课程目标：
APQP/FMEA/PPAP/SPC/MSA五大工具能力提升。
参训对象：
质量、技术、生产等相关管理人员及工程师
授课形式：
知识讲解、案例分析讨论、角色演练、小组讨论、互动交流、游戏感悟、头脑风暴、强调学员参与。
课程大纲：
Curriculum outline:
| 课程大纲（第2版） | |||||
主题/目标 Theme/objective | 讲 师 lecturer | 学 员 students | |||
课程导入 Curriculum import | 问题提出与小组组建 Problem raising and team building | 自我介绍/分组 Introduce yourself/group | |||
培训目标及要求 Training objectives and requirements | |||||
APQP基础知识 Basic knowledge of APQP | 质量从哪里来？ Where does the mass come from? | 提问及回答老师问题 Ask and answer teacher's questions | |||
APQP的本质 The essence of the APQP | |||||
APQP的关键问题 The key issue with APQP | |||||
APQP的成功法则 APQP's rules for success | |||||
项目开发主流程及关键节点 Main process and key nodes of project development | |||||
第一阶段：计划与确定项目 Phase 1: planning and identifying projects | 立项阶段必须解决的三大问题 Three major problems must be solved in the project establishment stage
| 顾客呼声与内外部输入 Customer voice with internal and external input | |||
制造可行性评估 Manufacturing feasibility assessment | |||||
三大目标、三大初始条件及保证计划 Three objectives, three initial conditions and assurance plans | |||||
三大问题剖析及整合性思考 Three problems analysis and integration thinking | |||||
第二阶段：产品设计与开发 Stage 2: product design and development | 产品设计的基本问题 Basic issues in product design | 功能与结构设计 Functional and structural design | 提问及回答老师问题 Ask and answer teacher's questions | ||
尺寸与公差设计 Dimension and tolerance design | |||||
材料与配方设计 Material and formula design | |||||
产品设计要考虑的三个方面 There are three aspects to consider in product design | DFMEA | ||||
| DFA/M | |||||
关键产品特性确定 Identification of key product characteristics | |||||
设计评审、验证与确认的策划与实施 Planning and implementation of design review, verification and validation | 三者的区别与联系 The difference and connection of the three | ||||
开发DVP The development of DVP | |||||
硬件设施的同步考虑 Synchronization considerations for hardware facilities | （新）设施设备清单 List of (new) facilities and equipment | ||||
（新）工装/检具清单 (new) tooling/fixture list | |||||
供应商的同步开发 Synchronous development of suppliers | 从BOM到选点 From BOM to select point | ||||
第三阶段：过程设计与开发 Stage 3: process design and development | 过程设计：5M的通盘考量 Process design: 5M overall consideration | layout设计与评估 Layout design and evaluation | 提问及回答老师问题 Ask and answer teacher's questions | ||
过程FMEA与过程系统风险 Process FMEA and process system risk | 过程流程图 Process flow chart | ||||
特殊特性矩阵 Special characteristic matrix | |||||
过程FMEA Process FMEA | |||||
关键控制特性 Key control characteristic | |||||
工艺改善计划实施与评估 Implement and evaluate process improvement plan | |||||
OTS样件与有效生产控制计划 OTS sample and effective production control plan | |||||
制造与检验规范的策划与实施 Planning and implementation of manufacturing and inspection specifications | |||||
包装标准与物流策划 Packaging standards and logistics planning | |||||
第四阶段：产品和过程确认 Stage 4: product and process validation | 有效生产的策划与实施 Effective production planning and implementation | 提问及回答老师问题 Ask and answer teacher's questions | |||
如何通过有效生产验证 How to pass effective production verification | 过程能力 Process capability | ||||
测量系统 Measurement system | |||||
生产节拍 Production of the beat | |||||
质量目标 Quality objectives | |||||
设计目标 Design goals | |||||
可靠性目标 Reliability target | |||||
包装规范 Packing specification | |||||
作业指导书 Operating instruction | |||||
先期策划总结与量产控制计划 Advance planning summary and mass production control plan | |||||
案例研究4 Case study 4 | |||||
第五阶段：反馈、评定和纠正措施 Stage 5: feedback, evaluation and corrective actions | 初期流动管理与早期遏制 Early flow management and early containment | 提问及回答老师问题 Ask and answer teacher's questions | |||
制造过程审核与持续改进 Manufacturing process audit and continuous improvement | 普通原因的研究与过程能力提升 Common cause research and process capability improvement | ||||
制造过程审核与流程改进 Manufacturing process audit and process improvement | |||||
顾客反馈的快速响应 Quick response to customer feedback | |||||
