APQP Control Plan

H thng qun l cht lng Cc yu cu ring cho s p dng ISO 9001:2000 i vi cc t chc sn xut v cc dch v lin qu

Technical specification APQP-Control plan

Li gii thiuMc ch ca s tay ny l trao i thng tin gia cc nh cung cp (ni b v bn ngoi) v cc nh thu ph, li hng dn chung ca Control Plan v hoch nh cht lng sn phm c xy dng bi t hp cc nh sn xut t Chrysler, Ford v General Motor. S tay cht lng ny cung cp cc hng dn a ra mt k hoch cht lng sn phm s h tr s pht trin ca sn phm hay dch v m lm tho mn khch hng (xem phn 1.6). Thut ng sn phm s c s dng trong sut s tay ny v ngha c hiu nh hoc sn phm hoc dch v. Thut ng nh cung cp cng s c s dng trong sut s tay ny v c d nh p dng cho tt c cc nh cung cp v cc nh thu ph. Mt s li ch mong i trong vic s dng cc hng dn l: gim s phc tp ca qu trnh hoch nh cht lng sn phm cho khch hng v nh cung cp.

mt cch thc cho nh cung cp trao i d dng cc yu cu hoch nh cht lng sn phm cho nh thu ph.

S tay tham kho ny cha ng cc hng dn m h tr cc yu cu c miu t trong cc yu cu h thng cht lng ca Chrysler, Ford, General motor.

Tt c cc biu mu trong s tay ny c cung cp nh l mt th d. Mc ch l tr gip Nhm Hoch nh Cht lng Sn phm trong vic xy dng cc biu mu trao i ph hp h tr vic p ng vc yu cu, nhu cu v s k vng ca khch hng.Cc t s, nn-shall, phi ch ra cc yu cu c tnh bt buc. T nn-should ch ra mt cch tip cn thch hp hn. Cc cch tip cn khc nhau c chn bi nh cung cp phi c th ch ra rng cch tip cn ca h p ng c mc ch ca s tay ny. Khi cc t c th v v d c dng, s la chn ph hp mt trong hai cho mt hng ring bit hay qu trnh nn c la chn.Vng trn hoch nh k hoch cht lng sn phm ch ra trn b mt trang giy l biu hoc cc chng trnh c th. Cc giai on khc nhau c sp xp ni tip nhau miu t thi gian hoch nh nhm chp hnh cc chc nng miu t. Mc ch ca vng trn hoch nh cht lng sn phm l nhn mnh: Lp k hoch t trn n trc: Gc 3/4 ca vng trn c dnh cho vic hoch nh cht lng sn phm t trn n trc thng qua s ph chun sn phm/qu trnh. Hnh ng thc hin: Gc 4/4 la giai on quan trng ca vic nh gi u vo tch ra thnh hai chc nng: + xc nhn nn khch hng c tho mn, v:

+ h tr hnh ng ca qu trnh ci tin thng xuyn.Vic m t qu trnh hoch nh cht lng sn phm nh mt vng trn minh ho khng bao gi c im kt thc ca qu trnh ci tin thng xuyn m c th t c bng cch nm bt kinh nghim trong mt chng trnh v vic p dng m yu cu s hiu bit n chng trnh tip theo.

Ma trn trch nhim hoch nh cht lng sn phmMa trn ch ra di y miu t cc chc nng hoch nh cht lng sn phm cho 3 loi hnh ca nh cung cp. N nhm tr gip cc nh cung cp trong vic xc nh vai tr cc trch nhim hoch nh ca h. Tham kho ti nn tng ca vic hoch nh cht lng sn phm trang bn. Ma trn khng miu t tt c cc chng loi khc nhau ca cc mi quan h n vic hoch nh cht lng sn phm m c th tn ti trong cc nh cung cp, nh thu ph v khch hng.Trch nhim ca thit kCh i vi Sn xutKho bi, vn chuyn

Xc nh vai trxxx

Hoch nh v xc nh (phn 1.0)x

Thit k v pht trin sn phm (phn 2.0)x

Tnh kh thi (phn 2.13)xxx

Thit k v pht trin qu trnh (phn 3.0)xxx

Ph chun sn phm v qu trnh(phn 4.0)xxx

Thng tin phn hi, nh gi v hnh ng khc phc (phn 5.0)xxx

Phng php k hoch kim sot(phn 6.0)xxx

Tham kho ti phn ch dn cc yu cu h thng cht lng ca Chrysler, Ford, General Motor di c kh nng p dng xc nhn cc phn ph hp ca s tay ny m p dng.

Nn tng c bn ca hoch nh cht lng sn phmHoch nh cht lng sn phm l mt phng php xy dng v vic xc nh v thit lp cc bc cn thit m bo rng sn phm lm tho mn khch hng. Mc tiu ca hoch nh cht lng sn phm l lm d dng s trao i vi mi ngi lin quan m bo rng tt cc bc yu cu c hon thnh ng thi gian. Hiu qu ca vic hoch inh cht lng sn phm ph thuc vo s cam kt ca lnh o cp trn ca cng ty n s l lc c yu cu trong vic t c s tho mn ca khch hng. Mt vi li ch ca hoch nh cht lng sn phm l: hng ti cc ngun lm tho mn khch hng.

nng cao s nhn bit d dng ca cc thay i c yu cu.

trnh cc thay i tr.

cung cp sn phm cht lng kp thi vi chi ph thp nht.Cng vic thc hnh, trang thit b v k thut thng k c miu t trong s tay cht lng ny c lit k trong mt trnh t logic to ra dng chy d hiu. Mi mt k hoch cht lng sn phm l duy nht. Thi gian chnh xc v trnh t chp hnh ph thuc vo cc nhu cu v k vng ca khch hng v/hoc cc vn thc t khc. Mt cng vic thc hnh, thit b v/hoc k thut thng k d dng hn c th c thc hin trong vng trn hoch nh cht lng sn phm.1. Thnh lp nhmBc u tin ca nh cung cp trong vic hoch nh cht lng sn phm l tr gip trch nhim ti nhm chc nng an cho. Vic hoch nh cht lng sn phm hiu qu yu cu khng ch mi phng cht lng m cc phng ban lin quan khc. Nhm ban u nn bao gm cc i din t cng ngh, ch to, kim sot vt liu, mua hng, cht lng, bn hng, dch v, cc nh thu ph v khch hng.2. Xc nh phm vi

N rt quan trng i vi nhm hoch nh cht lng sn phm trong giai on sm nht ca chng trnh sn phm nhn bit cc nhu cu, k vng v cc yu cu ca khch hng. mc ti thiu, nhm phi p ng : la chn mt ngi trng nhm ca d n c trch nhim v quan st qu trnh hoch nh. (trong vi trng hp n c th thun li thay i lun phin trng nhm trong sut vng trn hoch nh)

nhn bit cc khch hng ni b v bn ngoi. xc nh cc yu cu ca khch hng. (s dng QFD nu c th p dng, tham kho trong ph lc B) la chn cc nguyn tc, cc c nhn v/hoc cc nh thu ph m phi c thm vo nhm, v iu khng yu cu. Hiu c mong mun ca khch hng,.., thit k, s ln kim tra. nh gi tnh kh thi ca thit k d nh, cc yu cu thc hin v qu trnh ch to.

nhn bit cc chi ph, thi gian v cc p buc phi c xem xt.

xc nh s gip c yu cu t khch hng.

nhn bit qu trnh hay phng php vn bn ho.3. Phi hp nhmNhm hoch nh cht lng sn phm phi thit lp ng dy trao i thng tin vi cc khch hng khc v cc nhm cung cp. iu ny c th bao gm cc cuc hp u n vi cc nhm khc. S m rng lin lc ca nhm ph thuc vo s gii php yu cu ban hnh.4. o toS thnh cng ca k hoch cht lng sn phm ph thuc vo mt chng trnh o to hiu qu m trao i tt c cc yu cu v k nng pht trin thc hin cc nhu cu v s mong mi ca khch hng.5. Khch hng v nh cung cp lin quanKhch hng ch o c th xng qu trnh hoch nh cht lng vi nh cung cp. Tuy nhin, nh cung cp c bn phn xy dng mt nhm chc nng an cho qun l qu trnh hoch nh cht lng sn phm. Cc nh cung cp phi trng ch s thc hin ging nhau t cc nh thu ph ca h.6. Simultaneous engineering

Simultaneous engineering l mt quy trnh khi m cc nhm chc nng an cho phn u cho mc ch chung. N thay th cc chui tip theo ca cc giai on khi cc kt qu c chuyn ti khu vc thc hin k tip vi mc ch hoch nh cht lng sn phm sm hn. Nhm hoch nh cht lng sn phm m bo rng k hoch ca cc khu vc/nhm khc v cc hot ng m h tr mc tiu chung.7. Cc k hoch kim sot

Cc k hoch kim sot c tho ra miu t cc h thng v vic kim sot chi tit v qu trnh. Cc k hoch ring bit bao qut 3 phn tch bit nhau: To mu: miu t s o lng kch thc, nguyn vt liu v s thc hin kim tra m s xy ra trong sut qu trnh xy dng mu.

Sn xut th: miu t s o lng kch thc, nguyn vt liu v thc hin kim tra m s xy ra sau to mu v trc sn xut hon ton.

Sn xut hng lot: mt s dn chng ton din bng vn bn v cc c trng ca sn phm/qu trnh, kim sot qu trnh, kim tra, v h thng o lng m s xy ra trong sut qu trnh sn xut hng lot.8. Gii php lin quanTrong qu trnh hoch nh, nhm s gp mt s kh khn lin quan ti thit k v gia cng sn phm. Cc vn nn c vn bn ho trn mt ma trn c phn nh r trch nhim v thi gian thc hin. Trong cc tnh hung kh khn cc phng php gii quyt vn c nguyn tc nn c khuyn khch a ra. K thut phn tch c miu t trong ph lc B.9. Hoch nh thi gian cht lng sn phm

Trnh t u tin ca nhm hoch nh cht lng sn phm v kinh doanh theo nh cc hnh vi c tnh t chc nn l s xp dng k hoch thi gian. Chng loi sn phm, phc tp, cc mong mi ca khch hng nn c xem xt trong vic la chn cc yu t thi gian m phi c lp k hoch v lp biu . Tt c thnh vin ca nhm nn chp thun vi tng s kin, hnh ng v thi gian. Mt biu thi gian c t chc tt nn lit k cc nhim v, cc trch nhim v/hoc cc s kin khc. (phng php ng dn tiu chun c th p dng; tham kho ph lc B) Biu cng cung cp nhm hoch nh vi mt nh dng nht qun cho vic truy tm tin v b tr cuc hp ngh s. lm cho d dng vic bo co cc tnh trng, mi s kin phi c ngy bt u v ngy hon thnh vi mc ch chnh xc v tin c ghi li. Vic bo co tnh trng hiu qu h tr cho chng trnh nh gi vi s tp trung vo cc hng mc nhn bit m yu cu mc ch r rng.10. Cc k hoch lin quan ti biu thi gianS thnh cng ca mt vi chng trnh ph thuc vo vic p ng cc nhu cu v mong mi ca khch hng kp thi vi chi ph m biu trng l gi tr. Biu thi gian hoch nh cht lng sn phm di v vng trn hoch nh cht lng sn phm miu t, yu cu trc mt nhm hoch nh tp trung cc l lc vo phng nga khuyt tt. Phng nga khuyt tt c hoch nh bi Simultaneous Engineering cho vic thc hin bi cc hnh vi ca cng ngh ch to v sn phm din ra ng thi. Cc nhm hoch nh phi c chun b vic chnh sa cc k hoch cht lng sn phm p ng c cc mong mi ca khch hng. Nhm hoch nh cht lng sn phm c trch nhim v vic m bo rng thi gian p ng hoc vt qu k hoch thi gian ca khch hng.Biu thi gian hoch nh cht lng sn phm

