福特汽车公司的8D分析方法.doc

8D分析绪 论欢迎来到8D（8 Disciplines）课程，福特汽车公司使用8D作为问题解决的措施（见QS-9000规定之4.14.1.1）当福特的供方具有零件或过程的问题时，福特规定供方完毕8D过程以拟定主线因素并实行纠正措施背景：解决问题的措施—4.14.1.1 当外部或内部浮现与规范或规定不符合时，供方必须采用有效的解决问题的措施当浮现外部不符合时，供方必须按顾客规定的措施做出反映，参见顾客的有关文献什么是8D？D0：为8D过程做准备D1：成立小组D2：问题的描述D3：拟定临时纠正措施（ICA）的开发D4：拟定和验证主线因素和漏掉点D5：拟定和验证针对主线因素和漏掉点的永久性纠正措施（PCA）D6：实行和确认PCAD7：避免再发生D8：承认小组及个人的奉献8D报告示例Supplier A8D Concern Analysis ReportCONCERN NO:0X0000CONCERN TITLE:Mislabel 483 CA/AADATE OPENED:11/22/00ASSIGNED TO:QR Team(2) Describe Concern:Parts are labeled as 0X00-7D483-CA (Style C), parts are actually 0X00-7D483-AA (Style A).Return authorization 0X0011-00Need to certify next 4 shipmentsPRODUCT LINE:0X00PRODUCT NAME:Snap ring(1) Team MembersMike Paulson, Joan Huber, John DeCarlo, Denise Roxbury, Amy Bloom, Louis Keller, Michelle Fargo, Justine Williams(3) Define and Verify Containment Actions:Checked inventory 11/22/00 for mislabeled totes, 4 pallets found, all marked correctly.Quality Alert issued 11/22/00.Joan Huber in to Livonia to relabel parts 11/28/00 – no need to return parts. There were 39 totes to relabel.(4) Define Root Causes:Shipping department has put several new employees on all shifts, inexperienced packers used incorrect labels.(If additional analysis is required indicate completion dates)Completion Date:(5) % Contribution(each cause)100%(6) Implement Corrective Actions:Conducted meeting with managers and supervisors 11/29/00 to inform them of the issues discussed during the Livonia visit. Materials Manager conducted a meeting 11/30/00 with each shift of packers to retrain them on correct labeling and packaging. They were informed that any further problems with incorrect packaging will result in disciplinary action.(7) Preventative Actions:Purchasing paperwork holders that will be hooked on the front of the pallets and tubs for easier identification. Holders to be delivered weeks of 12/12/00.REPORTED BY:Joan HuberDATE:12/12/00Concurrence:SupervisorDATE:(8) Congratulate your team q:\Customer Corrective Action Reports\8D Blank Form.xls供方的8D报告必须回答问题问题是什么? (D2)问题如何解决? (D3至D6)将来该问题如何避免? (D7)顾客将通过确认8D报告来决定这些问题与否已经回答： 对零件的知识进行了充足论证。

完全拟定了主线因素并聚焦于该因素漏掉点已经被辨认拟定与主线相匹配的纠正措施纠正措施筹划的验证已经被拟定orrection涉及了实行纠正措施的时间筹划有证据显示供方将把纠正措施纳入整个系统8D的好处合适地完毕8D过程，除了能拟定主线因素和纠正问题的好处外，还涉及：对于供方：通过建立小组训练内部合伙的技巧(Discipline 1)推动有效的问题解决和避免技术改善整个质量和生产率避免相似或类似问题的再发生 提高顾客满意度对于顾客增强对供方的产品和过程的信心8D的有效实行需仰赖其她质量工具可靠性 设计验证，产品和过程确认Design ConceptsCraftsmanship潜在失效模式及后果分析 (FMEA)控制筹划 生产件批准程序 (PPAP)/节拍生产记录过程控制(SPC)实验设计 (DOE) 目的供方通过精确完毕8D过程，避免问题的再发生并改善整个制造系统有效分析8D报告分析的焦点是拟定主线因素，成功实行纠正措施筹划（CAP）目的描述顾客的供方技术支持人员在8D过程中的角色8D过程能描述、反映供方整个制造过程的局限性根据定义出的原则有效分析 8D报告例如，报告：涉及足够的细节以支持供方过程的每一步。

涉及紧紧环绕过程的数字化图示定义纠正措施合适地辨认系统的主线因素论证供方如何及时地使问题得到永久性纠正需要时，供方实行整个8D过程以辨认系统的主线因素：列出完毕8D过程的工具(例如, DOE, SPC, FMEA, 散点图, 检查单, 控制图等等).验证供方使用了合适的工具辨认当评审8D报告时需询问的8D报告验证供方与否精确执行和文献化8D过程保证供方通过启动和关闭问题已经验证了主线因素验证供方已经完整涉及所有可疑材料，涉及已经在装配工厂、运送中、仓库和过程中的零件问题的提出供方零件的问题一般分为：In most cases, a c自动问题点矩阵[Automated Issues Matrix (the AIM)]：顾客量产小组在实行质量问题点时提出 质量拒收（Quality Reject）: or 顾客工厂实行质量问题点时提出项目过程中 system. (问题N问题点是供方的职责吗?供方在24小时内以临时纠正措施反映供方规定8D在AIM中顾客项目的问题点在AIM中标记在AIM中关闭下面的流程图显示了项目过程中使用AIM系统导致问题的提出YResponding to a ConcernNo matter how a concern is issued or from whom, the concern requires an 8D as a response. Once again, to encourage a good working relationship between the Supplier and the Supplier’s customer, the STA Engineer should coach the Supplier to respond quickly, within at least 24 hours, to any concern that a plant has.Ideally, the Supplier should send a representative to the plant to review the concern and help determine the root cause of the problemIf the Supplier cannot send a representative to the plant, the Supplier should request that the part in question be shipped immediately to them so the Supplier can help resolve the concern.Waiting to respond to a concern sends a negative message to the Supplier’s customer. The longer a Supplier waits to respond, the more difficult it will be for the Supplier to resolve the concern. Responding with a positive attitude and an offer of assistance will make the process go quickly and smoothly.在现行生产中下面的流程图显示了在现行生产中使用QR导致问题的提出。

N问题点是供方的职责吗?供方在24小时以临时纠正措施反映供方被规定8DQR中工厂问题点问题QR问题点到供方改善矩阵顾客重新拟定职责例子：S公司为顾客制造零件，见下图：A根据顾客的工程规范，在零件A上必须镀银，否则顾客的产品无法完毕规定功能有一天，她们收到顾客工厂发来的问题点如下：由于没有镀银导致产品缺陷，整批拒收零件号H00651A501批号MT001206缺陷数39片缺陷种类没有电镀规定问题关闭日期1月03日问题：S公司应当如何反映？问题的反映不管问题如何提出或来自谁，都规定8D过程作为反映 为鼓励供方和顾客之间的良好联系，顾客的工程师应当供方以在24小时内对任何问题迅速反映抱负地，供方应当派一种代表到工厂评审问题，协助拟定问题的主线因素在派代表前，供方应当和工厂进货质量人员一起检查，如零件挑选如供方不能派代表到工厂，供方应祈求有问题的零件立即发运给它们以便供方可。