某汽車8D培訓(xùn)教材課件

Global8D全球8D系統(tǒng)Welcome歡迎來到Global8D全球8D系統(tǒng)Welcome歡迎來到1Course

ContentSectionOverviewofthe8Dprocess&analysistoolsDOPrepareforG8DprocessD1EstablishtheteamD2DescribetheproblemD3DevelopICAsD4Define&verifyRootCause&EscapePointD5Choose&verifyPCAsD6Implement&validatePCASD7PreventrecurrenceD8Recogniseteam&individualcontributionPage6245174110134162203228246CourseContentSectionPage2課程內(nèi)容章節(jié)8D程序及分析工具綜述DO全球8D程序的準(zhǔn)備D1創(chuàng)建工作團(tuán)隊(duì)D2故障描述D3

發(fā)展ICAsD4

定義并驗(yàn)證根本起因和忽略點(diǎn)D5

選擇并確認(rèn)永久性改正行動D6執(zhí)行并驗(yàn)證永久性改正行動D7預(yù)防錯(cuò)誤的重現(xiàn)D8肯定團(tuán)隊(duì)及個(gè)人的貢獻(xiàn)頁數(shù)6245174110134162203228246課程內(nèi)容章節(jié)頁數(shù)3FTEPModulesFordTechnicalEducationProgramTolerance

DesignThreadedFastenerJointDesignSystems

EngineeringFundamentalsStatisticalEngineeringProductReliabilityProcessFundamentalsProcessControlMethodsParameter

DesignManufacturingReliabilityGlobal8DFOASFMEAExperimental

DesignDV&PVAppliedConsumerFocusFTEPModulesFordTechnicalTole4FTEP模塊福特技術(shù)培訓(xùn)項(xiàng)目公差設(shè)置節(jié)點(diǎn)設(shè)置系統(tǒng)工程基本原理

統(tǒng)計(jì)工程產(chǎn)品可靠性過程基本原理過程控制方法參數(shù)設(shè)置制造可靠性全球8DFOASFMEA試驗(yàn)性設(shè)計(jì)DV&PV應(yīng)用顧客焦點(diǎn)FTEP模塊福特技術(shù)培訓(xùn)5Introductions介紹你的姓名你的工作職責(zé)以前對全球8D的了解你想從這門課程中獲得什么YournameYourresponsibilitiesPriorGlobal8DexperienceWhatyouhopetogetoutofthiscourseIntroductions介紹你的姓名Yourname6CourseObjectives課程目標(biāo)Aftercompletingthiscourseyoushouldbeableto:/完成這門課程之后你應(yīng)該能夠:DescribeeachstepintheG8Dprocess描述全球8D課程中的每個(gè)步驟的功能和目標(biāo)EffectivelyparticipateasaG8Dteammemberinyourworkplace在你的工作崗位上以一個(gè)全球8D團(tuán)隊(duì)成員的身份積極有效地參與。HelpFordreachitsgoaltobetheleadingautomotivemanufacturerthroughproductexcellenceandcustomersatisfaction幫助福特達(dá)到其遠(yuǎn)景目標(biāo)：通過提供優(yōu)秀的產(chǎn)品和令顧客滿意的服務(wù)成為世界上汽車制造業(yè)的主導(dǎo)公司。

CourseObjectives課程目標(biāo)Afterc7OverviewoftheG8DProcess全球8D程序綜述TheG8Dprocess全球8D程序:Askswhyaproductorprocessisoperatingoutsideofaperformancestandard考慮一種產(chǎn)品或過程為什么會運(yùn)行于其性能標(biāo)準(zhǔn)之外Seekstodefineandunderstandaproblem尋求對于故障的定義和理解Providesamechanismforidentifyingrootcauseandimplementingappropriatecorrectiveaction提供一種識別故障根本起因的機(jī)制并執(zhí)行合適的矯正行為Identifiestheneedforsystemicchanges,preventingtherecurrenceofaproblemandothersimilarproblems識別系統(tǒng)變化的需要，預(yù)防同一個(gè)故障以及其他類似故障的重現(xiàn)Emphasizesteamsynergy強(qiáng)調(diào)團(tuán)隊(duì)的協(xié)作OverviewoftheG8DProcess8OverviewoftheG8DProcess全球8D程序綜述G8Dalsoaimsto:/G8D還致力于:

Provideacommonprocessthatdefinesandresolvesproblemseffectivelyandpreventstheirrecurrence.提供一種通用的程序有效地定義和解決故障并防止故障的重現(xiàn)Increasemanagementunderstandingofproblemsandproblemresolution加強(qiáng)對故障理解和解決方面的管理Improveconcernresolutionandprevention改進(jìn)故障的解決和預(yù)防Promotefrankandopenproblem-solving鼓勵(lì)率直開放的解決故障的方法OverviewoftheG8DProcess9PhasesoftheG8DProcess

全球8D程序的幾個(gè)階段D0Preparefortheglobal8DprocessD0全球8D程序的準(zhǔn)備D1EstablishtheteamD1創(chuàng)建工作團(tuán)隊(duì)D2DescribetheproblemD2故障描述D3DevelopInterimContainmentActions (ICAs)D3發(fā)展ICAsD4DefineandverifyrootcauseandescapepointD4定義并驗(yàn)證根本起因和忽略點(diǎn)PhasesoftheG8DProcess

