品质中心八月总结报告

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,*,品质中心九月份总结报告,品质部,目录,客户投诉分析,内部不良品分析,内部审核,量具检查,外部PPM,客户投诉,8,月份投诉总量,8,月份属生产问题投诉数量,8,月份属非生产问题投诉数量,7,月份投诉总量,汽车定子,14,7,7,5,总成,12,12,0,6,转子,8,6,2,7,机壳,2,1,1,2,门电机,1,0,1,2,合计数量,37,26,11,22,电动车（士杰）,10,7,3,9,8,月份投诉分布情况,7月与8月投诉总量比照,8月份生产管理问题与非生产管理问题投诉的比照,主责定义：属于车间生产过程控制中产生的产品缺陷流到客户。,他责定义：产品在出厂后产生的缺陷例如运输异常、客户自 检把产品破坏等,汽车定子客户投诉主要分布情况,1.湖州德宏混装、槽形不齐、尺寸超差问题。,2.法国Valeo运输变形、错片。,3.大东吴运输过程定子外表磕碰电泳漆划伤,总成客户投诉主要分布情况,1.湖北Remy主要投诉问题：浸漆不饱满、铁芯外表有漆及其他外观问题。,2.德宏及杰诺瑞等客户投诉主要是：引出线问题。,转子客户投诉主要分布情况,1.,重庆颜宏厚度超差问题。,2.,其他客户主要投诉问题：生锈,内部不良品 一车间国外返修,返修（主责）,国外,比例,1,断焊,23.37%,2,接头不牢,21.65%,3,生锈抛光重压,14.71%,4,开口,13.62%,5,不能通规,10.74%,6,整形齿口掉角,3.66%,主责总数,37166,主责返修率,2.941507,返修（它责）,卷绕槽形不齐,它责总数,1452,它责返修率,0.114919,内部不良品 一车间国外报废,报废（主责）,1,齿头压坏,17.23%,2,槽形下陷,10.34%,3,焊坏,7.52%,4,卷绕扎带,7.01%,5,生锈,6.69%,6,平面压坏,5.98%,主责总数,2525,主责报废率,0.199841,报废（它责）,1,卷绕槽形不齐,70.23%,2,试模,23.06%,3,材料原因,6.29%,4,焊机问题,0.42%,它责总数,477,它责报废率,0.037752,内部不良品 一车间国内返修,返修（主责）,国内,比例,1,掉焊,27.82%,2,开口,15.42%,3,接头不牢,14.16%,4,断焊,5.16%,5,外径小,4.26%,6,止口掉角,3.90%,主责总数,51203,主责返修率,7.379347,返修（它责）,卷绕槽形不齐,它责总数,2484,它责返修率,0.357993,报废（主责）,1,齿头压坏,12.76%,2,严重开口,11.76%,3,齿头损坏,9.62%,4,冲槽错位,8.98%,5,槽形规通不过,4.56%,6,外径小,4.38%,主责总数,2194,主责报废率,0.316198,报废（它责）,1,卷绕槽形不齐,77.91%,2,试模,15.58%,3,材料原因,4.47%,4,焊机问题,2.03%,它责总数,738,它责报废率,0.10636,内部不良品 一车间国内报废,7月份,8月份,国内,国外,生产数,2489191,693869,1263502,入库数,2484064,690937,1260977,返修率,3.008,7.737,3.056,报废率,0.206,0.423,0.238,一次合格率,96.786,91.84,96.706,7月份与8月份一车间报废返修比较,8,月份一车间各周报废返修情况,WK31,WK32,WK33,WK34,返修率,4.35396,3.48873,2.7736,2.67890,报废率,0.13928,0.16044,0.15454,0.17241,一次合格率,95.5067,96.3526,97.0728,97.1508,内部不良品机壳返修,返修（主责）,机壳,1,外观不合格,95.51%,2,碰伤,3.34%,3,漏光,1.15%,主责总数,64963,主责返修率,46.07664,内部不良品机壳报废,报废（主责）,1,压痕,34.03%,2,破损,31.95%,3,外观有明显划痕,19.02%,4,漏光,6.84%,5,高度不够,4.61%,6,凸点打坏,3.57%,主责总数,1346,主责报废率,0.954684,7月份与8月份机壳报废返修比较,7月份,8月份,生产数,106291,140989,返修率,49.302,46.077,报废率,0.733,0.955,一次合格率,49.965,52.968,WK31,WK32,WK33,WK34,返修率,40.44881,39.2307,34.69249,12.53676,报废率,0.678822,0.424901,0.328828,2.647059,一次合格率,58.87237,60.34439,64.97868,84.81618,8,月份机壳车间各周报废返修情况,内部不良品转子返修,返修（主责）,转子,1,生锈,26.79%,2,A列内径小,19.13%,3,内径小,11.92%,4,平面度差（需整形）,11.55%,5,烘黄,9.72%,6,高度超差,6.74%,主责总数,32092,主责返修率,1.61,返修（它责）,槽口不齐,它责总数,396,它责返修率,0.0198244,内部不良品,转子,报废（主责）,1,内孔大,18.54%,2,开口,10.78%,3,碰伤,7.87%,4,大回转不正常,7.65%,5,高度矮,7.61%,6,断裂,5.29%,主责总数,22568,主责报废率,1.1297902,报废（它责）,1,槽口不齐,71.89%,2,槽形不齐,19.95%,3,试模,5.25%,4,材料生锈,2.91%,它责总数,4496,它责报废率,0.23,7月份与8月份转子车间报废返修比较,7月份,8月份,生产数,1759933,1997539,入库数,1728517,1970475,返修