课程小结： Curriculum summary: | PDCA循环与同步技术的应用 Application of PDCA cycle and synchronization technology | ||||
内容小结 Contents summary | 课程回顾 Curriculum review | ||||
回答学员问题及疑点澄清 Answer questions and clarification | |||||
课程应用 Curriculum application | 辅导学员制订培训后的APQP改善计划 Coach trainees to develop APQP improvement plan after training | 制订培训后的应用计划 Make application plan after training | |||
应用过程中可能出现的问题及解决途径 Possible problems and solutions in the application process | |||||
培训大纲（最新草案版） training outline (latest draft version) | |||||
主题/目标 Theme/objective | 讲 师 lecture | 学 员 students | |||
FMEA概述 FMEA overview | FMEA起源 FMEA origin | FMEA哲学 FMEA philosophy | 提问及回答老师问题 Ask and answer teacher's questions | ||
FMEA起源及推广 FMEA origin and promotion | |||||
FMEA框架 FMEA framework | FMEA基本格式及其最新变化 FMEA basic format and its latest changes | ||||
| DFMEA简介 | DFMEA应用时机 DFMEA application timing | 设计开发三种情形对比 Design and development of three cases of comparison | 提问及回答老师问题 Ask and answer teacher's questions | ||
基本步骤 Basic steps | 新版DFMEA六步法 New DFMEA six-step method | ||||
案例简析 Case analysis | 新版DFMEA简要剖析 New DFMEA brief analysis | ||||
| PFMEA | |||||
启动 FMEA 之旅 Start a FMEA tour | 定义范围 Define the scope | 定义范围 Define the scope | 提问及回答老师问题 Ask and answer teacher's questions | ||
常见缺陷归纳 Induction of common defects | |||||
结构分析 Structure analysis | 工艺流程图 Process flow chart | ||||
功能分析 Functional analysis | 产品/过程特性矩阵分析 Product/process characteristics matrix analysis | ||||
失效分析 Failure analysis | 失效模式分析 Failure mode analysis | 失效模式定义 Failure mode definition | |||
失效模式讨论 Failure mode discussion | |||||
失效后果分析 Failure consequence analysis | 产品失效的外部风险 External risk of product failure | ||||
产品失效的内部风险 Internal risk of product failure | |||||
失效起因分析 Failure cause analysis | 失效起因分析方法与深度 Failure cause analysis method and depth | ||||
小组讨论- 失效起因 Panel discussion - causes of failure | |||||
风险分析（1） Risk analysis (1) | 预防 Prevention
| 什么是预防 What is prevention | |||
常见的问题预防方式 Common ways to prevent problems | |||||
小组练习:所选产品/过程之预防方法 Group exercise: preventive measures for selected products/processes | |||||
探测 Detection | 什么是探测 What is detection | ||||
常见的问题探测方式 Common problem detection methods | |||||
小组练习:所选产品/过程之探测方法 Group exercise: detection methods for selected products/processes | |||||
风险分析（1） Risk analysis (1) | 严重度(S)评估 Severity (S) assessment | FMEA所推荐之严重度评分表 FMEA recommended severity rating form | |||
小组练习:严重度评价 Group exercise: severity evaluation | |||||
延伸-严重度与关键特性之关联 Extension - correlation between severity and key characteristics | |||||
频度(O)评估 Frequency (O) evaluation | FMEA所推荐之频度评分表 FMEA recommended frequency rating form | ||||
小组练习:频度评价 Group exercise: frequency evaluation | |||||
延伸-频度与PPM及CPK之关联 Extension - association of frequency with PPM and CPK | |||||
探测度(D)评价 Detection (D) evaluation | FMEA推荐探测度评分表之深度解析 Depth analysis of FMEA recommended probe rating scale | ||||
小组练习:探测度评价 Group exercise: detection evaluation | |||||
优化改进 Optimization to improve | 确定改进顺序 Determine improvement sequence | 两大基本原则 Two basic principles | 提问及回答老师问题 Ask and answer teacher's questions | ||
确定改进方案 Determine improvement plan | 改进方向探讨 Discussion on improvement direction | ||||
改进方案确定 Determination of improvement plan | |||||
评估改进效果 Evaluate the improvement effect | 改进效果追踪 Improvement effect tracking | ||||
RPN之重新计算 Recalculation of RPN | |||||
小组练习:如何降低过程风险 Group exercise: how to reduce process risk | |||||
课程小结 Curriculum summary | 内容小结 Contents summary | 课程回顾 Curriculum review | |||
回答学员问题及疑点澄清 Answer questions and clarification | |||||
课程应用 Course application | 辅导学员制订培训后的FMEA推广计划 Coach trainees to make promotion plan of FMEA after training | 制订培训后的应用计划 Make application plan after training | |||
应用过程中可能出现的问题及解决途径 Possible problems and solutions in the application process | |||||
培训大纲(第4版) Training framework (4th edition) | |||
