装配线质量分析AssemblyQualityAnalysisAQA是什么?Wha
tisit?红色,黄色和绿色意味着什么?Whatdoesared,yellow,greenjobmean?
AQA对我的工作有何影响?Howwillitaffectme?它能简化我们的工作吗?Willitmakemyj
obeasier?AQA是什么?Wh
atisAssemblyQualityAnalysis?AQA是生产线上将装配操作分类的一种工具AQAisat
oolusedtocategorizejobsontheassemblyline质量工程师会用一些标准评估来
自于每道工序的失效导致客户获得不良品的风险Basedonseveralcriteria,thequality
engineerwillmakeanassessmentastotheriskofthecustomer
gettingabadtoolfromafailureatthatstep不同技能的员工分配在不同类别的工作
岗位Wethenmatchoperatorskillswiththejobcategory新一代角磨机的
AQA分析AQAExample-NGSAGAQA分
析的益处Whatarethebenefit
sofAQA?给装配线提出一些须遵循的规则Providesdi
sciplinetoourassemblylines员工更换频繁的情况下,AQA帮助线长有效的安排员工的工作
Withhighemployeeturnover,itmakesiteasie
rforthelineleadertomakejobassignments当我们线上使用熟练的员工时,质量会提
高Qualityisimprovedwhenweuseskilledoperators
AQA可以激发员工的工作极积性Motivatesou
roperatorstoworkharder红色工作的评判标准Wha
tisaredtask?如果出现下列情况,我们说此操作是红色的
Wesayataskisre
dif:有潜在风险会产生重大次品,后续操作无可靠办法在出货之前发现失误
Ithasthepotential
togenerateaseveredefectandthereisnotareliabledetecti
onmethodintheassemblyprocessthatwouldcatchthismistakeb
eforeweshiptheproduct难操作工序,员工需具备特殊技能
Operationisverydif
ficultandrequiresspecialoperatorskills工序操作与安全有关
Operation
isrelatedtosafety,examplehi-pottesting例如Example:员工没有给齿轮加油
,这个失误很严重,由于齿轮磨损整机可能失效Operatordoesnotapplygreasetoagear,th
isdefectisseverebecausethetoolmayfailearlyduetogearw
ear.发生频次高,已发现这种问题Theoccurrencerateissignificantsincethist
ypeofdefecthasbeenobservedinthefield.检查办法不可靠,下道工序无法发现Th
edetectionmethodisnotreliablesincethereisnomeansforde
tectinggreaseplacementdownstream.黄色工作的评判标准
Whatisayellowtask?如果出现下列情况,我们说此操作是黄色的
Wesayataskisyellowif:本工序有产生次品的潜在危险,但是可被后续工序发现,不会到达客
户
Thetaskhasthepotentialtocreateadefectbutitwould
bedetectedduringtheassemblyprocessandthus,notreachingt
hecustomer本工序会引致额外的报废和返工The
processcausesexcessivescraporre-work例如Example:碳刷端子未插入,弹簧未
释放到位,Operatordoes’tinsertterminalcompletely,orspringnotre
leased.绿色工作的评判标准Whatisagreenta
sk?如果出现下列情况,我们说此操作是绿色的Wesayataskisgre
enif:工作非常简单,通常不会产生次品或问题Thetaskisfairly
simpleandshouldnotcauseanydefectsorprocessissues操作不要求特殊
技能Operationdoesno
trequireanyspecialskill如Example:打螺丝Drivingscrews装配手柄盖Ass
emblyhandlecoverhalf红黄绿的真正含义
Whatdoesred,yellow,andgreenactuallymean?做红色工序的员工须经品质部确认Op
eratorswhoperformaredoperationwillhavetobequalified.线
长须提供培训记录,以证明员工具有操作些工序的资质Lineleadersmusthavedocumentedtrainin
gandbeabletoprovethatoperatorcandothejobcorrectly.质
量工程师负责审核线长遵守AQA,没有让未经确认的员工操作红色工序Qualityengineerswillaudittha
tlineleaderisfollowingtheAQAguidelinesandnotputtingunq
ualifiedoperatorsinredoperationsAQA对我的工作有何影响?