1.0 Lp k hoch v xc nh chng trnhBiu thi gian hoch nh cht lng sn phm

u ra: Cc kt qu ca thit k

Cc kt qu tin cy v cht lng

BOM s b

Biu dng chy qu trnh s b

Lp danh mc v cc c trng ca sn phm v qu trnh c th s b

K hoch bo hnh sn phm

H tr ca lnh o1. Hng dnPhn ny miu t lm th no xc nh cc nhu cu v k vng ca khch hng cho vic lp k hoch v xc nh chng trnh cht lng. Tt c cng vic phi c lm vi khch hng lun lun ghi nh rng; cung cp tt hn sn phm v dch v so vi i th cnh tranh. Giai on u ca qu trnh hoch nh cht lng sn phm c cng m bo rng cc nhu cu v k vng ca khch hng c hiu thu.u vo v u ra c kh nng p dng ti qu trnh c th bin i theo qu trnh ca sn phm v cc nhu cu v k vng ca khch hng. Mt s gii thiu c cp trong phn ny nh sau:

u vo: Ting ni ca khch hng+ Nghin cu th trng

+ Lch s bo hnh v thng tin v cht lng

+ Kinh nghim ca nhm

K hoch kinh doanh/chin lc tip th

D liu chun ca sn phm/qu trnh

Cc gi nh v sn phm/qu trnh

Nghin cu tin cy ca sn phm

u vo ca khch hng

u ra (l u vo cho phn 2):

Cc kt qu ca thit k


BOM s b




H tr qun l

1.1. Ting ni ca khch hngTing ni ca khch hng bao gm cc phn nn, ngh, d liu v thng tin t c t cc khch hng ni b v/hoc bn ngoi. Mt s phng php v vic thu thp thng tin ny cp trong cc on mc di y.1.1.1. Nghin cu th trng

Nhm hoch nh cht lng cht lng sn phm c th cn t c d liu v thng tin nghin cu th trng c phn nh t ting ni ca khch hng. Cc ngun theo sau c th tr gip trong vic nhn bit cc lin quan/ nhu cu ca khch hng v bin cc lin quan thnh cc c trng ca qu trnh v sn phm. Phng vn khch hng Bn cu hi v kho st khch hng

Cc bo co xc nh x tr v kim tra th trng

Nghin cu tnh kh thi v cht lng ca sn phm mi

Nghin cu cht lng sn phm ca i th

Cc bo co Things gone right (TGD)

1.1.2. Lch s bo hnh v thng tin v cht lng

Mt bng danh mc v lch s cc lin quan/nhu cu ca khch hng nn c chun b nh gi tim nng v s ti din trong sut qu trnh thit k, ch to, lp t v cng dng ca sn phm. Cc iu nn c xem xt nh l mt s m rng v cc yu cu thit k khc v lin quan ti s phn tch cc nhu cu ca khch hng.Nhiu hng mc theo sau c th tr gip nhm trong vic nhn bit cc vn lin quan/mong mun ca khch hng v u tin cc gii php ph hp. Cc bo co TGR

Cc h s bo hnh

Cc ch th c kh nng

Cc h s gii quyt vn

Loi b v tr hng bi phn xng ca khch hng

Phn tch cc sn phm b tr v

1.1.3. Kinh nghim ca nhm

Nhm c th s dng vi ngun thng tin, bao gm: u vo t trnh ca h thng cao hn v cc d n xy dng chc nng cht lng (QFD) trong qu kh

Phn tch v bnh lun cc ghi chp ca bo ch v tp ch

Cc ngh v th ca khch hng

Cc bo co TGD/TGW (things gone wrong)

Cc bnh lun ca dn bun bn

Cc bnh lun ca khu iu hnh

Cc bo co dch v

Cc nh gi ni b c s dng bi ngi i din khch hng Cc bnh lun ca lnh o

Cc yu cu ca chnh ph v ngh nh

Xem xt hp ng

1.2. K hoch kinh doanh/chin lc tip th

K hoch kinh doanh v chin lc tip th ca khch hng s t ra b khung cho k hoch cht lng sn phm. K hoch kinh doanh c th t p buc (thi gian, chi ph, u t, xc nh v tr ca sn phm, cc ngun nghin cu v pht trin (R&D)) i vi nhm m tc ng trc tip hnh ng a ra. Chin lc tip th s xc nh khch hng mc tiu, cha kho mc tiu bn hng, v cc i th chnh.1.3. D liu chun ca sn phm/qu trnh

Cng dng ca vic ly du chun (tham kho ph lc B) s cung cp u vo xy dng cc mc tiu thc hin ca sn phm/qu trnh. Vic nghin cu v pht trin cng c th cung cp cc du chun v cc kin khi nim. Mt phng php ti vic ly du chun thnh cng l:

Nhn bit c cc du chun ph hp

Hiu nguyn nhn v s gt qung gia tnh trng hin ti ca bn v du chun Xy dng mt k hoch hoc lp i s gt qung, tnh ton du chun, hoc vt qu du chun1.4. Cc gi nh ca sn phm/qu trnh

s l cc gi nh rng sn phm cha ng cc c im, thit k, hoc cc khi nim qu trnh. iu bao gm s i mi k thut, cc nguyn vt liu cao cp, cc nh gi v tin cy, v cng ngh mi. Tt c nn c s dng nh l u vo1.5. Nghin cu tin cy ca sn phmLoi d liu ny xem xt thng xuyn v sa cha hoc thay th cc b phn trong sut cc thi k c ch nh v cc kt qu ca cc kim tra v tin cy/tnh bn di hn.1.6. u vo ca khch hng

Nhng ngi s dng sn phm tip theo c th c cung cp thng tin lin quan ti cc nhu cu v mong mi ca h. Thm vo , nhng ngi s dng sn phm tip theo c th c kt lun mt vi hoc tt c cc xem xt v nghin cu cp trn. Cc u vo nn c s dng bi khch hng v/hoc nh cung cp xy dng phng php o lng ph hp v s tho mn ca khch hng.1.7. Kt qu thit k

Cc kt qu thit k l mt s bin i theo ting ni ca khch hng thnh mc tiu thit k mang tnh cht thm d v o lng. S la chn ph hp cc kt qu thit k m bo rng ting ni ca khch hng khng b mt trong hnh ng thit k sau .1.8. Cc kt qu tin cy v cht lng

Cc kt qu v tin cy c thit lp da trn s mong mun v k vng ca khch hng, cc mc tiu ca chng trnh, v cc du chun ca tin cy. Th d v s mong mun v k vng ca khch hng c th l khng thiu s an ton hoc tin ch. Mt s du chun ca an ton c th l an ton sn phm ca i th, cc bo co ca ngi tiu th, hoc tn sut ca s sa cha vt ngoi thi k t sn. Kt qu tin cy ton din nn c m rng trong cc iu mc ca cc gii hn c th v tin cy. Kt qu cht lng tp trung da trn ci tin lin tc. Mt s th d l cc chi tit trn mt triu, cc mc tm thy, hoc gim thiu ph liu.1.9. BOM s b

Nhm nn xy dng BOM s b da trn cc gi nh ca sn phm/qu trnh v bao gm mt danh mc r rng cc nh thu ph. nhn bit cc c trng c th ca sn phm/qu trnh s b, n l thit yu la chn thit k v qu trnh gia cng ph hp.1.10. Biu dng chy qu trnh s bMt qu trnh ch to bit trc nn c miu t vic s dng biu dng chy qu trnh xy dng t BOM s b v cc gi nh v sn phm/qu trnh.1.11. Lp danh mc c s v cc c trng c th ca sn phm/qu trnhCc c trng c th v sn phm v qu trnh c nhn bit bi khch hng thm vo, cc iu c la chn bi nh cung cp thng qua s hiu bit v sn phm v qu trnh. giai on ny, nhm nn m bo rng cc danh mc v cc c trng c th ca sn phm v qu trnh c s dn n kt qu t s phn tch v u vo gn lin vi cc k vng v nhu cu ca khch hng c xy dng. Vic lp danh mc ny c th c xy dng t, nhng khng gii hn yu cu sau: Cc gi nh v sn phm da trn s phn tch cc nhu cu v mong i ca khch hng.

Nhn bit v cc kt qu ca tin cy/cc yu cu.

Nhn bit v cc c trng c th t qu trnh ch to bit trc.

FMEAs ca chi tit tng t.

1.12. K hoch bo hnh sn phmK hoch bo hnh chuyn cc kt qu thit k thnh cc yu cu thit k. Tng gi tr l lc dnh cho k hoch bo hnh sn phm bi nhm hoch nh cht lng sn phm da trn cc nhu cu, mong mi v cc yu cu ca khch hng. S tay ny khng qui nh mt phng php cho vic chun b k hoch bo hnh sn phm. K hoch bo hnh sn phm c th c xy dng trong nh dng c th hiu v nn bao gm, nhng khng gii hn ti cc hnh ng sau: Vic phc tho cc yu cu ca chng trnh.

Nhn bit v tin cy, bn, v cc kt qu ca s chia l/khu vc v/hoc cc yu cu.

S nh gi v cng ngh mi, phc tp, nguyn vt liu, mi trng, ng gi, dch v, v cc yu cu ch to, hoc mt vi nhn t khc m c th t chng trnh vo ri ro.

Xy dng v vic phn tch li FMA (tham kho ph lc H). Xy dng cc yu cu tiu chun cng ngh c s.

K hoch bo hnh sn phm l mt phn quan trng ca k hoch cht lng sn phm.