全球8D10PhasesoftheG8DProcess

全球8D程序的幾個(gè)階段D5ChooseandverifyPermanentCorrectiveActions(PCAs)forrootcauseandescapepointD5能夠針對根本起因和忽略點(diǎn)來選擇并確認(rèn)永久性的改正行動D6ImplementandvalidatePermanentCorrectiveActions(PCAs)D6執(zhí)行并驗(yàn)證永久性改正行動D7 PreventrecurrenceD7 預(yù)防錯(cuò)誤的重現(xiàn)D8RecogniseteamandindividualcontributionD8肯定團(tuán)隊(duì)及個(gè)人的貢獻(xiàn)PhasesoftheG8DProcess

全球8D11TypesofProblemsituations兩種故障類型Therearetwotypesofproblemsituations:有兩種故障類型:Change-inducedsituations變異引起的情況Never-been-theresituations從未發(fā)生過的情況TypesofProblemsituationsThe12G8Dand6-SigmaDMAIC

全球8D和6-SigmaDMAICTheG8Dprocessisparticularlysuitedtotheresolutionofchangeinducedproblems,orspecialcause.G8D程序?qū)τ诮鉀Q變異或者說特殊起因?qū)е碌墓收系男Ч秋@著的。The6-Sigmaprocessisespeciallysuitedtotheresolutionofneverbeenthereproblems,orcommoncause.6-Sigma方法尤其適合解決從未發(fā)生過的或者說共通起因?qū)е碌墓收?。G8Dand6-SigmaDMAIC

全球8D和6-S13ChangeInduced(G8D)變異導(dǎo)致(G8D)Initially,thesystemoperatesasexpected,butatsomepointitsuddenlydeviatesfromtheexpectedperformancelevel.起初，系統(tǒng)按預(yù)期效果運(yùn)行，但是在某個(gè)節(jié)點(diǎn)上它突然背離了預(yù)期的性能水平Thedeviationmightbeongoing,intermittent,oraone-timeevent(wherethereisalwaysthepotentialitcanreoccur).這種背離也許會持續(xù)、間斷或者僅僅是一次事件（在潛在的某個(gè)位置會重新發(fā)生）Ifthedeviationisintermittentitmighthappenrandomlyorinapattern.如果這種背離是間斷的，它也許會無規(guī)律地發(fā)生，或者按照某種模式發(fā)生Change-inducedproblemsdonotgoawayuntiltherootcauseisfound.變異導(dǎo)致的故障直到根本起因發(fā)現(xiàn)之后才會消失ChangeInduced(G8D)14NeverBeenThere(DMAIC)

從未發(fā)生過(DMAIC)Theperformanceofasystemhasneverachievedtheexpectedlevel.一種系統(tǒng)的性能從未達(dá)到過預(yù)期的水平Thesystemhasoperatedbelowexpectationsfromdayone(incapableprocess).系統(tǒng)從施行那天起就低于預(yù)期水平（無法勝任的程序）Never-been-thereproblemssometimesarecalledaday-onedeviation.從未發(fā)生過的故障有時(shí)稱為本身背離故障。Never-been-thereproblemsmaybeduetoanumberoffactorsincludinginadequatedesignandcommoncausevariation從未發(fā)生過的故障可能是由于許多因素所致，包括不適當(dāng)?shù)脑O(shè)計(jì)和共通起因的變更NeverBeenThere(DMAIC)

從未發(fā)生過15G8Dprocesstools/G8D過程工具FlowchartsthatstepthroughtheG8DprocessandshowthetransitionfromD0-D8.流程圖描述G8D的整個(gè)過程并顯示從D0到D8的轉(zhuǎn)變AssessingquestionstohelpdeterminewheneachphaseoftheG8Dprocessiscomplete.評估故障幫助確定G8D過程的每個(gè)階段什么時(shí)候完成Problem-SolvingWorksheet,to

helpG8DteamstoworkthroughtheG8Dprocess.故障解決工作表

幫助G8D小組完成G8D過程G8DWebapplication/LotusNotesIC8DtotrackthestatusandprogressionofaG8D.

G8D環(huán)球網(wǎng)應(yīng)用軟件/LotusNotesIC8D

跟蹤G8D進(jìn)行狀況和級數(shù)G8Dprocesstools/G8D過程工具Fl16Flowcharts流程圖Flowchartsaredesignedto:流程圖用來:Keeptheteamandthechampionfocusedontasks使小組和負(fù)責(zé)人集中精力于目標(biāo)范圍Serveasanadvancedorganizer作為一個(gè)先進(jìn)的組織者為整個(gè)過程服務(wù)Performaninterimcheckonprogressduringtheprocess在過程中進(jìn)行項(xiàng)目進(jìn)展程度的過渡性檢驗(yàn)Helpidentifywhatresourcesareneededandwhen幫助識別哪些資源是需要的，什么時(shí)候可以獲得BeaguideforcompletingG8Dsteps作為完成全球8D步驟的向?qū)lowcharts流程圖Flowchartsare17Assessing

QuestionsAssessingquestionshelpG8DteamsdetermineifthestepsoftheGlobal8Dprocesshavebeencompletedappropriately.Assessingquestionsaredesignedto:EnsureconsistentapplicationoftheG8DprocessAssisttheteaminachievingG8DdisciplineobjectivesKeeptheteamandthechampionfocusedontasksProvideaqualityassurancecheckServeasanadvancedorganizerPerformaninterimcheckduringtheprocessHelpidentifywhatresourcesareneededandwhenBeachecklistandamemoryjoggerforsuccessfulandeffectivecompletionofG8DstepsAssessingQuestionsAssessingq18評估故障評估故障幫助G8D小組確定G8D過程的每個(gè)步驟是否都是完全合適的評估故障用來:確保G8D過程一致的應(yīng)用程序