HowWillitAffectMe?所有线都要这样做
Alllineswillbeincluded线长要有培训记录,确保各岗位员工已被确认.
Lineleaderswillbeaskedtodocumenttrainingandt
omakesureoperatorsarecertifiedintheirstation问题解答
QuestionsandAnswers问题解答
QuestionsandAnswers目标Goal将红色变为绿色是改善工作的
重点Turning“Red”jobsto“Green”
willbethefocusoffutureimprovementefforts.公司会建立新产品必须达到的标
准.当前的标准是红色工序少于总工序的25%.
B&Dwills
etstandardsthatmustbemetbynewproducts.Currentstandardi
sredjobsmustbelessthan25%oftotaloperations.改善会帮助我们提高产
品质量.
Thiseffortwillhelpusallimprovethequalityofourwor
k为所有工序评估绿-黄-红
AssessallprocessStepsforGreen-Yellow-Red更新工序
卡来反映工作类别Upd
ateworkinstructionstoreflectcode推动工序进步LeadEffortsinRo
llingouttheProcess在反馈的基础上改善工序ImprovetheProcessBased
onFeedback每周审核装配线Audittheassemblyweekly更新数据资料KeeptheDat
abaseUptoDate确保做红色工序的员工接受了相应的培训Ensure
allAssociatesin“Red”Jobsaretrained在红色操作资质表上做记录,每周上交.
Documenttrainingon“RedOperationQualificationSheet”andTurn
InWeekly.完成每日红色操作审核
CompleteDailyProcessAuditSheetfor“Red”Jobs未与品质工程师商量,不能调换
员工.CannotsubstituteoperatorswithoutconsultingQE计划Wh
atistheRoll-OutPlan?1.评估所有装配员工Assessallassembly
operations:March-April2.线上张贴绿-黄-红卡片PostGreen-Yellow-R
edcardsonlines:March-April3.完成各班人员培训,执行本系统Complete
trainingonallshiftsandbeginfollowingsystem五月十五日选择生产线与线长和主
管一起评估ReviewWithLineLeaders/GroupLeadersonSelectedL
ines-5/15六月二十日与相关人员一起研究所选择的生产线PresenttoAssociatesonS
electedLines-Weekof6/20六月二十至二十七日,不间断培训并记录在案Roll-Out
TrainingandDocumentation-Weeksof6/20and6/27七月底,所选的线上建立
此系统SystemFullyinPlaceonSelectedLines7/31线长和返
员人员也需要有培训记录吗?DoIhave
todocumenttrainingformyrepairpersonormyself?不需要,我们认为线长
和返工人员已具备每道工序的装配知识和技能.No.Coordinatorsandrepairassociatesare
consideredtohavefullknowledgeofeachassemblystepanditsa
ssociatedrisks.我每天都要做培训记录吗?DoIhavetodocumenttrainingever
yday?只有当一个员工第一次做红色工序时才需要做.Onlyifyouha
vesomeonedoingaredjobforthefirsttime.当其它线上的员工在我的线上工作时,我
还要重新培训并做记录吗?DoIhavetotrainanddocumentassociatesfromother
lineswhentheyworkonmyline?如果他在另外一条线上也做同样的红色工作就不需要了.将来我们会发
出一个做红色工作的员工列表,这样就知道这个员工是否培训过.Notiftheydothesameredjobo
nanotherline.Wewillpublishalistofallassociatestrained
forallredjobsinthefuture.Thiswillmakeiteasiertoknow
ifanassociateisalreadytrained.如果做红色操作的员工离开一会儿,临时顶替的员工还要做培训
记录吗?DoIhavetodocumentthatsomeonefilledinonaredjobwhileanassociateleftthelineforafewminutes?不需要,但是除非是线长或返工员,否则需要有培训记录证明这个顶替的员工曾被培训过做这个工作.No.Butthepersonfillinginmustbedocumentedashavingbeentrainedforthatjobunlesstheyarethecoordinatororrepairperson.问题解答QuestionsandAnswers质量/项目工程师职责Quality/ResidentEngineeringResponsibilities线长职责LineLeadersresponsibilities下一步NextSteps |
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