1.13. H tr ca lnh o.

Mt trong nhng cha kho dn ti s thnh cng ca nhm hoch nh sn phm l s quan tm, cam kt v h tr ca lnh o cp trn. Nhm nn cp nht s qun l theo s kt lun v mi giai on hoch nh cht lng sn phm duy tr s quan tm ca cp lnh o cp trn, cng c thm s cam kt v h tr ca h. Cc cp nht v/hoc cc li yu cu v s tr gip c th xy ra mc thng xuyn hn nh l cc yu cu ca nhm. Cc cp nht nn chnh thc vi c hi v cc cu hi v cu tr li. Mt mc tiu chc nng ca nhm hoch nh cht lng sn phm l duy tr s h tr ca lnh o bng vic chng minh rng tt c cc yu cu hoch nh p ng v/hoc lin quan vn bn ho v lp k hoch cho gii php. S tham gia bi lnh o trong cc cuc hp v hoch nh cht lng sn phm l vn sng cn ti vic m bo s thnh cng ca chng trnh.2.0 Thit k v pht trin sn phm

Biu thi gian hoch nh cht lng sn phm

Gii thiuMc ny cp ti cc thnh phn ca qu trnh hoch nh trong sut giai on m cc c im v c trng ca thit k c xy dng trong mt mu biu gn cui cng. Nhm hoch nh cht lng sn phm nn xem xt tt c cc yu t thit k trong qu trnh hoch nh thm ch nu thit k c s hu bi khch hng hoc c chia s. Cc bc bao gm xy dng mu xc minh rng sn phm hoc dch v p ng c cc mc tiu ca ting ni ca khch hng. Mt thit k kh thi phi cho php p ng cc k hoch v khi lng sn xut, v nht qun vi kh nng p ng c cc yu cu cng ngh, cng vi cht lng, tin cy, chi ph u t, trng lng, chi ph n v v mc tiu thi gian. Du cho cc k hoch nghin cu v kim sot tnh kh thi c da trn cc bn v cng ngh v cc yu cu ca c tnh k thut, thng tin c gi tr c th c c bt ngun t cc cng c thng k c miu t trong phn ny n vic xc nh v u tin hn na cc c trng m c th cn cc kim sot sn phm v qu trnh c bit.Trong phn ny, qu trnh hoch nh cht lng sn phm c cng m bo mt s xem xt bao hm v tiu chun ca cc yu cu v cng ngh v cc thng tin k thut lin quan khc. giai on ny ca qu trnh, mt s phn tch tnh kh thi c s s c lm nh gi cc vn tim nng m c th xy ra trong sut qu trnh ch to.u vo v u ra c th p dng ti phn ny l theo nh sau:

u vo (bt ngun t u ra ca phn 1.0) Cc kt qu ca thit k


BOM s b




H tr qun l

u ra bi trch nhim thit k (bt u l u vo cho phn 3.0) Phn tch li v nh cc nh hng trong thit k (DFMEA).

Thit k cho nng lc ch to v lp rp.

Xc minh thit k.

Xem xt thit k

Xy dng mu.

Cc bn v cng ngh (bao gm d liu tnh ton)

c tnh k thut ca sn phm.

Cc thay i c tnh k thut v bn v

u ra bi nhm hoch ch cht lng sn phm ph hp (bt u l u vo cho phn 3.0)

Cc yu cu ca thit b, cng c v my mc mi.

Cc c trng qu trnh v sn phm c th.

K hoch kim sot to mu

Cc yu cu ca dng c o v thit b kim tra.

S cam kt tnh kh thi ca nhm v h tr ca lnh o.

2.1. Phn tch li v cc nh hng trong thit k (DFMEA).

DFMEA l mt k thut phn tch c nguyn tc m nh gi kh nng ca li cng nh nh hng ca li . Mt biu DFMEA l mt s phn tch li v cc nh hng tim nng ca h thng SFMEA. Mt DFMEA l mt ti liu sng c cp nht thng xuyn nh l cc nhu cu v mong mi ca khch hng yu cu. Vic chun b DFMEA cung cp cho nhm mt co hi xem xt cc c trng ca sn phm v qu trnh la chn trc v lm cc thay i, thm bt cn thit. S tay tham kho phn tch cc li v nh hng tim nng ca Chrysler, Ford, GM motor nn c s dng cho phng php c th chp nhn v vic chun b DFMEA. Danh mc kim tra FMEA trong thit k trong ph lc A-1 cng nn c xem xt m bo rng cc c trng thit k ph hp c xem xt.2.2. Thit k cho nng lc ch to v lp rp.

Vic thit k nng lc sn xut v lp rp l mt qu trnh Simultaneous Engineering c cng k vng vo mi quan h gia chc nng thit k, nng lc sn xut, v s khng rng buc v lp rp. Phm vi ca cc nhu cu v mong mi ca khch hng c xc nh trong phn 1.0 s xc nhn trong chng mc nht nh ca s lin quan ca nhm hoch nh cht lng sn phm ca nh cung cp trong hnh ng ny. S tay ny khng bao hm hoc ch dn ti ti mt phng php chnh thc v vic chun b mt cng cho k hoch nng lc ch to v lp rp. Vi mt s ti thiu, cc mc c lit k y nn c xem xt bi nhm hoch nh cht lng sn phm.: Thit k, khi nim, chc nng, v nhy bn v s bin i ca ch to.

Qu trnh ch to v/hoc lp rp.

Dung sai kch thc

Cc yu cu thc hin

S cc b phn chi tit iu chnh qu trnh

Bc xp nguyn vt liu

Kinh nghim, hiu bit ca nhm hoch nh cht lng sn phm, sn phm/qu trnh, cc ch nh ca chnh ph, v cc yu cu ca dch v c th yu cu nh l cc nhn t khc c xem xt.

2.3. Xc minh thit kXc minh thit k xc minh rng thit k sn phm p ng c cc yu cu ca khch hng bt ngun t cc hnh ng c miu t trong phn 1.02.4. Xem xt thit kXem xt thit k l cc cuc hp c k hoch thng xuyn c hng dn bi cc hnh ng cng ngh thit k ca nh cung cp v phi bao gm cc khu vc b tc ng khc. Xem xt thit k l mt phng php hiu qu ngn chn cc vn v s hiu sai; n cng cung cp mt c cu nh gi tin v bo co ti lnh o.Xem xt thit k l mt chui cc hnh ng xc minh rng c nhiu hn mt s theo di-kim tra cng ngh. Vi mt xem xt thit k ti thiu nn bao gm nh gi v:

S xem xt cc yu cu v thit k/chc nng

Cc kt qu ca tin cy v chc chn chnh thc

Cc vng nhim v ca b phn/h thng ph/h thng

Cc kt qu kim tra biu trng v m phng ca my tnh DFMEAs

Xem xt v thit k v s c gng ca nng lc sn xut v lp rp

Cc kt qu ca thit k thc nghim nghim (DOE) v s bin i ca xy dng lp rp

Li kim tra

Tin xc minh thit k

Mt chc nng chnh ca xem xt thit k l s theo di v tin xc minh thit k. Nh cung cp nn theo di tin xc minh thit k thng qua vic s dng biu mu k hoch v bo co, c tham chiu ti k hoch v bo co xc minh thit k (DVP&R) ca Chrysler v Ford. K hoch v bo co l mt phng php chnh thc m bo: Xc minh thit k

Ph chun sn phm v qu trnh ca cc b phn v lp rp thng qua s p dng v k hoch v bo co kim tra ton din

Nhm hoch nh cht lng sn phm khng gii hn n cc mc c lit k. Nhm nn xem xt v s dng k thut phn tch c lit k trong ph lc B.

2.5. K hoch kim sot xy dng muCc k hoch kim sot mu l mt s miu t v cc o lng kch thc v vt liu v cc kim tra chc nng m s xy ra trong sut qu trnh xy dng mu. Nhm hoch nh cht lng sn phm nn bo m rng mt k hoch kim sot mu c chun b. Phng php k hoch kim sot c miu t trong phn 6.0. Mt danh mc kim tra k hoch thit k c cung cp trong c hai ph lc A-8 v phn 6.0 tr gip s chun b v k hoch kim sot mu.Ch to chi tit mu cung cp mt c hi ti u cho nhm v khch hng nh gi lm th no sn phm hay dch v p ng cc mc tiu ca th lc khch hng. Tt c mu m thuc trch nhim ca nhm hoch nh cht lng sn phm nn dc xem xt :

m bo rng sn phm hoc dch v p ng c c tnh k thut v d liu bo co nh c yu cu

m bo rng cc ch c bit c a ra cc c trng ca sn phm v qu trnh c th S dng cc d liu v kinh nghim xy dng cc tham s qu trnh c s v cc yu cu ng gi

Trao i mt s lin quan, lch v/hoc chi ph tc ng ti khch hng

2.6. K hoch bo hnh sn phm

Cc thit k ca khch hng khng cn tr vic hoch nh trch nhim ca nhm xem xt cc bn v cng ngh theo cch sau; Cc bn v cng ngh c th bao gm cc c trng c th (ch nh ca chnh ph v an ton) m phi c ch trn k hoch kim sot. Khi cc bn v cng ngh ca khch hng khng tn ti, vic kim sot cc bn v nn c xem xt bi nhm hoch nh xc nhn cc c trng nh hng ph hp, chc nng, tnh bn v/hoc cc yu cu an ton ca ch nh ca chnh ph.Cc bn v nn c xem xt xc nhn nu l cc thng tin y cho mt layout kch thc ca cc chi tit ring bit. Kim sot hay b mt/ranh gii ca gc kch thc nn nhn bit r rng cc thit b v my o lng chc nng c th c thit k cho vic kim sot d dng. Cc kch thc nn c nh gi m bo tnh kh thi v tnh tng thch vi ch to cng nghip v tiu chun o lng. Nu ph hp, nhm nn m bo rng cc d liu tnh ton l tng thch vi h thng ca khch hng cho cc trao i hai chiu hiu qu.2.7. Cc c tnh cng nghMt qu trnh xem xt v hiu bit t m v vic kim sot cc c trng s gip nhm hoch nh k hoch cht lng sn phm nhn bit cc yu cu chc nng, tnh bn v bn ngoi ca b phn hay lp rp ch th. Quy m ly mu, tn sut, v tiu chun chp nhn ca cc thng s c xc nh tng qut trong phn kim tra qu trnh ang gia cng ca c tnh cng ngh. Ngoi ra, quy m ly mu v tn sut l c xc nhn bi nh cung cp v c lit k trong Control plan. Trong trng hp khc, nh cung cp nn xc nhn cc c trng nh hng n hoc kim sot cc kt qu m thc hin cc yu cu chc nng, tnh bn v b ngoi ca cuc hp.2.8. Cc c trng ca vt liu

Thm vo cc bn v hoc cc c trng thc hin, cc c trng vt liu nn c xem xt v cc c trng c th lin quan ti cc yu cu v tnh cht vt l, thc hin, mi trng, bc xp, v kho bi. Cc c trng cng nn c bao gm trong Control Plan.2.9. Thay i bn v v c tnh k thut

Khi cc thay i bn v v dc tnh k thut c yu cu, nhm phi m bo rng cc thay i c trao i mau l v lp vn bn mt cch ng n ti tt cc cc khu vc b tc ng.2.10. Cc yu cu v thit b, cng c v trang thit b mi.DFMEA, k hoch bo hnh sn phm v/hoc xem xt thit k c th nhn bit cc yu cu v thit b, cng c v trang thit b mi. Nhm hoch nh cht lng sn phm nn biu th cc yu cu bng vic thm cc hng mc ti biu thi gian. Nhm nn m bo rng thit b v cng c mi c kh nng v c giao hng ng thi gian. Tin ca trang thit b nn c nh gi m bo s hon thnh vt qua c kim tra th sn xut hoch nh. Tham chiu ti thit b, cng c v danh mc kim tra thit b kim tra th mi trong ph lc A-3.2.11. Cc c trng c th ca sn phm v qu trnh