幫助小組達(dá)到G8D學(xué)科目標(biāo)使小組和負(fù)責(zé)人集中精力于目標(biāo)范圍

提供一品質(zhì)保證檢查作為一個(gè)先進(jìn)的組織者為整個(gè)過程服務(wù)在程序進(jìn)行中實(shí)施過渡期間檢查幫助識別哪些資源是必需的以及什么時(shí)候需要它們是成功有效地完成G8D步驟的檢查清單和存儲器評估故障評估故障幫助G8D小組確定G8D過程的每個(gè)步驟是否都19Problem-solvingworksheet

故障解決工作表Primarytoolusedbyteamsinidentifyingtherootcauseofaproblem工作表是小組在識別故障根本起因時(shí)使用的主要工具Includesworksheetsfor:/工作表包括:ProblemDescription故障描述ComparativeAnalysis比較分析RootCauseTheories根本起因推測TestingRootCauseTheories測試根本起因推測Problem-solvingworksheet

故障解決20G8DWebapplicationG8D環(huán)球網(wǎng)應(yīng)用軟件TheG8DWebapplicationprovides:

G8D環(huán)球網(wǎng)應(yīng)用軟件:

G8DteamswithavaluabletooltotrackanddocumenttheG8Dprocess./為G8D小組跟蹤并證明8D過程提供了一個(gè)有價(jià)值的工具Additionalstructuretotheproblem-solvingprocessbyaskingforkeyinformationateachstep/通過在每個(gè)步驟尋求關(guān)鍵信息為解決故障過程提供了一個(gè)額外的體系A(chǔ)communicationstoolforteamsnotlocatedtogethergeographically/為位于不同地理位置的小組之間提供了通信工具A"lessonslearned"databaseofpastproblem-solvingeffortswithinFordMotorCompany/在福特汽車公司內(nèi)部提供了一個(gè)對以往解決的故障回顧的數(shù)據(jù)庫G8DWebapplication21ProblemCorrectionandPrevention故障修正和預(yù)防

Areliableproductorprocessisoneinwhichfailuremodesareavoided.可靠的產(chǎn)品或過程產(chǎn)生于失敗的模式被避免之后。Unfortunately,evenwiththemostdisciplinedprocessinplace,somelevelofmistakesisinevitable,andmistakesleadtoproblems.不幸的是，即使在適當(dāng)?shù)奈恢迷O(shè)置最合適的過程，某種程度的錯(cuò)誤還是不可避免，而這些錯(cuò)誤又導(dǎo)致了故障的出現(xiàn)。

ThegoalofG8Disto:/G8D的目標(biāo)是:Correctaproblem修正故障Preventrecurrenceofthisandsimilarproblems預(yù)防同一故障和其他類似故障的重現(xiàn)ProblemCorrectionandPrevent22Inductivevs.DeductiveProblemSolving歸納法vs.演繹法Aninductiveproblemsolvingapproachstartswithdatabasedonobservationsandsetsouttodevelopatheoryconsistentwiththedata.歸納法基于觀測數(shù)據(jù)，旨在形成一種與數(shù)據(jù)一致的推測。Adeductiveproblemsolvingapproachstartswithatheoryandattemptstoprovethatatheoryappliesinaparticularsituationbycollectingandanalysingdataandseeingifthedataisconsistentwiththetheory/演繹法以某種推測為基礎(chǔ)并將這種推測運(yùn)用于某一特殊情況，通過收集并分析數(shù)據(jù)，驗(yàn)證數(shù)據(jù)是否與推測一致。G8Dusesbothinductiveanddeductiveapproachestoresolveaproblem/G8D運(yùn)用歸納法和演繹法來解決故障Inductivevs.DeductiveProble236-Sigma(DMAIC)DMAICisasystematicanddisciplinedapproachtoreducedefectsresultingfromaprocess.EachletterintheDMAICacronymrepresentsadifferentphaseinthemethod:Define:Aproblemisdefinedandapotential6-SigmaDMAICprojectisscopedout.Measure:Dataonthecurrentperformanceoftheprocessismeasured.Analyse:Dataisanalysedtodeterminethesourceoftheproblemandhowtheoutcomeoftheprocessmightbeimprovedtoeliminateit.Improve:Animprovementoptionisselectedandimplemented.Control:Ongoingperformanceismonitoredandcontrolled.Asixthphase,Replicate,hasbeenadded,whichinvolvesreplicatingtheimprovementinotherareasofthecompanyandupdatingthecorporateknowledgebase.6-Sigma(DMAIC)DMAICisasys246-Sigma(DMAIC)DMAIC是一種減少過程中產(chǎn)生缺陷的系統(tǒng)的、統(tǒng)一的方法DMAIC中的每個(gè)字母都是只取首字母的縮寫詞，分別代表了這種方法中的不同階段：定義:

定義故障及潛在的6-SigmaDMAIC項(xiàng)目范圍確定測量:測量當(dāng)前過程的數(shù)據(jù)分析:

分析數(shù)據(jù)，確定故障來源以及過程改進(jìn)方法，從而消除故障改進(jìn):

