玻璃改善案例

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,2013-8-5,#,QDP Project,Ledsjo Glass Process Control Improvement,Edited by,：,Quality control department,update,：,April,2013(wk1318),Goal,Reduce the defect rate from 21% to 8%.,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,裂纹,刮花,口部不平,黑点,Wk1338(13.9,）,Wk1352(13.12),12%,8%,2,team,Define,Measure,Analyze,Improve,Control,小组成员,职位,姓名,职位,职责,项目组长,刘再清,质量经理,负责统筹、协调整个质量改善项目,;,成员,林雪梅,CQI,负责项目指导、项目实施,跟进,.,成员,麦艳池,QA,主管,负责拉线质量标准的制定与考核,.,成员,陈观信,SQE,负责供应商改善项目的确认与技术支持,供应商的考核,.,成员,刘鑫桂,采购员,负责对供应商质量要求的传达与跟踪,供应商的考核,.,成员,李威,总装车间主任,负责来料质量状况的收集、退货与跟踪,.,成员,陆杨,QA,主管,协助拉线缺陷分类的分析,来料质量状况的,反馈,.,成员,张艳佳,文员,负责拉线退货状况的分析与跟踪,.,成员,亿立思,供应商,玻璃不良品问题的改善,.,Extra Light,Ledsjo Glass,Quality,Development,plating,3,Time plan,finish,plan,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,4,Start up Meeting,雅耀内部,雅耀与供应商,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,5,Main defect type of glass with Plato analysis:,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,6,物,机,人,环,法,刮花,Fishbone diagram analysis,Define,Measure,Analyze,Improve,Control,来料碰花,包装设计不当,保护不良,烘炉线碰花,切边时玻璃碎片刮花,烘炉线速度过快,运输过程中碰花,包装方法设计不当,虚位大碰撞,制程碰花,员工操作不当,员工未培训,无作业指引,缺乏包装风险评估,制程刮花,工序安排不合理,吹制机速过快，相互碰撞,Extra Light,Ledsjo Glass,Quality,Development,plating,7,物,机,人,环,法,颈部短,Fishbone diagram analysis,Define,Measure,Analyze,Improve,Control,要求不明确,员工对标准不清晰,作业指导书要求不清晰,样板管理不当,磨具是按照正常壁厚吹制要求开，壁,厚加厚,以后模具,未做相应调整,对客户更改管理不完善,Extra Light,Ledsjo Glass,Quality,Development,plating,8,物,机,人,环,法,变形,Fishbone diagram analysis,Define,Measure,Analyze,Improve,Control,气压不稳定,模温不够,(,未完全预热,),要求不明确,员工对标准不清晰,作业指导书要求不清晰,样板管理不当,Extra Light,Ledsjo Glass,Quality,Development,plating,9,物,机,人,环,法,破碎 裂纹,Fishbone diagram analysis,Define,Measure,Analyze,Improve,Control,烘炉线碰撞,烘炉线速度过快,运输过程中碰撞,包装方法设计不当,虚位大碰撞,制程碰撞,员工操作不当,员工未培训,无作业指引,缺乏包装风险评估,新旧模混用,模具管理不当,模具管理无规范,Extra Light,Ledsjo Glass,Quality,Development,plating,10,Define,Measure,Analyze,Improve,Control,序号,改善行动,责任人,完成日期,完成情况,1,供应商验厂、考核,品控、采购,13.3,close,2,对员工进行系统性的培训与考核,合格后才可上岗,.,亿立思,13.4,close,3,制定工序操作指导书,对,CTQ,工位重点控制并打印挂于拉线指导员工操作,.,亿立思,13.5,close,4,重新评估各工序与出货的包装方法,更改包装,.,亿立思,13.5,close,5,制定玻璃物料检验标准卡,注明,零缺陷要求并传达给供应商,.,陈观信、刘鑫桂,13.5,close,7,建立质量数据库,对玻璃质量情况进行统计、分析,.,亿立思、雅耀,13.6,close,8,制定玻璃,CP(,控制计划,),、,FMEA,对各工序的质量进行控制,特别是相关设备参数,.,亿立思,13.6,On-going,9,制定客户更改管理指引与模具管理规范,(,特别是客户更改时模具的管理,).,亿立思,13.7,On-going,10,制定设备维修保养计划与记录,定期对设备进行保养,.,亿立思,13.7,On-going,改善行动,:,Extra Light,Ledsjo Glass,Quality,Development,plating,11,Define,Measure,Analyze,Improve,Control,改善行动,:,Extra Light,Ledsjo Glass,Quality,Development,plating,12,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,1. MSA:,13,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,1. MSA:,14,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,1. MSA:,15,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,2.,标准化,(,拉线检验指导书,):,16,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,2.,标准化,(,物料检验标准卡,):,17,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,3.,包装改良,:,18,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,4.,工艺改良,:,19,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,20,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality,Development,plating,21,Define,Measure,Analyze,Improve,Control,Extra Light,Ledsjo Glass,Quality Development plating,缺陷描述,原因分析,改善措施,负责人,计划完成日期,完成情况,透光,涂料粘度未达到要求,提高涂料的粘度,增加粘度测试使用粘度以达到要求,张建伟,13.5.20,Y,破碎,运输过程中碰撞,改变包装方式，四周加衬板保护缓冲,徐秀萍,13.,5,.20,Y,黑点,过烘箱时产生,(,退火炉有热风循环系统，因循环原因，会有少量灰尘黏在未硫化玻璃泡上，暂时工艺无法避免，,),全检时检出,徐秀萍,13.,4,.,18,Y,口部不平,割口不平整及涂胶时口部粘胶,割口机刀片位置,调整,巡检次数由每两小时一次改为每一小时一次,及时调整机器，,胡久亮,13.,6,.,10,Y,裂纹,制程碰撞，烘炉线速度过快，烘炉线碰撞,生产过程中避免碰撞,调整烘炉线速度,由,800,改为,600.,胡久亮,13.,6,.,5,Y,22,