Trong giai on v hoch nh cht lng c miu t phn 1.0, nhm nhn bit cc c trng c th ca sn phm v qu trnh dn n kt qu t vic hiu bit th luc ca khch hng. Nhm hoch nh cht lng sn phm nn xy dng da trn vic lit k ny v i n s nht tr trong sut qu trnh xem xt v pht trin cc c im thit k thng qua s nh gi v thng tin k thut. Ph lc C bao hm mt bng miu t cc k t m Chrysler, Ford, GM s dng biu th cc c trng c th. S nht tr l c vn bn ho trn Control Plan ph hp. Cc c trng c th ca k hoch kim sot v cc biu mu to im d liu Data point Coordinates c tham kho trong phn 6.0, cc b sung K v L, l cc phng php c ngh vn bn ho v cp nht cc c trng c th nh l mt yu cu, h tr cc k hoch kim sot to mu, chun b sn xut, sn xut. Nh cung cp c th s dng mt vi biu mu m hon thnh ging yu cu ti liu. Cc khch hng c th c cc yu cu ph duyt duy nht. Tham chiu n cc yu cu h thng cht lng ca C, F, GM, phn III cp chi tit.2.12. Cc yu cu v thit b o/kim traCc yu cu v thit b o/kim tra cng c th c nhn bit thi im ny. nhm hoch nh cht lng sn phm nn thm cc yu cu n biu thi gian. Tin s c nh gi sau m bo rng thi gian yu cu c p ng.

2.13. Cam kt tnh kh thi ca nhm v h tr ca lnh o

Nhm hoch nh cht lng sn phm phi nh gi tnh kh thi ca thit k c ngh thi im ny. Quyn s hu thit k ca khch hng khng cn tr n ngha v ca nh cung cp nh gi tnh kh thi ca thit k. Nhm phi m bo rng thit k c ngh c th c ch to, lp rp, kim tra, ng gi, v giao hng vi cht lng y , mt chi ph c th chp nhn n khch hng ng k hoch. Cc danh mc kim tra thng tin thit k trong ph lc A-2 cho php nhm xem xt cc l lc trong phn ny v lm mt nh gi v tnh hiu qu ca danh mc kim tra thng tin thit k. Danh mc kim tra thng tin thit k cng s cung cp nh l mt c s cho pht hnh m c cp trong s cam kt tnh kh thi ca nhm, ph lc E. S nht tr ca nhm m thit k c ngh c kh thi nn c vn bn ho cng vi tt c cc pht hnh m m yu cu gi quyt v c trnh ln lnh o cho s h tr ca h. Biu mu v cam kt tnh kh thi ca nhm ch ra trong ph lc E l mt v d v kiu vit bo co c ngh.3.0 Thit k v pht trin qu trnhBiu thi gian vic hoch nh cht lng sn phm

Gii thiuPhn ny tho lun cc c im chnh v vic pht trin mt h thng ch to v cc c im lin quan ti cc k hoch kim sot t c cc sn phm cht lng. Cc nhim v c hon thnh bc ny ca qu trnh hoch nh cht lng sn phm ph thuc trn s hon thnh ca cc giai on trc c bao hm trong cc phn 2. Bc tip theo c cng m bo s pht trin ton din ca h thng ch to hiu qu. H thng ch to phi m bo rng cc yu cu, nhu cu v mong mi ca khch hng c p ng.Cc u vo v u ra c th p dng ti bc qu trnh trong phn ny l theo sau:

Cc u vo (bt ngun u ra phn 2.0)

Phn tch li v cc nh hng trong thit k (DFMEA).


Xc minh thit k.

Xem xt thit k

Xy dng mu k hoch kim soat.


c tnh k thut ca vt liu.

c tnh cng ngh

Cc thay i c tnh k thut v bn v (nu c) Cc yu cu ca thit b, cng c v my mc mi.




u ra (l u vo ca phn 4.0 Cc tiu chun ng gi

Xem xt h thng cht lng ca sn phm/qu trnh

Biu dng chy qu trnh

Cch trnh by k hoch s b Ma trn cc c trng

PFMEA

K hoch kim sot chun b sn xut

Cc hng dn qu trnh

K hoch phn tch cc h thng o lng Cc c trng ng gi

H tr ca lnh o

3.1. Cc tiu chun ng giKhch hng thng c cc tiu chun ng gi m nn c hp nht thnh mt s c trng ng gi cho sn phm. Nu khng c ci g c cung cp, thit k ng gi nn m bo tnh trng nguyn vn mc ch s dng ca sn phm 3.2. Xem xt h thng cht lng ca sn phm/qu trnhNhm hoch nh cht lng sn phm nn xem xt s tay h thng cht lng ca khu vc ch to. Mt vi thay i kim sot v/hoc th tc yu cu sn phm c sn xut nn c cp nht trong s tay h thng cht lng v nn c bao gm trong k hoch kim sot ch to. y l c hi cho nhm hoch nh cht lng sn phm ci tin h thng cht lng ang tn ti da trn u vo ca khch hng, s tinh thng ca nhm, v kinh nghim trc . Danh mc kim tra cht lng ca sn phm/qu trnh cung cp trong ph lc A-4 c th c s dng bi nhm hoch nh cht lng sn phm tr gip trong vic nh gi.3.3. Biu dng chy qu trnhBiu dng chy qu trnh l mt s biu trng ca biu hin hnh hoc dng chy qu trnh c ngh. N c th c s dng phn tch ngun ca s bin i v my mc, vt liu, phng php, v nhn lc t khi bt u ti khi kt thc qu trnh ch to hoc lp rp. N c s dng nhn mnh tc ng ca ngun bin i trn qu trnh. Biu dng chy gip phn tch ton b qu trnh hn l cc bc ring bit trong qu trnh. Biu dng chy tr gip nhm hoch nh cht lng sn phm tp trung vo qu trnh khi qun l PFMEA v thit k k hoch kim sot. Danh mc thit b kim tra biu dng chy qu trnh trong ph lc A-6 c th c dng bi nhm hoch nh cht lng sn phm tr gip trong qu trnh nh gi.3.4. Trnh by k hoch snK hoch sn nn c xy dng v xem xt xc nhn kh nng chp nhn ca cc im theo di-kim tra, khu vc ca biu kim sot, kh nng p dng ca cc dng c h tr mt, khu vc sa cha chuyn tip, v khu vc kho cha cha ng vt liu khuyt tt. Tt c dng chy vt liu nn c chin n biu dng chy qu trnh v k hoch kim sot. Danh mc kim tra k hoch sn trong ph lc A-5 c th dc s dng bi nhm hoch nh cht lng sn phm tr giup qu trnh nh gi.3.5. Ma trn cc c trngMt ma trn cc c trng l mt k thut phn tch c ngh cho vic biu l mi quan h gia cc tham s ca qu trnh v cc khu vc sn xut. Xem k thut phn tch trong ph lc B cho vic hiu chi tit hn.3.6. Phn tch cc li v nh hng ca qu trnh.

Mt PFMEA nn c kim sot trong sut qu trnh hoch nh cht lng sn phm v trc khi bt u sn xut. N l mt nguyn tc xem xt v phn tch ca mt qu trnh mi/xem li v c kim sot lng trc, gii quyt hoc nh gi cc vn ca qu trnh tim nng cho mt chng trnh mi/xem li. Mt PFMEA l mt ti liu sng v cn thit c xem xt v cp nht nh l cc li mi c khm ph.Cc thng tin c chiu su trn vic sng to v duy tr v PFMEA tham chiu ti s tay FMEA. Danh mc kim tra FMEA ca qu trnh trong ph lc A-7 c th c p dng bi nhm hoch nh cht lng sn phm tr gip qu trnh nh gi.

3.7. K hoch kim sot chun b sn xut.

K hoch kim sot chun b sn xut l mt s miu t v cc o lng kch thc v vt liu v cc kim tra chc nng m s xy ra sau to mu v trc sn xut hon ton. K hoch kim sot chun b sn xut nn bao gm cc kim sot sn phm/qu trnh thm vo c thc hin cho n khi qu trnh sn xut c gi tr. Mc ch ca k hoch kim sot chun b sn xut l cha ng cc khng ph hp tim nng trong sut hoc trc khi sn xut t u hot ng. Th d l: Theo di-kim tra thng xuyn hn Cc im kim tra cui cng v trong gia cng nhiu hn

Cc nh gi thng k

Cc nh gi c gia tng

Cc thng tin c chiu su trn vic sng to v duy tr cc k hoch kim sot tham chiu ti phn 6.0. Danh mc k hoch kim sot trong ph lc A-8 c s dng bi nhm hoch nh cht lng sn phm tr gip trong qu trnh nh gi.

3.8. Cc hng dn qu trnh

Nhm hoch nh cht lng sn phm nn m bo rng cc hng dn qu trnh c th hiu cung cp chi tit y cho tt c ngi vn hnh m c trch nhim trc tip thc hin qu trnh. Cc ch dn nn c xy dng t cc ngun sau: FMEAs

K hoch kim sot Bn v cng ngh, cc c trng thc hin, cc c trng ca vt liu, cc tiu chun lin quan ti mt v cc tiu chun cng nghip.

Biu dng chy qu trnh Phc tho k hoch sn

Ma trn cc c trng

Tiu chun ng gi

Tham s qu trnh

Th tc thc hnh v hiu bit v cc qu trnh v sn phm

Cc yu cu bc xp

Nhng ngi vn hnh qu trnh

Cc hng dn qu trnh cho th tc vn hnh tiu chun nn c yt th v nn bao gm cc tham s set-up nh: tc my, vn tc, chu k v nn c kh nng ti tay ngi vn hnh v gim st. Cc thng tin thm cho s chun b hng dn qu trnh c th c tm trong cc yu cu h thng cht lng ca C-F-GM3.9. K hoch phn tch h thng o lngNhm hoch nh cht lng sn phm nn m bo rng mt k hoch hon thnh vic phn tch h thng o lng yu cu c xy dng. K hoch ny nn bao gm, ti thiu, trch nhim m bo thng, chnh xc, tin cy, v tng quan ca dng c o lng cho cc dng c o lng khc. Tham chiu ti s tay tham kho phn tch h thng o lng ca C-F-GM.3.9. K hoch nghin cu kh nng qu trinh s b.Nhm hoch nh cht lng sn phm nn m bo s pht trin ca k hoch kh nng qu trnh s b. Cc c trng c nhn bit trong k hoch kim sot s cung cp nh l c s cho k hoch nghin cu kh nng ca qu trnh s b. Tham kho s tay qu trnh ph duyt chi tit sn xut PPAP v s tay tham kho kim sot qu trnh thng k c bn - SPC ca C-F-GM hiu r hn.