選擇并執(zhí)行合適的改進(jìn)方法控制:監(jiān)控執(zhí)行新增的第六階段，重復(fù),致力于在公司的其他領(lǐng)域重復(fù)同樣的改善和知識基礎(chǔ)。6-Sigma(DMAIC)DMAIC是一種減少過程中產(chǎn)256-Sigma(DCOV)DCOVisFord’simplementationoftheDesignforSixSigma(DFSS)conceptDCOVusesSixSigmatoolstooptimisetherelationshipbetweencustomerperceivedperformanceanddesignparameters.EachletterofDCOVrepresentsaphaseinthemethod:Define:Customerrequirementsandwantsaresynthesizedintoproductand/orprocesscharacteristics.Characterize:Productandmanufacturingprocessdesignconceptsaregeneratedandselectedandthemannerinwhichthesystemmeetscustomerrequirementsisunderstood.Optimize:Theproductandthemanufacturingprocessdesignareoptimizedtobereliableandrobust.Verify:Theexpectedlevelofperformanceofthenewprocessorproductisconfirmed.6-Sigma(DCOV)DCOVisFord’s266-Sigma(DCOV)DCOV

是福特對6-Sigma概念的設(shè)計(jì)施行DCOV運(yùn)用6-Sigma工具使顧客感知的性能和實(shí)際設(shè)置之間的關(guān)系達(dá)到最優(yōu)化DCOV的每個(gè)字母都代表了這種方法的一個(gè)階段:定義:

顧客的需求被綜合到產(chǎn)品和/或過程特征里特征:產(chǎn)品和制造過程的設(shè)計(jì)概念產(chǎn)生并被選擇好后，滿足顧客需求的系統(tǒng)模式也就被了解了最優(yōu)化:

產(chǎn)品和制造過程設(shè)計(jì)的可靠性和強(qiáng)勁性被最優(yōu)化檢驗(yàn):

新過程或者產(chǎn)品的期待性能水平被驗(yàn)證6-Sigma(DCOV)27ProblemSolving&OtherRelatedProcesses故障解決及其他相關(guān)程序Abriefdescriptionofsomeoftheotherproblem-solvingmethodsinusebothinside&outsideofFord:對福特內(nèi)、外部正在使用的其他解決故障的方法的簡短描述14DHighMileageResolutionProcess(HMRP)高程度解決程序(HMRP)ShaininStructuredInventiveThinking(SIT)構(gòu)筑創(chuàng)造式思維(SIT)ProblemSolving&OtherRelate28D0D029Sectionobjectives:DefinethegoalofD0DescribeEmergencyResponseAction(ERA)DetermineifanERAisrequiredDistinguishbetweenverificationandvalidationChoose,verify,implement,andvalidateanERADeterminewhetherornottousetheG8DprocesstosolveaproblemDescribethefunctionoftheAssessingQuestions/ChecklistD0–“Preparefortheglobal8Dprocess”D0–“Preparefortheglobal830各章節(jié)目標(biāo):定義D0的目標(biāo)描述緊急反應(yīng)行為

確定緊急反應(yīng)行為是否是必需的區(qū)別核實(shí)確認(rèn)和批準(zhǔn)確認(rèn)選定，檢驗(yàn)，執(zhí)行以及驗(yàn)證緊急反應(yīng)行為確定是否使用G8D過程來解決故障描述故障/清單評估的作用D0–“全球8D過程的準(zhǔn)備”各章節(jié)目標(biāo):D0–“全球8D過程的準(zhǔn)備”31WhyShouldIPreparefortheGlobal8DProcess?我為什么要為全球8D過程做準(zhǔn)備?

TheG8Dprocesscanbeintensive.Alotoftime,people,andresourcescanbeinvolvedandwasted,ifusingtheprocessisnotjustified.全球8D過程應(yīng)該是徹底的。很多時(shí)候，如果過程使用不適當(dāng)，人力和財(cái)力將會很棘手并造成浪費(fèi)。D0helpsyoufocusontheproblemsothatyouuseresourcesefficiently.D0幫助你集中精力于故障，所以你可以有效地使用資源。PreparefortheG8DProcess全球8D過程的準(zhǔn)備WhyShouldIPreparefortheG32AnEmergencyResponseAction(ERA)isanyactiontakentoprotectcustomersandaffectedpartiesfromasymptomwhileyoudetermineifaG8Disnecessary.緊急反應(yīng)行動（ERA）是在你確認(rèn)G8D是否必要后所采取的行動，目的在于保護(hù)顧客及相關(guān)受影響的對象不致因一癥狀而蒙受損失。Acustomerisaperson,organisation,orclassofdriverexperiencingsymptoms.顧客可以是一個(gè)人，一個(gè)組織，或者驅(qū)動癥狀產(chǎn)生的某類事物。Affectedpartiesarepeople,organisations,orclassesofdriverswhoareorwillpotentiallybeaffectedbyasymptom.受影響的對象可以是人，組織，或者被癥狀影響或存在潛在影響的某些類事物。EmergencyResponseActions緊急反應(yīng)行動AnEmergencyResponseAction(33Problemsvs.symptoms故障vs.癥狀G8Ddistinguishesbetweenproblemsandsymptoms/G8D把故障和癥狀區(qū)分開來Symptomsaremeasurableeventsoreffects(thatmustbeexperiencedbycustomers)thatindicatetheexistenceofoneormoreproblems癥狀是顯示某一或更多故障中存在的可測量事件或效應(yīng)（必由顧客所經(jīng)歷）Withoutasymptom,youdon’tknowthatthere’saproblem沒有癥狀，你就無法得知故障的存在Problemsvs.symptoms34UsingToolstoMeasureandQuantifySymptoms使用工具測量并量化癥狀Symptomsshouldonlybeconsideredwhentheycanbemeasuredorquantified.只有當(dāng)趨勢可以被測量或者量化的時(shí)候才應(yīng)該被考慮ThereareanumberoftoolscommonlyusedwithinFordtomeasureandquantifysymptoms在福特，通常有許多工具可以用來測量并量化故障因素PaynterChart/Paynter圖Pareto/柏拉圖Run(trend)chart/運(yùn)行（趨勢）圖Hazardplot/Hazard圖UsingToolstoMeasureandQua35Payntercharts/Paynter圖

