First Time Quality PPM TIME

Transcription

1 PPM TIME

2 Training Objectives: To Understand ü What First Time Quality Is ü Why It Is Important ü Why We Need to Measure It ü How to Calculate It ü What the FTQ Deployment Process is ü What the Basic Quality Tools Are ü How to Apply the Quality Tools ü What the Deliverables are that each Plant Will be Responsible for Monitoring and Reporting 2

3 What is First Time Quality? üfirst Time Quality is a measure of the number of pieces rejected in a manufacturing process versus the total number of pieces attempted REJECTS 3

4 Why is FTQ important? ü Because if we don t make good parts the first time, we have to inspect in quality We know inspection is at best 85% effective Therefore, anytime FTQ is greater than 0, we are dependent on inspection to protect the customer ü To reduce manufacturing costs ü To eliminate waste through the value stream and meet customer requirements (takt time) 4

5 The Role of Inspection Catch Defects D D Inspection is like a filter Filter Inspection misses some defects Defects not caught D Voice of the Customer Problem 5

6 The Role of First Time Quality Process Catch & Count defects 1 2 React to LIMITS Follow Reaction Plan Reaction Plan ZERO Defects Forward Voice of the Customer 6

7 The Role of First Time Quality Process Analyze Data Problems Understand Defects and Decide the Order of Priority: A B C D Assign problems to Cross-Functional Group: Responsible Team Works Problems Select and Plan the Improvement: 1 Right Information 2 Right Cause 3 Right Timing DEFECT Hour Glass Fix the Biggest Problems First: 7

8 Why does FTQ need to be measured? ü Main Reasons: It is the first signal that a process is out of control It allows us to respond to problems internally before they reach our customers It measures improvement from corrective actions implemented If we don t fix our quality problems internally, we will never be able to fix our external customer issues 8

9 How is First Time Quality calculated? üftq is reported in parts per million (PPM) defective üit can be measured at any step in the manufacturing process where parts are rejected üit is calculated by counting the number of pieces rejected versus the total number of pieces attempted üthe total number of pieces attempted includes all good pieces produced plus all pieces rejected üpieces rejected are all parts scrapped or reworked prior to usage X 1,000,000 = FTQ PPM by subsequent processes. The actual calculation looks like this: 9 Number of Pcs. Rejected

10 Tally Sheet Operations 1 HR. 2 HRS. 3 HRS. 4 HRS. 5 HRS. 6 HRS. 7 HRS. 8 HRS. How is First Time Quality calculated? ü An example at the cell level: 1 2 Cell A has six operations Reject data is collected at operations 3 and 6 Cell A produced 1040 good pieces during the first hour of production. = X 1,000,000 = PPM FTQ At OP.3, 28 pcs. were rejected. 10 At OP.6, 16 pcs. were rejected.

11 What is the First Time Quality Improvement Process? ü FTQ process defines a common process to be used by all Delphi E & C manufacturing plants to meet the business plan requirements and drive defect-free manufacturing ü The FTQ process defines: Process Steps Stakeholders Deployment Chart (functional flow chart) for identifying lead functions Control Plan for Tracking Implementation 11

12 FTQ Improvement Process YES IMPLEMENT REACTION NO DEFINE REACTION & LIMITS IDENTIFY & COUNT DISCREPANT PARTS EXCEEDED? NO RECORD DATA ANALYZE DATA SELECT & IMPROVEMENT IMPLEMENT IMPROVEMENT EVALUATE NEW LEVEL OF QUALITY? YES INSTITUTION- ALIZE LESSONS LEARNED TOOLS FOR IDENTIFICATION: - PROCESS CONTROL - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: - CONTROL CHART TOOLS: - PARETO - CAUSE & EFFECT (FISHBONE) - CONCENTRATION DIAGRAM - FLOW CHART - HISTOGRAM - SCATTER DIAGRAM - CHECK SHEET - 5 WHY'S EXAMPLES: - CROSS-FUNCTIONAL TEAMS - CHANGE BOARDS - RPN REDUCTION - STATISTICAL ENGINEERING PROJECTS ACTION : - WHAT, WHEN, WHO TOOL: - ACTION TOOL: - RUN CHART - GATE CHART TOOLS: - PFMEA - PROCESS CONTROL - LOOK-ACROSS-CHART - 5 WHY'S IDENTIFY ANALYZE IMPLEMENT EVALUATE 12