3.11. Cc c trng ng gi.

Nhm hoch nh cht lng sn phm nn m bo rng vic ng gi sn phm ring bit (bao gm cc phn chia bn trong) c thit k v pht trin. Cc tiu chun ng gi ca khch hng hoc cc yu cu ng gi chung nn c s dng khi c th p dng. Trong tt c cc trng hp thit k ng gi phi m bo rng cc c trng v cng dng ca sn phm s duy tr khng thay i trong sut qu trnh ng gi, vn chuyn, v khng ng gi xy ra. Vic ng gi nn c s tng thch vi cc thit b nng hng bao gm c robot.3.12. H tr ca lnh o.Nhm hoch nh cht lng sn phm c yu cu lp k hoch xem xt chnh thc c cng cng c s cam kt ca lnh o kt lun v giai on thit k v pht trin qu trnh. Mc ch ca xem xt ny l thng bo ti ban lnh o cp trn v tnh trng ca chng trnh v t c s cam kt ca h tr gip trong vic gii quyt v mt s pht sinh m.4.0 Ph chun sn phm v qu trnh

Biu thi gian hoch nh cht lng sn phm

u ra: Sn xut th nghim

nh gi h thng o lng

Nghin cu kh nng ca qu trnh s b

Ph duyt chi tit sn xut

Kim tra ph chun sn xut

nh gi ng gi

K hoch kim sot sn xut

Dng hoch nh cht lng v h tr ca lnh oGii thiuPhn ny tho lun cc c im chnh v vic ph chun qu trnh ch to thng qua nh gi v sn xut th. Trong sut qu trnh ch to th, nhm hoch nh cht lng sn phm nn ph chun rng k hoch kim sot v biu dng chy qu trnh ang c k tip v cc sn phm p ng c cc yu cu ca khch hng. Thm vo , cc vn lin quan nn c xc nh cho s iu tra v gii quyt trc khi sn xut hot ng thng xuyn.u vo v u ra c th c p dng ti cc bc qu trnh trong phn ny theo nh sau:

u vo (bt ngun t u ra ca phn 3.0) Cc tiu chun ng gi


Biu dng chy qu trnh

Cch trnh by k hoch sn

Ma trn cc c trng

PFMEA


Cc hng dn qu trnh

K hoch phn tch cc h thng o lng

K hoch nghin cu kh nng ca qu trnh s b

Cc c trng ng gi

H tr ca lnh o

u ra:

Sn xut th nghim

nh gi h thng o lng




nh gi ng gi


Dng hoch nh cht lng v h tr ca lnh o

4.1. Sn xut th.Sn xut th phi c ch o dng cng c sn xut, thit b, mi trng (bao gm nhng ngi vn hnh sn xut), trang thit b, v chu k sn phm. S ph chun v tnh hiu qu ca qu trnh ch to bt u vi vic sn xut th. S lng nh nht ca sn xut th thng c t ra bi khch hng nhng c th c vt qu do quyt nh ca nhm hoch nh cht lng sn phm. u ra ca sn xut th c dng cho: nghin cu kh nng ca qu trnh s b

nh gi cc h thng o lng

tnh kh thi cui cng

Xem xt qu trnh


Ph duytt chi tit sn xut

nh gi ng gi

Nng lc t u (FTC) Dng hoch nh cht lng

4.2. nh gi h thng o lng.Cc thit b v phng php o lng c th nn c s dng kim tra cc c trng n c tnh cng ngh c nhn bit ca k hoch kim sot v c a n s nh gi h thng cht lng trong sut hoc trc khi qu trnh sn xut th. Tham chiu ti s tay tham kho phn tch h thng o lng ca C-F-GM.4.3. Nghin cu nng lc ca qu trnh s bVic nghin cu nng lc ca qu trnh s b nn c thc hin trn cc c trng c nhn bit trong k hoch kim sot. Vic nghin cu cung cp s nh gi v s sn sng cho sn xut. Tham chiu s tay tham kho qu trnh ph duyt chi tit sn xut ca C-F-GM cho cc lin quan chi tit ti s nghin cu nng lc ca qu trnh s b.4.4 Ph duyt chi tit sn xut

Mc ch ca ph chun chi tit sn xut l cng nhn cc sn phm lm ra t cc cng c sn xut v cc qu trnh p ng c cc yu cu cng ngh. Tham chiu ti s tay tham kho qu trnh ph duyt chi tit sn xut ca C-F-GM.4.5. Kim tra s ph chun sn xutKim tra s phn chun sn xut tham chiu ti cc kim tra cng ngh m cng nhn rng cc sn phm c lm ra t cng c sn xut v cc qu trnh p ng c tiu chun cng ngh. Tham chiu ti cc yu cu h thng cht lng ca C-F-GM cho cc yu cu c th.4.6. nh gi ng giTt c cc hng gi kim tra (nu c th kh thi) v cc phng php kim tra phi nh gi s bo v sn phm khi s ph hu bi vn chuyn thng thng v cc nhn t mi trng c hi. Vic ng gi c ch nh bi khch hng khng cn tr s lin quan ca nhm hoch nh cht lng sn phm trong vic nh gi phng php ng gi.4.7. K hoch kim sot sn xut

K hoch kim sot sn xut l mt vn bn miu t v cc h thng cho vic kim sot cc chi tit v cc qu trnh. K hoch kim sot sn xut l mt ti liu sng v nn c cp nht phn nh s thm/bt ca cc kim sot da trn kinh nghim t c bi vic sn xut cc chi tit. K hoch kim sot sn xut l mt s m rng c tnh logic v k hoch kim sot chun b sn xut. Sn xut hng lot cung cp cho nh sn xut c hi nh gi u ra, xem xt k hoch kim sot v to ra cc thay i ph hp. Phn 6.0. v ph lc A-8 a ra phng php lun ca k hoch kim sot v mt bng danh mc tr gip nh sn xut trong xem xt ny. c th l mt kiu loi khc ca cc k hoch kim sot. mt v d k hoch kim sot ng lc ca Ford (DCP) miu t trong ph lc B v chi tit trong ph lc G.4.8. Dng hoch nh cht lng v h tr ca lnh oNhm hoch nh cht lng sn phm nn m bo rng tt c cc k hoch kim sot v biu dng chy qu trnh c k tip sau . N c ngh rng nhm hoch nh cht lng sn phm thc hin xem xt k hoch kim sot v biu dng chy khu vc ch to v phi hp mt sign-off chnh thc. Mt vic xem xt v cc iu mc theo sau trc khi chuyn sn xut t u c yu cu: Cc k hoch kim sot: Cc k hoch kim sot nn tn ti v c gi tr mi thi im cho tt c cc hnh ng b tc ng/nh hng Hng dn cng vic: Vic xc minh rng cc ti liu cha ng tt c cc c trng c th ch r trong k hoch kim sot v tt c cc ngh ca PFMEA c biu th. S so snh cc hng dn qu trnh v biu dng chy qu trnh vi k hoch kim sot. Thit b o lng v kim tra: Nu cc dng c o kim, g hoc thit b kim tra c bit c yu cu trn k hoch kim sot, th phi xc minh kh nng lp li v ti sinh ca dng c o (GR&R) v s s dng hp l. (tham chiu ti ph lc D v s tay tham kho phn tch cc h thng o lng thng tin)H tr ca lnh o l thit yu trc khi dng hoch nh cht lng. Nhm nn c kh nng ch ra tt c cc yu cu hoch nh c p ng hoc cc vn lin quan c vn bn ho v a vo chng trnh xem xt ca lnh o. Mc ch ca xem xt ny l thng bo vi lnh o cp trn v tnh trng ca chng trnh v t c s cam kt ca h d tr gip trong mt s pht sinh m. Bo co tm tt v dng hoch nh cht lng sn phm ch ra trong ph lc F l mt th d v ti liu c yu cu h tr mt d dng hoch nh cht lng sn phm hiu qu.5.0 Thng tin phn hi, nh gi v hnh ng khc phcBiu thi gian hoch nh cht lng sn phm

u ra Gim thiu s bin i S thon mn ca khch hng

Giao hng v dch v

Gii thiuHoch nh cht lng khng kt thc vi s ph chun v lp t qu trnh. N l giai on ch to ca b phn nu u ra c th c nh gi khi tt c cc nguyn nhn bnh thng v c bit v s bin i c biu hin. y cng l thi im nh gi tnh hiu qu ca vic l lc hoch nh cht lng sn phm. K hoch kim sot sn xut l c s cho vic nh gi sn phm. Cc d liu bin i v thuc tnh phi c nh gi. Cc hnh ng ph hp nh c miu t trong s tay tham kho qu trnh phn tch thng k c bn ca C-F-GM phi c a ra. N l ngha v ca cc nh cung cp p ng cc yu cu ca khch hng trn tt c cc c trng. Cc c trng c th phi p ng c cc yu cu trong bng ch thch c ch r bi khch hng.u vo v u ra c th p dng n bc qu trnh trong phn ny l nh sau:

u vo:

Sn xut th nghim

nh gi h thng o lng




nh gi ng gi


Dng hoch nh cht lng v h tr ca lnh o

u ra

Gim thiu s bin i

S thon mn ca khch hng

Giao hng v dch v

5.1. Gim thiu s bin iCc biu kim sot v k thut thng k nn c s dng nh l cng c nhn bit s bin i ca qu trnh. Cc hnh ng phn tch v khc phc nn c s dng gim thiu s bin i. S ci tin thng xuyn yu cu ch khng ch i vi cc nguyn nhn c bit ca s bin i ngoi vic hiu bit cc nguyn nhn chung v vic tm kim cc cch gim cc ngun ca s bin i . Cc ngh nn c xy dng bao gm cc chi ph, thi gian, v s ci tin lng trc cho vic xem xt ca khch hng. Thng thng s gim thiu hoc loi b mt nguyn nhn thng thng dn n kt qu cc chi ph thp hn. Cc nh cung cp khng nn min cng chun b cc li ngh da trn s phn tch v gim thiu s bin i v gi tr S quyt nh i vi thc hin, m phn, hoc tin b ti trnh thit k sn phm tip theo l c quyn ca khch hng. Tham chiu ti s tay tham kho qu trnh phn tch thng k c bn ca C-F-GM cho s hiu bit chi tit trn kh nng di hn, cc nguyn nhn c bit v thng thng ca s bin i.5.2. S tho mn ca khch hngCc hnh ng hoch nh t m v kh nng ca qu trnh c dn chng v sn phm hoc dch v lun lun khng bo m s thomn ca khch hng. Sn phm hoc dch v phi thc hin trong mi trng ca khch hng. Giai on s dng sn phm yu cu s tham gia ca nh cung cp. Trong giai on ny khi hu ht c th hc c bi c hai nh cung cp v khch hng. Hiu qu ca cc l lc hoch nh cht lng sn phm c th c nh gi trong giai on ny. Nh cung cp v khch hng phi l cc i tc trong vic to ra cc thay i cn thit khc phc s thiu st t c s tho mn ca khch hng.5.3. Giao hng v dch v.Giai on giao hng v dch v ca hoch nh cht lng lin tc l s cng tc ca nh cung cp/khch hng trong vic gii quyt cc vn v ci tin lin tc. Cc chi tit thay th v cc hot ng ca dch v ca khch hng lun lun phi tng xng vi s xem xt v cht lng, chi ph v giao hng. T cc li n khc phc mt vn ln u lun lun ph hu danh ting ca nh cung cp v s cng tc ca khch hng. N rt quan trng m c hai nh cung cp v khch hng nghe theo Voice of the Custommer.Kinh nghim t c trong giai on ny cung cp cho khch hng v nh cung cp s hiu bit cn thit nh vic gim gi sn phm bng cch gim thiu qu trnh, hng tn kho, v cc chi ph v cht lng v cung cp b phn hay h thng chnh xc cho sn phm tip theo.