Helptrackoneormoresymptoms.幫助追蹤與癥狀有關(guān)的一種或多種故障說明Showseffectofproductactions顯示產(chǎn)品作用的效果Canbedisplayedgraphicallyorasatableofdata以圖畫或數(shù)據(jù)表格的形式顯示Payntercharts/Paynter圖Hel36Pareto柏拉圖AParetochartranksallpotentialproblemareasorsourcesaccordingtocostorfrequency柏拉圖將所有產(chǎn)生故障的潛在范圍和因素根據(jù)成本和頻次排列Canhelpsortouttheimportantfewpiecesofdatafromthetrivialmany柏拉圖有助于從瑣碎的眾多因素中挑選出重要的幾類數(shù)據(jù)Pareto柏拉圖AParetochartranks37Run(Trend)Chart

運(yùn)行（趨勢）圖Arun(trend)chartprovidesapictureofprocessvariationovertime運(yùn)行圖顯示了在績效上隨著時(shí)間而產(chǎn)生的方向性變化Itisusedtodiscerndatatrendsorpatterns.運(yùn)行圖用來辨別數(shù)據(jù)變化趨勢或數(shù)據(jù)類型Run(Trend)Chart

運(yùn)行（趨勢）圖Arun38HazardPlot/Hazard圖Useswarrantyrepairinformationtocreateanestimateofhowmanyvehicleswillexperienceaparticularfailuremode使用正確的修理信息對即將產(chǎn)生特殊故障模式的汽車數(shù)量進(jìn)行估計(jì)Candescribethetypeoffailurerate(increasing,decreasing,constant)可以描述故障率的類型（漸增型，漸減型,不變型）Mostusefulforlookingatindividualpartfailuresasopposedtosystemfailures,assystemshavehigherlikelyhoodofmultiplerootcauses對于相對于系統(tǒng)故障的個(gè)別零件故障一般都很有用，因?yàn)橄到y(tǒng)故障更有可能出現(xiàn)重復(fù)的根本起因HazardPlot/Hazard圖Useswarr39某汽車8D培訓(xùn)教材課件40Questions故障Whattwoproblemsarecreatingthegreatestfrequencyofconcerns?哪兩種故障引起關(guān)注的頻次最高？Questions故障Whattwoproblems41Questions故障WhateffectdidERA‘a(chǎn)’&‘b’haveontheproblem,asshowninthePaynterchart?關(guān)于上表中敘述故障，緊急應(yīng)變行動”a”和”b”分別有什么效果?Questions故障WhateffectdidERA42Emergency

ResponseActions

緊急應(yīng)變行動Isbasedontheinformationyouhaveathand它是基于你所掌握的信息而采取的行動Maybeasextensiveasstoppingallshipmentsorasminimalasdoingnothingatall它可能大到停止所有發(fā)運(yùn)，也可能小到什么都不做Isanimmediateimplementation-youdon'tspendalotoftimeresearchinganERA是立即就要采取的措施——你不必事先花很多時(shí)間來研究應(yīng)急措施EmergencyResponseActionsIs43DeterminetheneedforanERA

考慮采取緊急應(yīng)變行動需要作何準(zhǔn)備AnERAisnotalwaysnecessary并不是所有故障都需要采取應(yīng)急措施TheseriousnessoftheproblemanditseffectonthecustomerwilldetermineifanERAisrequired應(yīng)該根據(jù)故障的嚴(yán)重性和它對顧客產(chǎn)生的影響來確定是否需要采取應(yīng)急措施Whereimmediateactionisrequiredduetotheseriousnessoftheproblem,anERAmaybeimplementedbeforetheG8Dteamisformed根據(jù)故障的嚴(yán)重性來決定如何采取應(yīng)急措施。在成立全球8D的團(tuán)隊(duì)之前就可以采取應(yīng)急措施了DeterminetheneedforanERA

44SelectandVerifyanERA

TomakesureanERAwillprotectcustomers,youneedtoverifyittoensureitwillworkasexpectedanddoesnotintroduceanewfailuremode.為了確定應(yīng)急措施可以保護(hù)消費(fèi)者，需要驗(yàn)證它以保證它按照期望的狀態(tài)進(jìn)行，并且不會導(dǎo)致新的失效模式Y(jié)oucanverifyanERAonanon-productionproductsuchasaprototypeorcomputersimulation.你可以在非產(chǎn)品上面做ERA的驗(yàn)證，比如采用模型或者計(jì)算機(jī)模擬的方式

SelectandVerifyanERATom45Implement&ValidateandERA實(shí)施&驗(yàn)證以及ERAPre-customervalidationincludes:先于消費(fèi)者的確認(rèn)包括：Tests測試Inspections檢查Observations觀察Qualitychecksonproductsandprocesses產(chǎn)品和過程中的質(zhì)量檢查Customervalidationincludes:消費(fèi)者的確認(rèn)包括Warrantyanalysis(Paynter)返修事件的起因分析NVQSresultsNVQS結(jié)果Implement&ValidateandERAPr46G8DApplicationCriteria