13 FTQ Improvement Process CELL 1 Stakeholder Footprint Plant A CELL Plt B 2 3 OPERATOR OPERATOR OPERATOR OPERATOR OPERATOR Plt C N TEAM LEADER CROSS- FUNCTIONAL TEAM MEMBERS: - TEAM LEADER - OPERATIONS/MANUFACTURING - QUALITY ENGINEER - PROCESS ENGINEER - INDUSTRIAL ENGINEER - MAINTENANCE - PRODUCT ENGINEER - SUPPLIER QUALITY PROCESS ENGINEERING MANAGER OPERATIONS MANAGER PRODUCT ENGINEERING MANAGER QUALITY MANAGER MAINTENANCE MANAGER PC&L MANAGER T MANAGER 13

14 Improvement Process Deployment Flow Chart PROCESS CFT DEFINE REACTION & LIMITS QUALITY ENGINEER OPERATIONS PROCESS ENGINEER PRODUCT ENGINEER MAINTENANCE INDUSTRIAL ENGINEER IDENTIFY & COUNT DISCREPANT PARTS IMPLEMENT REACTION (IF EXCEEDED) RECORD DATA ANALYZE DATA SELECT & IMPROVEMENT IMPLEMENT IMPROVEMENT EVALUATE INSTITUTIONALIZE LESSONS LEARNED LEAD SUPPORT 14

15 Process Step 1 DEFINE REACTION S & LIMITS DEFINE REACTION & LIMITS IDENTIFY & COUNT DISCREPANT PARTS IMPLEMENT REACTION YES NO EXCEEDED RECORD? DATA ANALYZE DATA SELECT & IMPROVEMENT IMPLEMENT IMPROVEMENT EVALUATE NO YES INSTITUTION- NEW LEVEL ALIZE OF LESSONS QUALITY? LEARNED Define reaction plan and alarm limits TOOLS FOR IDENTIFICATION: - PROCESS CONTROL - BOUNDARY SAMPLES TOOLS FOR COUNTING: - PARTS COUNTERS - TALLY SHEETS - SIZED CONTAINERS TOOLS: TOOLS: EXAMPLES: TOOL: TOOL: - CONTROL - PARETO - CROSS-FUNCTIONAL - ACTION - RUN CHART CHART - CAUSE & EFFECT TEAM S (FISHBONE) - CHANGE BOARDS - CONCENTRATION - RPN REDUCTION DIAGRAM - STATISTICAL ENGINEERING - FLOW CHART PROJECTS - HISTOGRAM - GATE CHART - SCATTER ACTION : DIAGRAM - WHAT, WHEN, WHO - CHECK SHEET - 5 WHY'S TOOLS: - PFMEA - PROCESS CONTROL - LOOK-ACROSS-CHART - 5 WHY'S You have to start someplace IDENTIFY ANALYZE IMPLEMENT EVALUATE üalarm limits must be based on current process reject data or available data from MQ2, Run at Rate, historical data, etc. üalarm limits must be statistically calculated üalarm limits must be communicated to operators so they can react üif alarm limits are exceeded, there must be a reaction plan to implement 15

16 Process Step 2 IDENTIFY & COUNT DISCREPANT PARTS IMPLEMENT REACTION YES DEFINE NO IDENTIFY & REACTION SELECT & COUNT IMPLEMENT & EXCEEDED RECORD ANALYZE EVALUATE DISCREPANT IMPROVEMENT? DATA DATA IMPROVEMENT PARTS LIMITS TOOLS FOR TOOLS: TOOLS: EXAMPLES: TOOL: TOOL: IDENTIFICATION: - CONTROL - PARETO - CROSS-FUNCTIONAL - ACTION - RUN CHART - PROCESS CONTROL CHART - CAUSE & EFFECT TEAM S (FISHBONE) - CHANGE BOARDS - BOUNDARY SAMPLES - CONCENTRATION - RPN REDUCTION DIAGRAM - STATISTICAL ENGINEERING TOOLS FOR COUNTING: - FLOW CHART PROJECTS - PARTS COUNTERS - HISTOGRAM - GATE CHART - TALLY SHEETS - SCATTER ACTION : - SIZED CONTAINERS DIAGRAM - WHAT, WHEN, WHO - CHECK SHEET - 5 WHY'S NO YES INSTITUTION- NEW LEVEL ALIZE OF LESSONS QUALITY? LEARNED TOOLS: - PFMEA - PROCESS CONTROL - LOOK-ACROSS-CHART - 5 WHY'S Identify and count discrepant parts IDENTIFY ANALYZE IMPLEMENT EVALUATE ü Operators must have sufficient tools and skills in order to identify product discrepancies ü Tools to enhance the operator s ability to identify product discrepancies include: Boundary Samples Illustrations Photographs Gages 16 ü Tools for counting discrepant parts include: Parts Counters Tally Sheets Sized Containers