6.0. Phng php lun ca k hoch kim sot

6.1. Bng ni dung.

Trang

6.2.Tng quan

6.3.S miu t hng ct trong k hoch kim sot

1)To mu, chun b sn xut, sn xut

2)S k hoch kim sot

3)Mc thay i cui cng/ s chi tit

4)Tn/s miu t chi tit

5)Nh cung cp/nh xng

6)M nh cung cp

7)Cha kho lin lc/in thoi

8)Nhm tr ct/nng ct

9)Ph duyt/ngy nh cung cp/nh xng

10)Ngy (bt u)

11)Ngy (nh gi li)

12)Ph duyt/ngy cng ngh ca khch hng

13)Ph duyt/ngy cht lng ca khch hng

14)Ph duyt/ngy khc

15)S chi tit/qu trnh

16)Miu t tn/vn hnh ca qu trnh

17)My mc, dng c, g cng c cho ch to

Cc c trng

18)S

19)Sn phm

20)Qu trnh

21)Phn loi cc c trng c bit

Phng php

22)c tnh k thut/dung sai ca sn phm/qu trnh

23)K thut nh gi/o lng

24)Quy m ly mu/tn sut

25)Phng php kim sot

26)K hoch hng ng li

6.4Phn tch qu trnh

6.5B sung

A)Thit b: V d k hoch kim sot qu trnh chi phi ca setup

B)Thit b: V d k hoch kim sot qu trnh chi phi ca my mc

C)Thit b: V d k hoch kim sot qu trnh chi phi ca g/pallet

D)Thit b: V d k hoch kim sot qu trnh chi phi ca cng c

E)Con ngi: V d k hoch kim sot qu trnh chi phi ca vn hnh

F)Nguyn vt liu: V d k hoch kim sot qu trnh chi phi ca b phn hoc nguyn vt liu

G)Phng php: V d k hoch kim sot qu trnh chi phi bo dng phng nga

H)V d k hoch kim sot qu trnh chi phi ca thi tit

I)Bng k hoch kim sot

J)Danh mc kim tra k hoch kim sot

K)Bng ghi cc c trng c th ca k hoch kim sot

L)Cc kt hp im d liu

6.2. Tng qut.Mc ch ca phng php k hoch kim sot ny l tr gip trong ch to v cc sn phm cht lng theo nh cc yu cu ca khch hng. iu ny c thc hin bng vic cung cp mt cch tip cn c cu cho thit k, la chn v thc hin ca cc phng php tng thm gi tr cho ton b h thng. Cc k hoch kim sot cung cp mt vn bn miu t tm tt v cc h thng c s dng trong vic ti thiu s bin i ca qu trnh v sn phm. Mc ch cu bng biu k hoch kim sot c biu trng trong phn ny l cung cp th d v cc thng tin ny c th c vn bn nh th no. Mt nh dng tng t c th c s dng vi iu kin n cha ng cng mt thng tin. K hoch kim sot khng thay th thng tin c cha ng trong cc hng dn vn hnh chi tit. Phng php ny c th p dng ti mt di rng ca cc qu trnh v cng ngh ch to. K hoch kim sot l mt phn khng th thiu ca qu trnh cht lng ton din v l c s dng nh mt ti liu sng. V vy, phn ny nn c s dng cng vi cc ti liu lin quan khc.Mt giai on quan trng ca qu trnh cho hoch nh cht lng l qu trnh pht trin v mt k hoch kim sot. Mt k hoch kim sot l mt vn bn miu t v h thng cho vic kim sot cc chi tit v qu trnh. Mt k hoch kim sot n c c th p dng cho mt nhm hoc family cc chi tit m c sn xut bi cng qu trnh cc ngun ging nhau. Bng phc tho, nh l yu cu cn thit, c th c nh km ti k hoch kim sot cho vic minh ho cc mc ch. Trong s h tr ca k hoch kim sot, cc hng dn nh gi qu trnh nn c xc nh v c s dng thng xuyn.Trong qu trnh ang c hiu lc, k hoch kim sot miu t cc hnh ng m c yu cu tng giai on ca qu trnh bao gm vic tip nhn, trong qu trnh, sp kt thc, v cc yu cu nh k m bo rng tt c u ra ca qu trnh s l trong kim sot. Trong sut qu trnh sn xut thng thng, k hoch kim sot cung cp s nh gi qu trnh v cc phng php kim sot m s c dng kim sot cc c trng. T khi cc qu trnh c mong i n khi cp nht v ci tin thng xuyn, k hoch kim sot phn nh mt chin lc m sn sng p li i vi cc iu kin qu trnh thay i .K hoch kim sot c duy tr v c s dng trong sut vng i ca sn phm. u vng i ca sn phm mc ch nguyn s ca n l vn bn ho v trao i k hoch khi u cho kim sot qu trnh. Ri sau , n ch dn ch to trong vic lm th no kim sot qu trnh v bo m cht lng sn phm. Sau cng, k hoch kim sot cn l mt ti liu sng, fn nh cc phng php hin hnh ca kim sot, v cc h thng o lng s dng. K hoch kim sot c cp nht nh cc h thng o lng v cc phng php kim sot c nh gi v c ci tin.V vic kim sot v ci tin qu trnh c hiu qu, s hiu bit c bn v qu trnh phi t c. Mt nhm a bn c thit lp pht trin k hoch kim sot bng vic s dng tt c thng tin c gi tr t c s hiu bit tt hn v qu trnh, nh:

Biu dng chy qu trnh

Phn tch li v cc nh hng trong h thng/thit k/qu trnh Cc c trng c bit

Cc bi hc t cc chi tit tng t

S hiu bit ca nhm v qu trnh

Cc xem xt thit k

Cc phng php lc quan.

Li ch ca vic xy dng v thc hin k hoch kim sot bao gm:+ Cht lng

Phng php k hoch kim sot gim thiu cc lng ph v ci tin cht lng ca cc sn phm trong sut qu trnh thit k, ch to, v lp rp. Nguyn tc cu trc ny cung cp mt s nh gi trit sn phm v qu trnh. K hoch kim sot nhn bit cc c trng ca qu trnh v gip nhn bit cc ngun bin i ca chng (u vo bin i), m nguyn nhn bin i trong cc c trng ca sn phm (u ra bin i).+ S tho mn ca khch hng.

K hoch kim sot tp trung cc ngun vo cc qu trnh v sn phm lin quan ti cc c trng m rt quan trong i vi khch hng. S phn phi ph hp ca cc ngun trn cc iu mc chnh gip gim thiu chi ph khng cng vi vic hy sinh cht lng.+ Trao i.

Nh l mt ti liu sng, k hoch kim sot nhn bit v trao i cc thay i trong cc c trng ca sn phm v qu trnh, phng php kim sot, v o lng c tnh k thut.

6.3. Cc miu t hng ct ca k hoch kim sot.

1. To mu, chun b sn xut, sn xut.Ch ra cc phm tr ph hp. To mu: Mt s miu t v cc kim tra o lng kch thc, vt liu v cng dng xy ra trong sut qu trnh xy dng mu.

Chun b sn xut: Mt s miu t v cc kim tra o lng kch thc, nguyn vt liu, v cng dng m s xy ra sau to mu v trc khi sn xut bnh thng.

Sn xut: Mt ti liu ton din v cc c trng ca sn phm/qu trnh, cc kim sot qu trnh, cc kim tra, v cc h thng o lng xy ra trong sut qu trnh sn xut bnh thng.2. S k hoch kim sot.in vo s ti liu ca k hoch kim sot c s dng cho vic theo di. V cc trang kim sot nhiu mi, in vo s trang (page of ).

3. Mc thay i cui cng s chi titin vo s h thng, h thng ph, hay cc b phn ang c kim sot. Khi c th p dng, in vo mc thay i cng ngh cui cng v/hoc ngy pht hnh t c trng ca bn v.4. Miu t/tn chi tit

in vo tn v s miu t v sn phm/qu trnh ang c kim sot5. Nh cung cp/nh xngin vo tn ca cng ty v khu vc hnh chnh/nh xng/vn phng chun b k hoch kim sot.6. M nh cung cp

in vo s nhn bit (Duns, Z-Code, GSDB)7. Cha kho lin lc/in thoiin vo tn v s in thoi ca c trch nhim lin lc chnh cho k hoch kim sot8. Nhm nng ct

in vo tn v s in thoi ca ngi/nhm chu trch nhim ring r cho vic chun b k hoch kim sot n s xem xt cui cng. N ngh rng tt c tn cc thnh vin ca nhm, s in thoi v cc khu vc c bao gm trn danh mc phn pht nh km.9. Ph chun/ngy nh cung cp/nh xng.

t c s ph duyt v nh xng ch to c trch nhim (nu c yu cu)10. Ngy bt uin vo ngy m k hoch kim sot gc c hon thnh11. Ngy nh gi li

in vo ngy m k hoch kim sot cui cng cp nht12. Ph duyt/ngy cng ngh ca khch hngt c ph duyt cng ngh c trch nhim (nu c yu cu)13. Ph duyt/ngy cht lng ca khch hng

t c s ph duyt ca ngui i din cht lng ca nh cung cp c trch nhim (nu c yu cu)14. S ph duyt/ngy khc

t c mt s ci khc c ng da trn s ph duyt (nu dc yu cu)15. S chi tit/qu trnh

S danh mc ny thng c tham kho t biu dng chy ca qu trnh. Nu cc s ca nhiu chi tit tn ti (lp rp), lit k cc s ca chi tit ring bit v cc qu trnh theo .16. Miu t tn/vn hnh ca qu trnh

Tt c cc bc trong qu trnh ch to ca mt h thng, h thng ph hoc b phn c miu t trong mt biu dng chy qu trnh. Nhn bit tn ca qu trnh/vn hnh t biu dng chy m tt nht miu t hnh ng ang biu th.17. My mc, dng cng, g, cng c cho ch toi vi tng vn hnh m c miu t, nhn bit thit b gia cng,, my mc, dng c, g, hoc cc cng c khc cho ch to, nh yu cu ph hp.