G8D的適用標(biāo)準(zhǔn)sixcriteriaforinitiatingtheGlobal8Dprocess:開始進(jìn)行全球8D需要滿足六個(gè)要求Symptomdefined該故障的定義Customershavebeenidentified顧客是經(jīng)過鑒別的Performancegapexists該故障存在改進(jìn)的空間Causeisunknown

起因未知Managementiscommittedtofixingtheproblemattherootcauselevelandpreventingrecurrence管理層致力于從根本起因的層面去解決故障并采取預(yù)防措施防止故障再次發(fā)生Complexityofthesymptomexceedstheabilityofonepersontosolvetheproblem故障很復(fù)雜，不可能單憑一個(gè)人的能力完成

G8DApplicationCriteriasixc47ApplicationCriteriaInstructions對運(yùn)用條件的說明

Readthescenarioandthenanswerthefollowingquestions.根據(jù)情況回答以下的故障

1.DoesthesituationdescribedmeettheApplicationCriteria?

該情況是否滿足應(yīng)用8D的條件？

2.Whyorwhynot?

為什么？

ApplicationCriteriaInstructi48Answer答案"ThissituationwarrantsaG8Dproblem-solvingteam.“

對這種情況可以應(yīng)用G8D的解決方法

Answer"Thissituationwarrants49D0AssessingQuestions/ChecklistD0評估故障/故障清單EmergencyResponseAction(ERA)緊急應(yīng)變行動 Toensureconsistencyinapplicationoftheprocess,thelistofquestionsinyourhandbookhasbeendevelopedtoassisttheteaminachievingtheobjectivesofthisdiscipline為確保整個(gè)過程的連貫性，需要建立一個(gè)故障清單幫助團(tuán)隊(duì)達(dá)到本次訓(xùn)練的目標(biāo)D0AssessingQuestions/Checkli50D0Global8DSoftware

D0全球8D軟件Global8DSoftwareatD0

/全球8D的D0階段Additionalstructuretotheproblem-solvingprocessbyaskingforkeyinformationateachstep在故障處理過程中另外還需要了解每一步中的關(guān)鍵信息Acommunicationstoolforteamsnotlocatedtogethergeographically團(tuán)隊(duì)的通訊工具不要放在同一個(gè)地方A“l(fā)essonslearned”database一個(gè)可供學(xué)習(xí)的數(shù)據(jù)庫Accesstosupplierinformation,partinformation,CQIScodes,suppliercodes,vehiclecodes,etc有權(quán)使用供應(yīng)商信息、零件信息、CQIS代碼、供應(yīng)商代碼、汽車代碼等D0Global8DSoftwareGlobal851D0Global8DSoftware全球8D的D0階段D0Global8DSoftware52D0

Quiz

D0測驗(yàn)D0Quiz

D0測驗(yàn)53D0Summary:D0概述PrepareforGlobal8D/全球8D的準(zhǔn)備Inthissectionwehavelookedathowto:在這一階段我們將關(guān)注：UsetheG8DApplicationCriteriatodeterminewhetherornottousetheG8Dprocesstosolveaproblem如何依據(jù)適用標(biāo)準(zhǔn)決定是否需要使用全球8D程序來解決故障Choose,verify,implement,andvalidateanERA如何選擇、驗(yàn)證、實(shí)施并validate緊急應(yīng)對措施UseassessingquestionsateachstepintheG8DprocessasaconfirmationthatyouarereadytomoveontothenextstepintheprocessExplainthekeyfunctionsoftheG8Dsoftware說明全球8D的關(guān)鍵functionsD0Summary:D0概述Inthissectio54D1D155D1–“EstablishtheTeam”

D1-成立工作團(tuán)隊(duì)

ThefocusofD1istoestablishtheteamnecessarytosolvetheproblemandimplementcorrectiveactionsandtobegintheteambuildingprocessD1首先要建立工作團(tuán)隊(duì)，由團(tuán)隊(duì)去解決故障、實(shí)施反應(yīng)措施，并開始團(tuán)隊(duì)建立的流程D1–“EstablishtheTeam”

D1-成56D1SectionObjectives

D1階段目標(biāo)Describetheguidelinesfordeterminingteammembership選擇團(tuán)隊(duì)成員的準(zhǔn)則Describeteamroles,rolefunctions,andhowtheyareimplemented團(tuán)隊(duì)角色、角色構(gòu)成、以及角色之間如何配合行動Explainthethreeelementsofteamoperatingprocedures解釋團(tuán)隊(duì)運(yùn)作程序的三個(gè)要素Describecharacteristicsofteamsynergy描述團(tuán)隊(duì)synergy的特征D1SectionObjectives

D1階段目標(biāo)57EstablishtheTeam

組建團(tuán)隊(duì)

WhyEstablishaTeam?

