproduceattractiveattractiveproductswithproductswithattractiveattractivecostscostsToproduceToproduceproductsbyproductsbymostmostappropriateappropriatedesigndesignTomaketheTomakethemostefficientmostefficientproductionproductionlinesystemlinesystemP Pl la an nn ni in ng gD De ev ve el lo op pmme en nt t D De es si ig gn nP Pr ro od du uc ct ti io on n t te ec ch hn ni iq qu ue es sP Pr ro od du uc ct ti io on nProductiontechniquestoestablishefficientproductionsystemProductiontechniquestocreatemostappropriatelydesignedproductsFig.1.8:Roleofproductionengineering23237 76 65 54 43 32 21 1Planning&Planning&DevelopmentDevelopmentDesignDesignProductionProductiontechniquestechniquesFacilitiesFacilitiesPlanningDevelop-PlanningDevelop-mentmentDesignDesignProductionProductiontechniquestechniquesFacilitiesFacilitiesProductionProductionProductionProductionFig.1.9:SystematicActivitiesfromDesigntoProduction2424*Developmentofproductiontechnique*Developmentofproductiontechniquetosupportoptimallydesignedproductstosupportoptimallydesignedproducts*Shorteningdevelopmentperiod*ShorteningdevelopmentperiodbycarryingtiesbycarryingtiesAimsAims2525NecessaryActivitiesforQualityAssuranceNecessaryActivitiesforQualityAssurancea)QualityControlofDesign*ReliablequalityfunctionQualityfunctiondeployment*ReliableproductdesignSpecificationsofparameters,specificationsoftolerances*ReliablequalityassuranceDesignreview,FMEA,FTA,ontrolofimportantpoints*ReliablequalityconfirmationReliabilitytesting2626b)QualityControlofManufacturing*DesignofreliablemanufacturingprocessesSpecificationofparameters,specificationoftolerances,investigationofprocesscapability*ReliablequalityassuranceProcessFMEA,qualityassuranceovertheentireprocess,controlofimportantpoints,reliabilitytestingduringproductionpreparations*TotalinspectionatthecriticalprocessesAutomatictesting,foolproofdevices,screeningsystem,debuggingsystem*ReliableworkforceQCcircles,evaluationofskills2727c)Evaluationofqualitycontrolactivities*Evaluationofproductquality(Evaluationoftheresult)*Evaluationofthequalityassuranceorganization(Evaluationofthequalityassuranceprocess)QAmeetingQualityauditingsystemQCdiagnosis2828Table1.4QualityAssuranceSystemStepEngineeringDepartmentQualityAssuranceDepartmentManufacturingDepartmentQCRequirementstoManufacturingDepartmentDrawingsAssessmentofEngineeringRequirementsQualityFunctionDeploymentProductPlanningProductionDesignResearchofProductionTechnologyQualitySpecificationsFMEA/FTADesignationofEarly-stageManufacturingControlQualityAudit/ReliabilityTestPrototypeZeroPhaseDesignReview/ZeroPhaseQualityAssurancemeetingFirstDesignReview/FirstQualityAssurancemeetingProductplanningProductDesign/Prototype2929QualityAssuranceSystem(contd)StepEngineeringDepartmentQualityAssuranceDepartmentManufacturingDepartmentProductpreparationMassProductionProcessPlanningPlanningofMachinesandToolsProcessFMEAQualityAudit/ReliabilityTestMassProduction(Early-Stage)InspectionSpecificationsQualityAudit/ReliabilityTestPreparationofmachinesandToolsAssessmentofQualityProcessMassProduction(routine)SecondDesignReview/SecondQualityAssurancemeetingThirdDesignReview/ThirdQualityAssurancemeetingQA.NetworkProcessControlChartReleasefromEarly-StageManufacturingControlPilotProductionProcessCapabilityStudyWorkStandardTrainingofworkers3030Fig.1.10:ConceptofParameterDesign(StabilityDesign)Fig.1.10:ConceptofParameterDesign(StabilityDesign)ItisusefultomakeparameterdesigninordertoassureproductreliabilityItisusefultomakeparameterdesigninordertoassureproductreliabilitydemandedcharacteristicsnoisebetweenproducts(Variationofpartsandmaterialformakingthesameproducts)Variationofitemsdemandedcharacteristicsexternalnoise(Environmentalusedconditionssuchastemperature,humidity,voltageandusecondition)Givenconditionsdemandedcharacteristicsnoiseduetodeterioration(Deteriorationandwearduetousage)SpecifiedperiodA1,B1andC1,arestabledesignparameterstomeetdemandedcharacteristics.3131Fig.1.11:TheStructureofReliabilityTestingDevelopmentDesignPrototypesProcessplanningTrialmassproductionMassproductionDesignchangeprocessReliabilitytesting(Step)ReliabilitytestingofthetrialproductsReliabilitytestingplanReliabilitytestingoftheproductsoftrialmassproductionReliabilitytestofthemassproducedproducts0thDR,0thQAmeetingSecondaryDR,SecondaryQAmeetingFirstlyDR,FirstlyQAmeeting*1-Checkingtheconditionswhichleadtothefailure.Checkingtheapplicabilityoftheproductinuseenvironments.*2-Checkingthereliabilityincludingthevariationscausebymanufacturing.*1*2ReliabilitytestingReliabilitytesting3232Table1.5QAMeetings1stQAmeeting2ndQAmeeting3rdQAmeeting4thQAmeeting5thQAmeetingPlanningtheproductthatwillsatisfycustomers.Realizationofqualitytargets.ImportantqualityspecificationsConfirmationofdesignqualityEvaluationofdegreetowhichqualitytargetshavebeenachievedStipulationofqualitycontrolcriteriaSecuringmachineandprocesscapacityConfirmationofinspectionprocessesandmethodsConfirmationofmanufacturingqualityandprocesscapabilityStrivingforqualityinmanufacturingEnsuringthequalityofincomingmaterialsandpartsConfirmationofthequalityofthenewproductsProductplanningProductdesignPrototypedesign/manufacture/test/evaluationProductionpreparingMassproduction(earlystage)Trialproductiontest/evaluationMassproduction3333Fig.1.12:QualityControlattheManufacturingProcessearlystageproductiontypeofthedistributionsystematicchangetakesplaceInvestigationofprocesscapabilityMachine,lotMaterialTimeSpecifictablesforprocesscontrolstatisticalControlofprocessControlchartChecksheethistogramAutomatictestingFoolproofdevicessporadicControlpointControlitemstrialmassproductionnormalproductionQualityCharacteristicsTimeabnormal3434ProductplanProductdesignTestingproductTrialmassproductionEarlystageproductionUseofprocesscapabilityinformationQAoftheequipmentEquipmentplanningProcessplanningEquipmentdesignManufacturingadjustmentTrialproductionEarlystageproductionQAoftheproductUseofprocesscapabilityinformationFig.1.13:TheStructureofProcessCapabilityCheckingEstablishmentofqualitystandardsCheckingofprocesscapabilityAnalysisofcauseandeffectsImprovementofprocessStandardization,evaluationMaintenanceandimprovementofprocesscapabilityProductionengineeringdiv.Equipmentmanufacturingdiv.Qualitycontroldiv.Manufacturingdiv.Manufacturingdiv.Normalproduction3535Fig.1.14ControllingVariationsofProcessCharacteristicsd-dd+d-d+dtolerancelimitsOUTCOMEOFPROCESSCAPABILITYSTUDYlengthd+3636Developequipmentendowedwithhighprocesscapability(a)DesignengineersControlthevariationsmiddlevalue(b)Productionsite60mToleranceABCFig.1.15Therolesofequipmentdesignengineersanditsoperators3737ProcessFMEAProcessFMEAStudyoftheprocessStudyoftheprocessFacilityprocurementFacilityprocurementInvestigationofprocessInvestigationofprocesscapabilitycapabilityEarly-stageproductionEarly-stageproductionbeforemass-productionbeforemass-productionTransferthemaintenanceTransferthemaintenanceroletotheproductionroletotheproductiondivisiondivisionBuild-indesignqualityatthepr