Cc c trng: Mt s phn bit c im, kch thc hay tnh cht ca mt qu trnh hoc u ra ca n (sn phm) trn d liu bin i v thuc tnh c th c thu thp. Vic s dng cc h tr lin quan ti mt khi c th p dng.18. S

in vo s tham kho an cho t tt c cc ti liu c th p dng nh, nhng khng gii hn n biu dng chy qu trnh, in mu xanh c ghi s, FMEAs, v cc phc tho (Sinh ra t my tnh hoc ngoi ra), nu c yu cu.Cc biu mu cng vic khng bt buc v li ch thch ca cc biu mu cng vic c xc nh trong mc b sung K v L ca phn ny.19. Sn phmCc c trng ca sn phm l cc c im hoc cc tnh cht ca chi tit, c chi tit hoc lp rp m c miu t trn bn v hay cc thng tin cng ngh c bn khc. Nhm nng ct nn nhn bit cc c trng ca sn phm m su tp ti liu v cc c trng ca sn phm t tt c cc ngun. Tt c cc c trng c th phi c lit k trn k hoch kim sot. Thm vo , nh ch to c th lit k cc c trng sn phm khc cho cc kim sot ca qu trnh c theo di u n trong sut qu trnh sn xut bnh thng.20. Qu trnh Cc c trng ca qu trnh l cc bin i ca qu trnh (cc bin i u vo) m c mi quan h nguyn nhn v hu qu vi c trng ca sn phm nhn bit. Mt c trng ca qu trnh c th ch c o lng thi im n xy ra. Nhm nng ct nn nhn bit cc c trng ca qu trnh i vi s bin i phi c kim sot gim thiu s bin i ca sn phm. iu c th l mt hoc nhiu cc c trng ca qu trnh c lit k cho tong c trng ca sn phm. Trong mt s qu trnh, mt c trng ca qu trnh c th nh hng ti nhiu c trng ca sn phm.21. Phn loi c trng c th

Vic s dng s phn loi ph hp nh c yu cu bi OEM, nh ra loi c trng c bit hoc hoc phm vi ny c th li khong trng cho cc c trng khng c ch nh khc. Cc khch hng c th s dng cc k t duy nht nhn bit cc c trng quan trng, ging nh cc k t m tc ng ti an tonh ca khch hng, ng vi cc quy nh, choc nng, s ph hp, hay hnh dng bn ngoi. Cc c tnh c gi khc nhau theo tong trng hp, Critical, Key, Safety hay Signficant. Ph lc C cung cp mt s tham kho an cho i vi cc k t v cc thut ng miu t.Cc phng php: Mt k hoch c tnh h thng s dng cc th tc v cc cng c khc kim sot mt qu trnh.22. c tnh k thut/dung sai ca sn phm/qu trnhCc c tnh k thut/dung sai c th t c t cc ti liu cng ngh a dng, nh l, nhng khng gii hn ti, cc bn v, cc xem xt thit k, tiu chun vt liu, d liu thit k h tr bi may tnh, ch to, v/hoc cc yu cu lp rp.23. K thut o lng/nh gi

Ct ny nhn bit h thng o lng ang c s dng. iu ny c th bao gm cc dng c o, g, cng c, v/hoc thit b kim tra c yu cu o lng chi tit/qu trnh/thit b ch to. Mt s phn tch v thng, kh nng ti sn xut, kh nng lp li, kh nng n nh v chnh xc ca h thng o lng nn c thc hin trc khi da vo mt h thng o lng v cc ci tin c lm ph hp.24. Quy m ly mu/tn sut

Khi ly mu c yu cu lit k quy m ly mu v tn sut ly mu khp nhau.25. Phng php kim sot

Ct ny cha ng mt miu t tm tt v s vn hnh nh s c kim sot nh th no, bao gm cc s th tc khi c th p dng. Phng php kim sot c dng nn c da trn s phn tch hiu qu ca qu trnh. Phng php kim sot c xc nh bi loi hnh ca qu trnh tn ti. Cc vn hnh c th c kim sot bi, nhng khng gii hn ti, kim sot ca qu trnh thng k, theo di-kim tra, d liu thuc tnh, chng sai li (t ng/khng t ng), v k hoch ly mu. Tham chiu ti cc v d v cc qu trnh tiu biu c kim sot nh th no. S miu t k hoch kim sot nn phn nh vic hoch nh v chin lc ang c thc hin trong qu trnh ch to. Nu cc th tc kim sot t m c s dng, k hoch s c tham kho ti liu th tc tiu biu bng mt tn v/hoc s ca nhn bit c th.Phng php kim sot nn c nh gi thng xuyn v hiu qu ca kim sot qu trnh. Th d, cc thay i ng k trong qu trnh hoc kh nng ca qu trnh nn hng dn ti mt s nh gi v phng php kim sot.26. K hoch ti hnh ngK hoch ti hnh ng ch r cc hnh ng khc phc cn thit trnh vic sn xut cc sn phm khng ph hp hoc ngoi s kim sot. Cc hnh ng nn l trch nhim bnh thng ca nhng ngi lin quan gn nht ti qu trnh, ngi vn hnh, ngi thit lp cng vic, hoc ngi gim st, v c nh r trong k hoch. Cc gim st nn c lu vn bn.Trong tt c cc trng hp, cc sn phm nghi ng v khng ph hp phi c nhn bit v c cch ly r rng v s sp xp c thc hin bi ngi c trch nhim nh r trong k hoch ti hnh ng. Ct ny cng c th tham chiu ti mt con s k hoch hnh ng c th v nhn bit ngi c trch nhim cho k hoch ng li6.4. Phn tch qu trnh.Cc dng khc nhau ca cc qu trnh a ra cc th thch v cc c hi cho kim sot v gim thiu s bin i. Cc loi qu trnh c th lin quan ti hu ht cc ngun bin i thng thng ca chng hoc cc yu t chi phi trong vic xc nhn cht lng ca sn phm. iu c nhiu phng php hiu qu ca vic thc hin phn tch qu trnh. N l t trn ti cc nh cung cp xc nhn phng php tt nht phn tch qu trnh. Th nh l:

Phn tch biu xng c

Phn tch cc thc nghim

Nguyn nhn v hu qu (xem hnh 1)

Hnh 1 sp xp cc loi ca cc qu trnh trong m hnh nguyn nhn v kt qu, khi cc nhm c s l: Con ngi, nguyn vt liu, phng php v h thng, v mi trng. Th d miu t cc tnh hung ch to v lp rp vi mt k hoch kim sot vi mt k hoch kim sot tng ng ch ra mt ti liu c th nh m t trong theo cc trang k tip. Cha kho xy dng thnh cng v chi ph cc qu trnh hiu qu l nhn bit v cc ngun bin i v cc phng php kim sot ph hp.6.5. Cc b sung.Thit b: Set-up qu trnh chi phi: Qu trnh c kh nng v s n nh cao, v vy set-up l bin s chnh tc ng n s thay i ca sn phm. Cc chi tit nha t c sn xut trn cc my p phun. Sau set-up khun, my phi c iu chnh sn xut cc chi tit chnh xc v kch thc. Cc chi tit b thiu st, ng chy, vt co gt trn b mt. My p phun c kh nng lc hi v cao bi v cc thng s c my tnh kim sot. Mt th set-up cung cp cc c trng v vic thit t tt c cc kim sot trn my. Sau khi thit t my i vi cc c trng mt chi tit v d c sn xut. Chi tit ny c kim tra v cc kch thc quan trng i vi vic cc l v s ph hp ca chu vi, v c theo di-kim tra bng mt. Set-up l bin s then cht trong trong loi hnh ca qu trnh ny. Kh nng nghin cu trn cc c tnh ca sn phm ch ra rng khi set-up y , s vn hnh c kh nng v n nh cao. Cc c trng ca Set-up bt u cc c trng ca qu trnh m tc ng n cc c trng ca sn phm.

Cc loi hnh ca kim sot v cc c trng ca qu trnh bao gm cc th tc kim tra b phn u tin, v s xc minh m cc thit t my l ng cn c cho cc th set-up. Cc c trng ca sn phm c o lng bo m set-up l ng v khng mt nghun nhn c th thng thng no xy ra. Trong mt s trng hp s kim sot l c th l ph hp gia cc kim tra,

Danh mc kim tra k hoch kim sot.Khch hng hoc m s chi tit ni b:_____________________NoQuestionYesNoComment/Action requiredPerson ResponsibleDueDate

1Phng php kim sot c tham kho trong phn 6.0 dng cho vic chun b k hoch kim sot khng?

2Tt c cc lin quan ca khch hng hiu c c nhn bit lm d dng s la chn v cc c trng c th ca sn phm/qu trnh khng?

3Tt c cc c trng c th ca sn phm/qu trnh c biu th trong Control Plan khng?

4SFMEA, DFMEA, PFMEA c s dng chun b Control Plan khng?

5Cc c trng nguyn vt liu yu cu theo di-kim tra c c nhn bit khng?

6K hoch kim sot biu th cc u vo (vt liu/cc b phn) thng qua gia cng/lp rp k c ng gi khng?

7Cc yu cu kim tra thc thi cng ngh c nhn bit khng?

8Cc dng c o lng v thit bi kim tra c gi tr nh c yu cu bi Control Plan khng?

9Nu c yu cu, khch hng c c ph duyt contron plan?

10Cc phng php o lng tng thch gia nh cung cp v khch hng khng?

Biu mu cc c trng ca k hoch kim sot (B sung K)S miu t/l do cn bn ca hng ct bao gm tt c cc c trng c th ca sn phm/qu trnh c ng bi nhm choc nng cho nhau. Cc s lin tip c ch ra tong c trng c lit k m bo khng mt thc g c b st bi nh cung cp khi Control Plan c hon thnh (chi tit2). Xy dng mt l do cn bn cho tong c trng v thm thng tin ny ti danh mc s sng lc. Khi c xem xt cn thit, mt biu mu b sung (b sung L) s miu t cc to v g to ca o lng. Biu muc ny, khi s dng, s c xem xt s m rng ca Control Plan.

Ph lc G: Hoch nh kim sot ng hcMiu t v hoch nh kim sot ng hc (Dynamic Control Planning)nh ngha:DCP l mt s tip cn ca nhm n tng bc hiu bit v kim sot cc qu trnh ch to.Kinh nghim ca nhm, cc cng c phn tch v cc k nng hoch nh c s dng a ra h thng v s hiu bit ca qu trnh. Cc kim sot qu trnh c pht trin v thc hin t h thng ca s hiu bit. Mc tiu ca DCP l pht trin mt qu trnh ch to c kh nng sn xut cc sn phm c cht lng cao, vi mt mc chi ph cnh tranh, theo k hoch thi gian sn xut.