為什么組建團(tuán)隊(duì)？

D1:EstablishtheTeamiswheretheG8Dprocessreallybegins.建立一個(gè)團(tuán)隊(duì)是全球8D程序真正的開始 ThepurposeofD1istoassembleateamofpeoplewiththecharacteristicsandmotivationneededtosolveaproblem.D1階段的目的是組建一個(gè)團(tuán)隊(duì)，它的成員需要具有解決該故障的相關(guān)技能。EstablishtheTeam

組建團(tuán)隊(duì)Why58TeamMembership

團(tuán)隊(duì)成員Differencebetweengroupsandteams一群人和一個(gè)團(tuán)隊(duì)的區(qū)別Agroupisanumberofindividualswhohaveacommongoal一群人是由一些帶著各自目標(biāo)的個(gè)體組成的Ateamisanumberofindividualsworkingtogetherasacohesiveunittowardacommongoal而一個(gè)團(tuán)隊(duì)是由一群團(tuán)結(jié)一致向著共同目標(biāo)努力的個(gè)體組成的TeamMembership

團(tuán)隊(duì)成員Difference59GuidelinesforTeamMembership

團(tuán)隊(duì)成員資格的指導(dǎo)方針Whendeterminingteammembership:

當(dāng)考慮吸納人員成為團(tuán)隊(duì)成員時(shí)：Limitmembershiptobetweenfourand10members團(tuán)隊(duì)成員的人數(shù)控制在4到10個(gè)之間Choosememberswiththerightskills,knowledge,resources,authority,etc.,tosolvetheproblemathand選擇具有相應(yīng)技能、知識、資源、權(quán)力等的人作為團(tuán)隊(duì)成員，這樣更利于解決故障Choosetherightmixofqualifications各類成員之間合理搭配Changeteammembershipasneeded按需要調(diào)整團(tuán)隊(duì)成員GuidelinesforTeamMembership60GuidelinesforTeamMembership

團(tuán)隊(duì)成員資格的指導(dǎo)方針

Readthescenarioandthenanswerthequestionsthatfollow.

根據(jù)情況回答下面的故障GuidelinesforTeamMembership61TeamRoles

團(tuán)隊(duì)角色

Teammembersneedtoworkaseffectivelyaspossible.團(tuán)隊(duì)的成員應(yīng)該盡可能以高效率的方式工作 TheG8Dprocessdependsupontheeffortsofallteammemberstoachievetheteam‘sobjectives.Todothis,eachteammemberperformsarole.全球8D的過程有賴于團(tuán)隊(duì)所有成員的共同努力去達(dá)到團(tuán)隊(duì)的目標(biāo)，因此每個(gè)成員都有他們自己扮演的角色TeamRoles

團(tuán)隊(duì)角色

Teammembe62某汽車8D培訓(xùn)教材課件63某汽車8D培訓(xùn)教材課件64GuidelinesforImplementingTeamRoles

實(shí)現(xiàn)團(tuán)隊(duì)角色的指導(dǎo)方針

Rolesarenotpeople.Rolesarefunctions角色不是特指某個(gè)人，而是一個(gè)組成部分Membersoftenholdrolesforthedurationofthemeetingorlonger成員通常在會議或更長的時(shí)間內(nèi)充當(dāng)某個(gè)固定的角色Changingrolesduringameetingcanbedisruptive會議中角色的互換會導(dǎo)致混亂Somerolescanbeshared一些角色是可以分享的WhentheLeaderoffersanopinion,heorsheautomaticallyleavestheroleofLeader當(dāng)團(tuán)隊(duì)領(lǐng)導(dǎo)人提出一項(xiàng)建議時(shí)，她或他就自動的偏離了領(lǐng)導(dǎo)這個(gè)角色TheChampionisaroleintheG8Dprocessandisnotconsideredateammember。

Champion是全球8D的一個(gè)角色但不是團(tuán)隊(duì)的成員GuidelinesforImplementingTe65TeamOperatingProcedures

團(tuán)隊(duì)運(yùn)作程序Threeelementsofteamoperatingprocedures:團(tuán)隊(duì)運(yùn)作程序的三個(gè)要素：EstablishGroundRulesforTeamwork

建立基本的角色ConductTask,Maintenance,andProcessObservation設(shè)置分配任務(wù)、項(xiàng)目保持人員以及過程觀察員UseCommunicationSkills運(yùn)用通訊技能

TeamOperatingProcedures

團(tuán)隊(duì)運(yùn)66某汽車8D培訓(xùn)教材課件67TeamOperatingProcedures

團(tuán)隊(duì)運(yùn)作流程Instructions:

介紹Readthescenariothenanswerthequestionsthatfollow讀圖表并回答下面的故障

TeamOperatingProcedures

團(tuán)隊(duì)運(yùn)68某汽車8D培訓(xùn)教材課件69TeamSynergy

團(tuán)隊(duì)協(xié)作

OneofthemainreasonsforformingateamatstepD1istogainsynergy在D1階段成立團(tuán)隊(duì)的主要原因之一在于開展團(tuán)隊(duì)協(xié)作

Synergyoccurswhenthewholeofateam’soutputisgreaterthanthesumofitsinputs當(dāng)團(tuán)隊(duì)的輸出大于其輸入時(shí)，意味著團(tuán)隊(duì)協(xié)作發(fā)生作用了

Synergisticteamscanoutperformcompetitorswhomaybemoreskilledorhavebetterormoreresources一個(gè)相互協(xié)作的團(tuán)隊(duì)可以遠(yuǎn)勝于一個(gè)技能更高或資源更多更好的競爭對手TeamSynergy

團(tuán)隊(duì)協(xié)作

Oneofthe70某汽車8D培訓(xùn)教材課件71D1AssessingQuestions/Checklist評估問題/清單

Toensureconsistencyinapplicationoftheprocess,thelistofquestionsinyourhandbookhasbeendevelopedtoassisttheteaminachievingtheobjectivesofthisdiscipline為確保整個(gè)過程的連貫性，需要建立一個(gè)問題清單幫助團(tuán)隊(duì)達(dá)到本次訓(xùn)練的目標(biāo)D1AssessingQuestions/Checkli72某汽車8D培訓(xùn)教材課件73Global8DSoftwareatD1