主题/目标 Theme/objective | 讲 师 lecture | 学 员 students | |
测量系统与测量误差 Measurement system and measurement error | 测量系统 Measurement system | 测量过程与测量系统 Measuring process and measuring system | 讨论/分析公司主要测量仪器所构成的测量系统及常见问题 Discuss/analyze the measuring system and common problems of the company's main measuring instruments |
测量系统变差 The measuring system goes bad | 测量过程变差来源 Source of variation in measurement process | ||
测量误差的来源 Source of measurement error | |||
测量系统变差对过程决策的影响 Measure the effect of system variation on process decision making | |||
过程变差剖析 Process variation analysis | |||
案例研究1 Case study 1 | |||
测量系统的统计特性 Statistical characteristics of measurement systems | 测量仪器分辨率 Resolution of measuring instrument | 提问及回答老师问题 Ask and answer teacher's questions | |
测量系统的位置变差与宽度变差 The position variation and width variation of the measuring system | |||
测量系统五性 Five characteristics of measuring system | 偏倚（Bias) | ||
| 稳定性(Stability) | |||
| 线性(Linearity) | |||
| 重复性(Repeatability) | |||
| 再现性(Reproducibility) | 提问及回答老师问题 Ask and answer teacher's questions | ||
测量系统分析策划 Measurement system analysis and planning | 分析时机与前期准备 Analyze timing and preparation | 测量系统研究的准备 Preparation of measurement system research | |
测量系统分析的两个阶段 Two stages of measurement system analysis | |||
什么时候需要分析测量系统? When does the measurement system need to be analyzed? | |||
选用适当方法 Use appropriate methods | MSA方法分类与选用 Classification and selection of MSA method | 提问及回答老师问题 Ask and answer teacher's questions | |
计量型测量系统研究 Research on metrological measurement system | 确定测量系统偏倚的独立样本法 Independent sample method for determining measurement system bias | 偏倚分析指南 Guidelines for bias analysis | |
偏倚分析的MINITAB/EXCEL应用 Bias analysis using MINITAB/EXCEL | |||
偏倚产生的原因分析 Analysis of the causes of bias | |||
案例研究2 Case study 2 | |||
确定测量系统线性 Determine the linearity of the measurement system | 线性分析指南 Linear analysis guide | 提问及回答老师问题 Ask and answer teacher's questions | |
线性分析的MINITAB/EXCEL应用 Application of MINITAB/EXCEL for linear analysis | |||
非线性产生的原因分析 Cause analysis of nonlinearity | |||
确定测量系统稳定性 Determine the stability of the measurement system | 稳定性分析指南 Stability analysis guide | 提问及回答老师问题 Ask and answer teacher's questions | |
稳定性分析的MINITAB/EXCEL应用 Stability analysis of MINITAB/EXCEL application | |||
不稳定性产生的原因分析 Cause analysis of instability | |||
确定测量系统重复性&再现性(R&R) Determination of repeatability & reproducibility of measurement system (R&R) | R&R分析指南 R&R analysis guide | 提问及回答老师问题 Ask and answer teacher's questions | |
R&R分析的MINITAB/EXCEL应用 Application of R&R analysis in MINITAB/EXCEL | |||
重复性/再现性偏大的原因分析 Cause analysis of high repeatability/reproducibility | |||
案例研究 Case study | |||
计数型测量系统研究 Research on counter measurement system | 假设检验分析-交叉表方法 Hypothesis test analysis - cross table method | 交叉表方法指南 Cross table method guide | 提问 Ask questions |
交叉表方法分析的MINITAB/EXCEL应用 Cross table method analysis of the application of MINITAB/EXCEL | |||
课程小结 Curriculum summary | 内容小结 Contents summary | 培训内容回顾及案例点评 Training content review and case review | |
回答学员问题及疑点澄清 Answer questions and clarification | |||
培训大纲(第2版) Training outline (2nd edition) | |||
主题/目标 Theme/objective | 讲 师 lecture | 学 员 students | |
基础知识 Basic knowledge
| 变差及其来源 Variation and its source | 什么是变差 What is variation | 提问及回答老师问题 Ask and answer teacher's questions |
变差之主要来源 The main source of variation | |||
均方根定律 Root mean square law | |||
变差与正态分布 Variation and normal distribution | 正态分布之特点与判定方法 Characteristics and determination methods of normal distribution | ||
普通原因与特殊原因 Common cause and special cause | 什么是产生变差的普通原因 What are the common causes of deterioration | ||
什么是产生变差的特殊原因 What are the specific causes of variation | |||
普通原因与特殊原因之判定方法 Determination of common and special causes | |||
小组练习:5M与两类原因之关联 Group exercise :5M associated with two types of causes | |||