率,2.054,1.629,报废率,1.785,1.359,一次合格率,96.161,97.02,8,月份转子车间各周报废返修情况,WK31,WK32,WK33,WK34,返修率,3.003974,2.941997,1.761066,1.796826,报废率,1.339862,16.34939,1.757372,0.979451,一次合格率,95.65616,80.70861,96.48156,97.22372,内部不良品绕线车间返修,返修（主责）,绕线车间,1,绝缘纸不到位,47.33%,2,断线,29.01%,3,槽楔纸不到位,21.37%,4,嵌错线,2.29%,主责总数,131,主责返修率,0.062183,返修（它责）,1,相地短路,62.46%,2,相间短路,37.54%,它责总数,2728,它责返修率,0.297623,内部不良品绕线车间报废,报废（主责）,1,变形（主）,22.69%,2,浸漆报废,20.24%,3,伤线（主）,12.74%,4,抛线（主）,11.34%,5,砂头断线（主）,10.12%,6,断线（主）,5.41%,主责总数,573,主责报废率,0.271991,报废（它责）,1,匝间短路(他）,51.83%,2,变形(他）,17.54%,3,铁芯撬片（他）,11.64%,4,伤线（他）,9.25%,5,线圈中间断线（他）,7.18%,6,生锈（他）,0.96%,它责总数,627,它责报废率,1.294922,7月份与8月份绕线车间报废返修比较,7月份,8月份,生产数,176531,210669,入库数,175790,209469,返修率,0.094,1.357,报废率,0.419,0.570,一次合格率,99.486,98.073,8,月份绕线车间各周报废返修情况,WK31,WK32,WK33,WK34,返修率,0.048463,1.444679,0.927229,0.996051,报废率,0.466677,0.42076,0.726143,0.494698,一次合格率,99.48486,98.13456,98.34663,98.50925,8月份各产品生产、报废及返修的比较,一车间国内,一车间国外,机壳,转子,绕线,生产数,693869,1263502,140989,1997539,210669,入库数,690937,1260977,1970475,209469,返修率,7.737,3.056,46.077,1.629,1.357,报废率,0.423,0.238,0.955,1.359,0.570,一次合格率,91.84,96.706,52.968,97.02,98.073,8,月份各车间生产入库情况,8月份各产品生产、报废及返修的比较,内部审核,时间,产品生产线,8,月,1,日,Valeo SG7,总成生产线抽样过程审核,8,月,12,日,Remy,产品生产线过程审核,8,月,25,日,52.5x13.3x26,生产过程审核,8,月,31,日,绕线车间,DR23,总成过程审核,内部审核主要问题,1.Valeo SG7总成生产线抽样过程审核主要问题：,1.车间没有相关工序过程记录卡,2.车间操作工没有检测量具卡尺,3.嵌线工不了解产品引出线角度问题及匝间测试仪点检方法不了解,2.Remy产品生产线过程审核主要问题：,1.车间过程记录卡身背点检卡未填写,2.无专用检具卡尺及油品无标识,3.工艺卡片使用的是老版本。,生产过程审核主要问题：,1.无专用检具千分尺、槽口棒等,2.现控制方案版本过久，需要添加许多内容没有整形工序、模具参数设置等,4.绕线车间DR23总成过程审核,1.无专用检具卡尺,2.控制方案的内容与作业指导书内容不符,3.所有过程记录表单全无,量具检查,量具抽查,车间外购量具抽查,车间内置量具抽查,8,月,24,日量具抽查,1,、外购：电子称：合格证模糊不清或无合格证,带表卡尺：有盒无量具,/,量具盒内有杂物,/,无合格证，量具过期,外径千分尺：量具过期,2,、自制：塞规,/,槽形塞规,/,止口塞规 ：合格证模糊不清,8,月,31,日量具抽查,1,、外购：带表卡尺：量具盒内有杂物,/,无合格证,电子秤：无合格证,2,、自制：槽形塞规,/,塞规,/,止口环规：无合格证,量具检查主要内容,月份,1月,2月,3月,4月,5月,6月,7月,8月,我司质量原因退货数(台),21,0,0,911,35,0,82,0,我司发错货退货数(台),0,0,0,898,0,0,0,0,我司产品混装退货数(台),0,0,4,13,0,0,0,0,运输原因退货数(台),809,3726,905,2800,67,0,4706,0,客户放我司车加工退货数（台),120,0,0,0,0,0,0,0,客户试样后退货数（台),0,0,0,0,0,0,0,0,客户原因退货数(台),196,248,311,8863,21,287,7545,6176,退货总数,1146,3974,1220,13485,123,287,12333,6176,发货总数(台),1070961,688408,1080470,945374,862229,817357,676494,813150,标准值(PPM),150,150,150,150,150,150,150,150,我司质量原因交付不合格率(PPM),20,0,0,964,41,0,121,0,我司发错货交付不合格率(PPM),0,0,0,950,0,0,0,0,我司产品混装交付不合格率(PPM),0,0,4,14,0,0,0,0,运输原因交付不合格率(PPM),755,5412,838,2962,78,0,6956,0,客户放我司车加工交付不合格率（PPM),112,0,0,0,0,0,0,0,客户试样交付不合格率（PPM),0,0,0,0,0,0,0,0,客户原因交付不合格率(PPM),183,360,288,9375,24,351,11153,7595,出厂交付不合格率(PPM),107