R3 training

nullnullReduce Rework & Rejects 减少返工和不合格 R3Prepared by: Trans Gaonull(1)What & Why: 什么是R3, 为什么做R3 Reduce Reject / Reworks (waste in capacity & scrap) 减少不合格和返工 To establish standardized approach to process 建立标准方法 And keep on the positive trend on RTY etc. so enhance customer’s satisfaction . 保持良好的质量目标趋势，从而增强顾客满意。 null(2)How: 怎么做 Empowering employee to visualize the line problems for quick containment & off-line resolution 激励员工来显现生产线问题以快速围堵和离线解决 VS leader is accountable for planning and execution VS经理负责活动的 策划 活动策划ppt下载游戏策划下载民宿策划下载游戏策划shu下载英文歌曲大赛策划免费下载 和执行 PQE is responsible for managing the related activities PQE负责管理相关的实施活动 PP/PE support the related activities PP/PE支持有关活动 Site Quality leader or his/her backup take lead to conduct the assessment process 工厂质量经理或执行质量经理领导R3评估过程 null（3）What is the signal of problem (R3 line stop) 什么时候触发R3停线安灯 Pre-condition: qualified EOL with MSA(type1 and 2) 前提：EOL测试台合格稳定 Line stop rule – 3G/2Y/1R (monthly updated limit based on previous month performance?) 停线规则： 3G/2Y/1R（红、黄、绿界限每月根据上月绩效更新） Common cause / special cause (shuttle bus 5 min late or 30 min late) 区分一般原因/特殊原因 一般原因对策： 过程、方法、设备、材料、人员、环境标准变更 特殊原因对策：过程、方法、设备、材料、人员、环境偏差纠正 路上出事故了吗？？？？null（4）What is the standard operation? 标准作业方式 Record： Operator perform a simple failure analysis and record all failure 记录： 操作者对每个失效件进行简单分析并在R3表上记录失效模式 Andon： Operator trigger Andon and stop line according R3 rules 安灯：操作者按照R3规则停线并按动安灯 Response: Standard investigation conducted by Line leader (Shift leader) & PQE/MQE/TE 班(线）长/过程质量工程师/原材料质量工程师/测试工程师进行标准化调查 Restart: Line start sign-off by line leader after making sure problem is contained or eliminated 确认问题受控、排除之后，班长签字认可重启生产线 Rework/analysis instruction – how to detect the problem (WPL benchmark – ABS failure mode) 按照返工分析指导，检测不合格件的问题，并记录在案。null（5）How to deal with defective parts? 如何处理不合格件 Failure parts must be marked/labeled immediately. No retest allowed before the rework. 失效件必须立即进行标识。在返修前不允许进行二次测试。 Failure parts must be stored in the physical R3 boxes. 失效件必须存放到R3存放盒中。 Failure parts can only be reworked by qualified operator(s) before the shift closure or the change-over for the next variant 失效件只能在本班结束前或者下个变型切换前由有资格的操作员工执行。(如：ABS-WS03） The components disassembled must be scrapped following the scrap component list. No reuse allowed! 按照报废件清单对拆解后的零件进行报废，不可再用于新产品的生产或者返修。 （目前ABS 仅有一种件8979800224-O型圈） The reworked parts must be retested at EOL 返工后的成品必须重新经过EOL检测未返修重测 null(6) What is the communication and the problem-solving off-line? 沟通和离线后的问题解决 Daily/Shift change-over meeting (problem, containment, off-line countermeasures) 日常/交接班会议(问题，围堵，离线对策） Weekly meeting（ organized by VS quality team） 质量周会（VS质量人员组织） DRM Quality meeting 日常质量会议 Problem solving (RCCA) team (SDMS/CFT/SIT) 问题解决团队 Escalation to the management 扩大化管理 nullExpectation 期望 Respect the EOL results – No re-test without rework/analysis 尊重零件首次测试结果，必须分析该零件测试不合格的原因，重复测试不做分析是不允许的。 Strictly follow the Line stop rule, trigger the Andon for the alerting 严格执行停线规则，遵循安灯响应 流程 快递问题件怎么处理流程河南自建厂房流程下载关于规范招聘需求审批流程制作流程表下载邮件下载流程设计 Allow time for problem analysis and decision on containment & problem solving 允许时间用于问题解决，以决定质量围堵和解决问题。 Strictly follow the rework scrap instruction: no re-use of the to-be scrapped components 严格遵照返工报废指导：不重复使用应该报废的原材料。null- Special qualified personnel can operate the station. 只有专门认证人员能够在此岗位上工作 - The station is separate from other stations in the line process 在生产过程中此岗位与其它岗位分离。 - Immediate labeling/marking of failure parts is necessary. Information attached to device shall include failure mode/code from test bench. 测试不合格零件必需立即标识，附上装置信息必须包括试验台测验不合格的模式/代号。nullreused after disassembly for repair/analysis. 返修工作站必须有一个在返修和拆解后不能使用的物料和零件清单 - There must be defined rules how to investigate parts before reuse (damaged cannot be reused).必须定义重新利用返修后的零件规则（损坏的件不能重复使用）。 - There must be available a checklist for rework – how, what and when to check.返工的检查清单必须可用（如何检查，检查什么，什么时候检查）。nullExpectation 期望 Instruction must be prepared with analysis steps for repair operator, key points marked (error codes and reactions to them). 作业指导必须有返修操作的分析阶段，标出关键点（错误代号和反应情况） Locations must be defined for all needed rework tools (5S). 返修工作站必须定义所有必需的返工工具。 Simple coding system should be implemented (ex. Q1 – o-ring damaged) between work Station, EOL and analysis station. 在工作岗位，终端试验和分析岗位间，实行简单的代号系统（例如：Q1- O型圈坏损）。nullOthers 其他 R3 chart by left/right test benches 测试台左右侧分开统计 Line shut-down rule  escalation rule: 3 stops on same failure  Line Shut-down for response team 停线准则：同一种失效模式连续3次—〉需要呼叫班组长—〉停线进行响应团队调查