确定过程控制模式 Identify process control patterns | 两类过程模式 Two types of process patterns | 传统制造模式之特点与局限 Characteristics and limitations of traditional manufacturing models | 提问及回答老师问题 Ask and answer teacher's questions |
预防为主的SPC模式 Prevention oriented SPC model | |||
SPC改善循环 SPC improvement cycle | 4类过程的识别与转换 4 types of process identification and transformation | ||
SPC应用循环-AMI SPC application cycle -AMI | |||
小组讨论-我们的过程模式及改善方向 Group discussion - our process model and improvement direction | |||
过程失控判定 Process loss of control determination | 知识准备 Knowledge to prepare | 基本统计概念 Basic statistical concept | 提问及回答老师问题 Ask and answer teacher's questions |
正态分布与控制图 Normal distribution and control graph | |||
控制图:两大类与两阶段 Control diagrams: two categories and two phases | |||
常规控制图及其判异 Routine control chart and its judgment | 常规控制图选用 General control chart selection | ||
常规控制图制作与应用 General control chart making and application | |||
常规控制图判异法则 General control graph rule | |||
案例研究 Case study | |||
过程能力分析 Process capability analysis | 过程能力分析之常用指标 Common indicators for process capability analysis | CP/CPK | 提问及回答老师问题 Ask and answer teacher's questions |
| PP/PPK | |||
| CM/CMK | |||
过程能力与PPM之换算 Conversion of process capacity to PPM | 过程能力与西格玛水平 Process capability and sigma level | ||
过程能力与PPM Process capability and PPM | |||
小组练习:CPK计算 Group exercise :CPK calculation | |||
课程小结 Curriculum summary | 内容小结 Contents summary | 培训内容歌诀化记忆 Training content to memorize songs | |
回答学员问题及疑点澄清 Answer questions and clarification | |||
课程大纲（第4版） Syllabus (4th edition) | |||
主题/目标 Theme/objectives | 讲 师 lecture | 学 员 students | |
PPAP目的和意义 Purpose and significance of PPAP | a) 关键定义 key definitions | 提问及回答老师问题 Ask and answer teacher's questions | |
| b) PPAP的目的 the purpose of the PPAP | |||
| c) PPAP适用对象 PPAP applies to objects | |||
| d) PPAP流程图 The flow chart of PPAP | |||
| PPAP提交的时机及三类情况 | a) 必须提交 Must submit | ||
| b) 通知顾客 Inform the customer | |||
| c) 不必自找麻烦 Don't look for trouble | |||
小组练习 Group practice | |||
PPAP提交等级及主要内容 PPAP submission level and main content | PPAP提交等级确认-顾客-企业-供应商 PPAP submits level confirmation - customer - enterprise - supplier | 提问及回答老师问题 Ask and answer teacher's questions | |
PPAP提交内容详解 PPAP submission details | 可销售产品的设计记录 Design records of marketable products | ||
—专利权的零部件/详细数据 —Patented parts/details | |||
—所有其他零部件/详细数据 —All other parts/details | |||
工程变更文件 Engineering change document | |||
客户工程批准（如果需要） Customer engineering approval (if required) | |||
设计FMEA Design FMEA | |||
过程流程图 Process flow chart | |||
过程FMEA Process FMEA | |||
控制计划 The control plan | |||
测量系统分析 Measurement system analysis | |||
全尺寸测量结果 Full size measurement results | |||
材料、性能试验结果 Material and performance test results | |||
初始过程研究 Initial process study | |||
合格实验室文件 Qualified laboratory documents | |||
外观件批准报告（AAR）（如需要） Exterior approval report (AAR) (if required) | |||
生产件样品 Production sample | |||
标准样品 Standard sample | |||
检查辅具 Check the assistive devices | |||
符合顾客特殊要求的记录 A record of meeting special customer requirements | |||
零件提交保证书（PSW） Parts submission guarantee (PSW) | |||
散装材料检查表 Bulk material checklist | |||
案例研究 Case study | |||
PPAP提交结果及处理 PPAP submission results and processing | a) 完全批准，临时批准，拒收 full approval, provisional approval and rejection | 提问及回答老师问题 Ask and answer teacher's questions | |
b) 完全批准后的实施要点 implementation points upon full approval | |||
c) 什么情况下可能会导致临时批准 under what circumstances may provisional approval be granted | |||
d) 临时批准的紧急应对及注意事项 Temporary approval of emergency response and precautions | |||
e) 批准记录的保存及更新 Approve record keeping and update | |||
课程小结： Curriculum summary | PPAP与APQP之关联 Association of PPAP and APQP | ||
内容小结 Contents summary | 课程回顾 Curriculum review | ||
回答学员问题及疑点澄清 Answer questions and clarification | |||
