五大工具的整合应用课程特色与背景

课程目标：

APQP/FMEA/PPAP/SPC/MSA五大工具能力提升。

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:

<Advanced Product Quality Planning and control plan >  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

<FMEA>培训大纲（最新草案版）

<FMEA>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

<Measurement Systems Analysis>培训大纲(第4版)

<Measurement Systems Analysis>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

<Statistical Process Control >培训大纲(第2版)

<Statistical Process Control >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

<Production Part Approval Process >  课程大纲（第4版）

<Production Part Approval Process > 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

课程主讲

刘老师

资深国家注册顾问师。

教育背景Education：

1994年，郑州煤炭学院,  矿山机械

Zhengzhou Coal College, Mining Machinery

2004年，重庆大学，会计学

Chongqing University, Accounting

2013年，山东大学，工商管理硕士

Shandong University, MBA

2017年，南京大学，国际经济

Nanjing University, International Economics

专业资格Expertise Qualification：

1998年 德尔福-清华QS-9000评审员/Delphi-Qinghua QS-9000 Assessor

2001年 江苏省标准化从业资格证/ Jiangsu Province Qualification Certificate of Standardization

2002年 福特Q1-2002 /Ford Q1-2002 Training

2002年 美国品士ISO/TS16949评审员/USA Plxus ISO/TS16949 Assessor

2002年 美国MAS 六西格玛黑带/USA MAS 6 Sigma Black Belt

2002年 IRCA ISO9001注册评审员/IRCA ISO 9001 Auditor

2003年 SGM-QSB/ SGM-QSB Training

2003年 国家注册咨询师/Nation Registered Consultant

2004年 香港品质保证局 TL9000审核员/HKQAA TL9000 Assessor

2005年 英国TEC AS9100审核员/UK TEC AS9100 Assessor

2006年 法国贝尔  IRIS审核员/AFAQ AFNOR Certification,  IRIS Auditor

2008年 国军标 GJB 9001审核员/GJB9001 Auditor

2013年 PMI 项目管理专业证书/PMI Project Management Professional

2015年 VDA VDA6.3过程审核员/VDA  VDA6.3 Process Auditor

2016年 IATF 16949:2016培训师/IATF 16949:2016 Trainer

2017年 GM-BIQS /GM-BIQS Training

2017年 AS 9100D & AS9110 & AS9120培训师/AS 9100D & AS9110 & AS9120 Trainer

2017年 ISO/TS 22163培训师/ISO/TS 22163  Trainer

2017年 国军标 GJB9001培训师/GJB9001 Trainer

2017年 TL 9000(R6.0/5.5)培训师/TL 9000(R6.0/5.5) Trainer

课程对象

质量、技术、生产等相关管理人员及工程师

备注

课程费用：6000元/人

含授课费、资料费、午餐费、茶点费、会务费、税费

不包含学员往返培训场地的交通费用、住宿费用、早餐及晚餐