全球8D的D1階段

TheD1Teamscreenhastwomainfunctions:D1的團(tuán)隊(duì)screen主要有兩個(gè)作用：TorecordwhoisorhasparticipatedontheGlobal8Dteam記錄有哪些人參加了或曾經(jīng)參加全球8D團(tuán)隊(duì)TocontrolaccesstoG8Ddocuments對可訪問G8D檔案的權(quán)限進(jìn)行控制Global8DSoftwareatD1

全球8D74D1

Quiz

D1測驗(yàn)D1Quiz

D1測驗(yàn)75D1Summary/D1總結(jié)Inthissectionwehavecoveredhowto:本章節(jié)我們介紹了如何：Describetheguidelinesfordeterminingteammembership描述確定團(tuán)隊(duì)角色關(guān)系的原則Describeteamroles,rolefunctions,andhowtheyareimplemented描述團(tuán)隊(duì)角色、角色構(gòu)成、以及它們之間如何合作Explainthethreeelementsofteamoperatingprocedures解釋團(tuán)隊(duì)運(yùn)作流程的三個(gè)要素Describecharacteristicsofteamsynergy描述團(tuán)隊(duì)協(xié)作的特征D1Summary/D1總結(jié)Inthissect76D2D277D2–“DescribetheProblem”

D2-描述問題D2drivestherestoftheG8Dprocess,becauseestablishingaclearproblemstatement

andanobjectiveproblemdescriptionduringD2leadstoeffectiveproblemsolving.

D2驅(qū)動G8D的其他步驟，因?yàn)樵贒2中需要把問題陳述清楚并擬定清晰的目標(biāo)，這樣才能使團(tuán)隊(duì)能夠迅速有效的解決問題。D2helpsteamsfocusontherealproblemandavoidjumpingtoconclusions

ormakingunsubstantiated

assumptionsabouttheproblem.D2幫助團(tuán)隊(duì)關(guān)注問題本身，避免憑主觀的假設(shè)判斷問題，或者對問題作出毫無現(xiàn)實(shí)根據(jù)的判斷。D2–“DescribetheProblem”

D278D2SectionObjectives

D2階段目標(biāo)Explaintheprocessfordescribingaproblem解釋描述問題的過程Identifyprocessflow掌握流程圖Developaproblemstatements進(jìn)行問題陳述Developaproblemdescription

進(jìn)行問題描述D2SectionObjectives

D2階段目標(biāo)Ex79WhyDescribetheProblem?

為什么要對問題進(jìn)行描述

Tobeaneffectiveproblemsolver,youneedtoknowasmuchaspossibleabouttheproblembeforeyoupickasolution.作為一個(gè)有效率的問題解決者，在開始著手解決問題之前你應(yīng)該知道盡可能多的關(guān)于該問題的信息WhyDescribetheProblem?

為什么80Actsasadatabasefordescribingtheproblem在描述問題這一步驟中它充當(dāng)了資料庫的角色DrivestherestoftheG8Dprocess驅(qū)動全球8D的其他階段D2helpsyouavoidinefficiencybyfocusingontheproblemathand.D2:D2幫助你關(guān)注問題本身從而避免無效率的行為Helpsyoudefinetheproblemasaccuratelyaspossible它有助于盡可能準(zhǔn)確的定義問題WhyDescribetheProblem?

為什么要對問題進(jìn)行描述Actsasadatabasefordescrib81Practice練習(xí)Instructions:Readthecasestudyandthendeterminewhatyouthinktheproblemis.說明：閱讀這一例子，然后確定你認(rèn)為問題出在哪兒Practice練習(xí)Instructions:Readt82Observationsvs.Conclusions

觀察報(bào)告VS結(jié)論

Whenyoudescribeaproblem,areyoumakinganobservationorreachingaconclusion?There’sabigdifferencebetweenthetwo.當(dāng)你描述一個(gè)問題時(shí)，你是否做了觀察報(bào)告或是得到一個(gè)結(jié)論？這兩者是有很大的區(qū)別的。Observationsvs.Conclusions

觀83Observationsvs.Conclusions

觀察報(bào)告VS結(jié)論

Sowhat’sthedifferencebetweenanobservationandaconclusion?

觀察報(bào)告和結(jié)論的區(qū)別是什么呢？

Theflowfromobservationtoconclusionislikeaone-waystreet—itseemsimpossibletobackup.Onceaconclusionisreached,itisextremelydifficultformostpeopletoreexaminethefacts.

從觀察報(bào)告到產(chǎn)生的結(jié)論就像一條單行道—是沒有可能倒退的。對于大多數(shù)人來說，一旦產(chǎn)生了結(jié)論，就很難再重新審視事實(shí)。Observationsvs.Conclusions

84Observationsvs.Conclusions

觀察報(bào)告VS結(jié)論Observations觀察報(bào)告Consistofobservable,quantifiableinformation

由可視的及可估量的信息組成Haveahighincidenceofaccuracy

精確性影響范圍較大Tendnottobedisputedsincetheyareusuallyjustalistoffacts

因?yàn)橥ǔＪ抢e事實(shí)，所以無須爭議Usuallydescribewhat,who,when,whereandhowbig

通常需要描述什么問題、誰、時(shí)間、地點(diǎn)和問題的大小Detailtheeffect