Cc mong iTt c cc qu trnh phi a ra tt c cc c trng ti c tnh k thut da trn nn tng ca sn xut. Nu cc mong mi khng p ng c, th phi lp mt k hoch khc phc vn v bo v khch hng. Cc c trng y (SCs) phi c trong mt trng thi ca kim sot thng k vi Ppk1.67 v Cpk1.33. DCP c p dng ti tt c cc c trng, khng ch SCs.Phm vi

DCP l ai? Cc nhm chc nng cho ca nhn vin chnh v nhn vin tr lng theo gi thc hin qu trnh DCP. DCP c yu cu cho cc nh my v khch hng ca Ford. Cc hot ng khc cng s dng DCP v yu cu n cho cc nh cung cp ca h.Ai l ngi ph duyt k hoch kim sot? k hoch kim sot phi c k/ph duyt bi mt ngi i din ca CDP, k s sn phm, k s SQE (cho cc nh cung cp), v vi c hi cho s ph duyt bi vic s dng ca cc nh my.

Khi no k hoch kim sot c thc hin? S thc hin DCP ban u phi xy ra ng thi vi qu trnh ph duyt chi tit sn xut (PPAP). Nhm tn ti v vng i sn phm. s cp nht v ci tin ca DCP l mt nhim v dwx dng ca nhm.Xem xt:

Mi ngi lin qua ti sn xut l cc khch hng ca DCP. DCP thnh cng ch ra trong cc hng dn cng vic hu ch, cc phng php kim sot hiu qu, v cc k hoch ti hnh ng xc thc.

Teamwork l lng ct ch yu. Nhm DCP bao hm mi ngi lin quan ti sn xut, cc k s sn phm, cc k s ch to, cc khch hng, cc nh cung cp, v mt s khc cn thit i vi nhm. S h tr ca lnh o cp trn vng mnh c yu cu m bo s thnh cng ca nhm. DCP l qu trnh ch to c tp trung, t cc nguyn vt liu trong sut qu trnh lp rp. Cc c trng ca sn phm v qu trnh c xem xt cng nhau cho tng hot ng ch to. DCP thc hin c hai s pht trin v cc qu trnh ch to mi v s nh gi lc quan v qu trnh ang tn ti. DCP l cuc chy ua v ni dung. Nhm phn u xy dng v s dng hiu qu s hiu bit. Cc ti liu DCP l cch n gin m s hiu bit c ghi li v c chia s.Dng chy ca DCP

Giai on I: Hiu bit v qu trnh ch to (t bc 1 n bc 8)

Giai on II: Xy dng kh nng. (t bc 9 n bc 15).

S hiu bit qu trnh ng n yu cu cc h thng v qu trnh o lng c kh nng.Nhm phi:

Xy dng kh nng o lng

S dng h thng o lng kim tra u ra ca qu trnh

nh gi du cho tong bc s thc hin ti mc tiu v trong nhm dung sai c nh r.

Thc hin cc hiu chnh n cc vn ca kh nng ca qu trnh hoc xy dng cc bin php i ph. m bo rng khi mt qu trnh sn xut n l sn xut mt family chi tit m qu trnh l c kh nng bao qut ton b cc loi chi tit trong family.

Giai on III: Xy dng cc kim sot qu trnh.(t bc 16 n bc 27)

Giai on IV: Thc hin v ci tin (t bc 28 n bc 31)

Dng chy ca DCPMt s tp trung vo qu trnh sn xut

xng/ph

duyt khi nim

Lp k hoch

Ph chun

sn phm v qu trnh

Xc minh

thit k v pht trin qu trnh

Xc minh

thit k v pht trin sn phm

Lp k hoch

v xc nh

chng trnh

Chun b

Th im

nh gi thng tin phn hi v hnh ng khc phc

Ph chun

sn phm v qu trnh

Xc minh


Xc minh


Lp k hoch

v xc nh

chng trnh

Chun b

Th im

To mu

Ph duyt

chng trnh

Lp k hoch

Lp k hoch

T.k v P.trin sn phm

Thit k v pht trin qu trnh

Ph chun qu trnh v sn phm

Sn xut


xng/ph

duyt khi nim


Cc hung dn qu trnh

K hoch phn tch cc h thng o lng

K hoch nghin cu kh nng qu trnh s b

Cc c trng ng gi

H tr ca lnh o

u ra

Cc tiu chun ng gi


Biu dng chy qu trnh

Cch trnh by k hoch sn

Ma trn cc c trng


PFMEA


Ph chun

sn phm v qu trnh

Xc minh


Xc minh


Lp k hoch

v xc nh

chng trnh

Chun b

Th im

To mu

Ph duyt

chng trnh

Lp k hoch

Lp k hoch

T.k v P.trin sn phm



Sn xut


xng/ph

duyt khi nim

u ra bi nhm hoch ch cht lng sn phm ph hp

Cc yu cu ca thit b, cng c v my mc mi.


K hoch kim sot to mu



u ra bi trch nhim thit k

Phn tch li v nh cc nh hng trong thit k (DFMEA).


Xc minh thit k.

Xem xt thit k

Xy dng mu.



Cc thay i c tnh k thut v bn v


Ph chun

sn phm v qu trnh

Xc minh


Xc minh


Lp k hoch

v xc nh

chng trnh

Chun b

Th im

To mu

Ph duyt

chng trnh

Lp k hoch

Lp k hoch

T.k v P.trin sn phm



Sn xut


xng/ph

duyt khi nim


T.k v P.trin sn phm


Ph chun

sn phm v qu trnh

Xc minh


Xc minh


Lp k hoch

v xc nh

chng trnh

Chun b

Th im

To mu

Ph duyt

chng trnh

Lp k hoch

Lp k hoch

T.k v P.trin sn phm



Sn xut


xng/ph

duyt khi nim


Ph chun

sn phm v qu trnh

Xc minh


Xc minh


Lp k hoch

v xc nh

chng trnh

Chun b

Th im

To mu

Ph duyt

chng trnh



Sn xut


Lp k hoch

printed page controled

To mu

Ph duyt

chng trnh

Lp k hoch

Lp k hoch

T.k v P.trin sn phm



Sn xut


xng/ph

duyt khi nim

Teamwork . Ci tin lin tc

Thit b

My mc

Khoang vt liu

g

Cng c

Thng hiu

Tnh cht vt l

Tnh cht ho hc

Chng loi nha

Nguyn vt liu

2.

Question log

4. Flow Diagram Symbol

7.

Souece of Variation

5. Characteristic

1.

Form team

3. Support Information

6. knowledge

Gaps

8. knowledge Gaps

6.1.Measurement

OK?

6.2. Fill

measurement

Gap

6.3. Fill

Knowledge

Gaps

6.4 Change

Flow

Go to

step

4

No

Yes

Yes

Yes

No

No

No

Yes

9. Measurement

Inventory

10. Inventory

Complete?

11. measurement

Capability

12. measurement

capability ok?

12.1. measurement

capability

corrections

13.

Process

Capability

14.1.

Corrections

or

counter measures

14.Process

capability ok?

15. Change Flow?

Go to

step

4

Nhim v rt quan trng ca mt nhm DCP m nhim l vic t c v lu vn bn mt s thu hiu v qu trnh ch to ca chng.

Tt c cc nhim v ca DCP khc ph thuc trn s thnh cng ca hnh ng ny.

Nhm phi:

Xy dng mt l trnh cu hi

Thu thp cc ti liu tham kho quan trng nh FMEA v SFMEA.

Xc nh cc c trng ca qu trnh v sn phm chy cng nhau nh th no.

Xy dng h thng o h tr s iu tra v l hng kin thc.

Xy ng cc mc tiu v dung sai.

Nhn bit cc ngun bin i.

N rt quan trng m nhm xem xt cc ng dn v cng vic bin i lp y cc l hng kin thc

No

Yes

No

Yes

Yes

No

No

Yes

16. Characteristic Matrix

17.

Change Flow?

Go to

Step

4

18. Characteristic Type

20.

FMEA

19. Operational Importance

21.

Change Flow?

Go to

Step

4

22.

Control Factors

23.

Control

Classification

24.

Change Flow?

Go to

Step

4

25.

Control Methods

26.

illustration& instructions

27.

Do they work?

27.1.

Change


Kim sot qu trnh hiu qu da trn:

Mi quan h gia cc c trng v cc bc qu trnh.

Kh nng o lng v qu trnh.

Cc nh hng ca c tnh t cc iu kin trong v ngoi c tnh k thut.

Cc phng php kim sot m biu th cc ng thi bin

i/trng tm trong phm vi c tnh k thut v/hoc nguyn nhn li.

- Cc kim sot hin ti m phng nga v/hoc tm li.

- Cc minh ho, cc cu trc, v cc k hoch ti hnh ng m lm thc s

28.

Implement

29. Maintain& periodically review

30. Revision or improvement

31. Make chages

Yes

No

Tm m rng ca DCP l cung cp thm gi tr, cc thng tin thn thin hn t pha ngi dng ti tt c cc cp ca nh my.

cung cp thnh cng cc thng tin ny, nhm DCP phi:

hoch nh cn then v chp hnh thc hin cc kim sot, minh ho, v hng dn.

nh gi v i ph vi cc thay i sn phm, cc thay i qu trnh v cc i mi.

DCP l mt cng c quan trng cho vic qun l s thay i. Nhm phi lin tc p ng c mt cch u n i ph vi s thay i

18. Characteristic Type

Yes

16. Characteristic Matrix

11. measurement

Capability

No

=Decision

Yes

No

Yes

6.1.

Measurement OK?

8. knowledge Gaps?

6. knowledge Gaps?

5.

Characteristic

7.

Souece

of

Variation

3.

Support Information

4.

Flow Diagram Symbol

1.

Form team

2.

Question log

6.2.

Fill

measurement

Gap

6.3.

Fill

Knowledge

Gaps

6.4

Change

Flow?

Go to

step

4

No

Yes

Yes

Go to

step

4

No

No

Yes

yes

17

Change Flow?

10.

Inventory

Complete?

No

9. measurement

Inventory

No

Yes

=Action

23.

Control

Classification

Go to

step

4

22.

Control Factors

21

Change Flow?

20.

FMEA

19. Operational Importance

Go to

step

4

15

Change

Flow?

14.

Process

capability ok?

13.

Process

Capability

14.1. corrections

or counter

-measures

12.1. measurement

capability

corrections

12.

Measurement

capability ok?

Cc thnh phn ca DCP

Nhm DCP

L trnh cu hi

Cc thng tin h tr

Biu dng chy qu trnh

Cc h thng o lng

Kh nng ca qu trnh

Ma trn c trng

S quan trng v vn hnh

PFMEA

Cc nhn t kim sot

Cc loi kim sot

Cc phng php kim sot

Cc minh ho v cc hng dn

No

yes

30.

Revision or improvement

No

Yes

No

Yes

No

Yes

No

Go to

step

4

24

Change Flow?

25.

Control

Methods

26.


27.1.

Change


27

Do they work?

31

. Make changes

29. Maintain& periodically review

28.

Implement

PAGE 14 ISO 2002-All rights reserved

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APQP Control Plan