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8DAnalysis 长安福特完整培训资料.pdf

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DANALYSIS 长安 福特 完整 培训资料
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? 2001 Ford Motor Company ? 2001 Ford Motor Company Global 8D Analysis Yan GuangluG8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Purpose/ A Supplier’ s accurate completion of the G8D Process helps prevent recurrence of problems and improves the Supplier’ s overall manufacturing system. This course provides specific criteria for analyzing a G8D Report from a Supplier, as well as ways of coaching a Supplier through the G8D Process. / G8D G8D G8DG8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Goal/ The goal of the G8D Analysis course is to prepare participants to effectively analyze a Supplier’ s G8D Report. The focus of the analysis is on the identification of the root cause of the problem and the successful implementation of the Corrective Action Plan (CAP), ultimately ensuring improvement of a Supplier’ s manufacturing system./G8D G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Objectives –1 / -1 l Describe the role of an STA Engineer in the G8D Process/ STA G8D l Describe how the request for a G8D reflects on the deficiency of the overall manufacturing system of a Supplier/ G8D l Effectively analyze a G8D Report based upon defined criteria/ G8DG8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Objectives –2 / -2 l Coach a Supplier, as necessary, to perform the total G8D Process to identify the systemic root cause/ G8D l Ensure that the Supplier has verified the root cause by turning the problem on and off/ l Verify that the Supplier has adequately contained all suspect material, including parts already at the assembly plant, in transit, in warehouse, and in process/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Objectives –3 / -3 l Verify that the Supplier is taking corrective action to solve the systemic root cause, including ensuring that the CAP has been transposed into the FMEA, Control Plan, and Process Sheets/ FMEA l Verify that the Supplier has implemented effective ICA and PCA to immediately safeguard Ford plants from receiving defective parts/ l Ensure that the Supplier’ s quality system is capable of quickly responding to a quality problem, containing it, and resolving its cause/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Objectives –4 / -4 l Verify that the prevention steps have been validated and implemented/ l Explain the relationship between G8D and the rest of the quality tools/ G8D l Identify additional resources to assist with the conduct or analysis of a G8D/ G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Global 8D Ford Motor Company’ s method of choice for problem solving/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Notes Concerning Use of the Term “ G8D” / G8D l Encourage Suppliers to use G8D instead of 8D/ G8D 8D u G8D includes important enhancements./G8D u Many assembly plants prefer G8D./ G8D l Term refers to the process and not to the procedures on the Ford G8D database/ G8DG8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Responsibilities in Program/ The STA Program Engineer/ STA : lIssues concerns to Suppliers/ lReviews all G8D Reports/ G8D lCloses or escalates concerns G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Responsibilities in Current Production/ The Ford plant issues concerns, and the STA Site Engineer coaches Suppliers to complete the process./ STA G8D l For Segment 1 and 2 Suppliers/ : u Work closely with them/ u Review all G8D Reports/ G8D l For other Suppliers/ : u Review reports as needed/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Initiation of a Concern/ l AIM: Ford launch teams’ system for processing quality issues/ lQR2: Ford plants’ system for processing quality issues/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Responding to a Concern –1/ -1 l Requires a G8D/ G8D l Coach the Supplier to respond quickly and positively/ : u Ideally, the Supplier should send a representative to the plant./ u If this is not possible, the Supplier should request the part in question./ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Responding to a Concern –2/ -2 l Waiting to respond to a concern sends a negative message/ : u The longer the wait, the more difficult resolution becomes./ u A positive attitude and offer of assistance helps the process go quickly and smoothly./ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Verifying that There Is a Problem/ To confirm that the concern is with the Supplier’ s part, request that the plant/ : lSupply nonconforming parts/ lProvide analysis of non-conformance/ lQuantify the problem/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Continuing with the G8D Process –1/ G8D -1 l Supplier issue/ : u Begin the containment step of G8D/ G8D l Design issue/ : u Begin the G8D Process/ G8D u Get a WERS number/ WERS u Give IQ at the plant the WERS number and supporting documentation/ WERS G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Continuing with the G8D Process –2/ G8D -2 l Plant issue/ : u Begin the G8D Process/ G8D u Assist the plant to verify the problem/ u With supporting documentation and the G8D report, ask the plant supervisor to sign off on the G8D/ G8D G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Completing the G8D Process/ G8D Ford policy is completion within 30 days, but if a concern requires more time, the Supplier should provide an update on/ 30 : l Why the root cause has not been determined and verified/ l The plan to continue the process/ l The timeframe for completion of the process/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Closing a G8D/ G8D In program/ : l Program STA Engineer closes in AIM./ STA AIM In current production/ : l STA Site Engineer should verify completion of the process and close the G8D as necessary./ STA G8D G8D u QR2 may show that a concern is closed but not that a G8D is closed./QR2 G8D u Plants may close a concern after containment but not follow through on G8D process completion./ G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Impacts of a Concern on a Supplier/ l A problem should have been detected and contained earlier/ lImmediately contain defective parts/ l Identify and fix the immediate problem and systemic issues/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company A Deficient G8D/ G8D lAccurate completion of the G8D Process results in benefits for everyone./ G8D lDeficiencies in the G8D Process impact everyone negatively./ G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Impacts of a Deficient G8D on a Supplier’ s Customer/ G8D l Recurrent problems/ l Increased workload/ lDeteriorating relationships l Increased cost/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Impacts on an STA Engineer –1/ STA -1 STA Engineers will have less involvement if they coach Suppliers to/ STA : l Maintain a positive relationship with customers/ l Complete the G8D Process accurately/ G8D l Document the process well in the G8D Report/G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Impacts on an STA Engineer –2/ STA -2 A deficient G8D means increased workload since it involves G8D : l Working closely with the Supplier/ l Analyzing the Supplier’ s G8D Report/ G8D l Ensuring that corrective actions are completed/ l Coaching the Supplier on presentation skills/ l Verifying data in the FMEA, Control Plan, and Process Sheets/ FME G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Benefits of Completing the Process/ For the Supplier/ : l Builds partnering skills/ l Promotes problem solving and prevention/ l Improves quality and productivity/ l Prevents future problems l Improves customer satisfaction/ l Supports ISO/QS registration/ ISO/QS For the Supplier’ s customer/ : l Increases confidence in a Supplier/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company A Quality Process –1/ -1 The basis of a well-written report is accurate completion of the process./ l If a Supplier does not strive for quality in the process, it will be reflected in the report./ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company A Quality Process –2/ -2 l To carry out a quality process, the Supplier must/ : u Select knowledgeable team members/ –Designate in-house experts/ –Send personnel for training/ u Commit time and resources/ u Complete the entire process and document each step/ u Use quality tools/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Referencing Quality Tools –1/ lFTEP Global 8D Participant’ s Guide/FTEP G8D : u A list of supplemental tools for each discipline u Appendix on process tools/ l The Memory Jogger/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Referencing Quality Tools –2/ The STA Engineer/STA : l Must know which tools a Supplier should use/ l Should be prepared to recommend appropriate tools/ l Must ensure reports reflect use of appropriate tools/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Questions the Report Must Answer/ lWhat was the problem? (D2)/ l How will the problem be fixed? (D3 through D6)/ l How will the problem be prevented in the future? (D7)/ G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Answering the Questions/G8D Ensure the report/ : l Demonstrates knowledge / l Identifies and focuses on the root cause/ l Identifies the escape point/ l Defines corrective actions l Identifies the verification of PCA/ PCA l Contains a timely plan to implement PCA/ PCA l Provides proof of absorption into the entire quality systemG8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company Other Criteria/ l Factual/ lSupported by data/ l Self-explanatory/ l Supported by digital pictures or other visuals/ l Concise/G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D Paynter) ERA ICA PCA (Trend) (Pareto) G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D Paynter)G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D (Trend)G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D (Pareto)G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D ERA G8D Analysis ? 2001 Ford Motor Company ? 2001 Ford Motor Company D0 G8D ERA
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