COQ--质量成本分析

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1、,COST OF UALITY,品 質 成 本,Q,Poor Quality,Poor Business!,品質差,生意差!,It is a time bomb waiting to,Explode!,COQ高,是一顆等待爆炸的定時炸彈！,IF COQ high,如果,COQ,高,Why?,Hidden failure cost,隱藏的失效本钱,Commonly measured,failure cost,通常量度的失效本钱,True,Failure,Costs,真正的失效本钱,Scrap,報廢,Rework,翻工,Warranty,保證,Engineering time,工程設計時間,Man

2、agement time,管理時間,Shop and field downtime,工場壞機時間,Increased inventory,增加存貨,Decreased capacity,削弱生產能力,Delivery problems,交貨問題,Lost orders,訂單減損,Commonly measured failure cost is only the tip of the True Failure Costs.,通常量度的失效本钱只是真正失效本钱中的冰山一角。,Quality cost is a measure of the achievement and non achievem

3、ent of product quality.,Tip of the Ice Berg,冰山一角,Why?,The Cost Pyramid 本钱金字塔,Process Control,工藝控制,Inspection,檢 查,Field Service,服 務,Design,設計,Cost of Quality,QFD,SPC,DOE,Why?,Money spend to fix,an issue at different,stages:,不同階段修正某個問,題所花的金錢：,Design:1$,設計:1$,Production:100$,生產,:100$,Customer:1000$,到客戶

4、手中,:1000$,Resultant Cost 結果本钱 =Failure Cost 失效本钱,Defect Cost 次品本钱.,Controllable Cost 可控本钱=Prevention and Appraisal Cost.預防和評估本钱.,Poor Quality is Poor Business,品質差即是生意差,0,10,20,30,40,50,60,Controllable Effort,Cost,Total Cost,總本钱,Controllable,Cost可控本钱,Resultant Cost,結果本钱,A,Low,High,Why?,Effect of Good

5、 Preventive Activities,良好的預防活動產生的效果,0,10,20,30,40,50,60,Controllable Effort,Cost,A,B,Old Total,舊的總本钱,Controllable,Cost,可控本钱,Resultant Cost,結果本钱,Low,High,New Tota,新的總本钱,l,Good Preventive activities usually begin at front end of process,with better effect on resultant cost.,良好的預防活動通常開始于工序前沿,對結果本钱產生較好的

6、影響。,Why?,Taguchi Quality Loss Function(QLF),Taguchi,品質損失運算(,QLF),We cannot reduce cost without affecting quality.我們不能削減本钱而不影響品質,We can improve quality without increasing cost.我們可以不增加本钱而改善品質.,We can reduce cost by improving quality.我們可以通過改善品質而降低本钱.,We can reduce cost by reducing variations.我們可以通過減少差異

7、而降低本钱.,Taguchi QLF strive for minimal variation around target values without adding cost.,He defines loss as“the lost imparted to society from the time the product is shipped,this loss includes,Taguchi QLF 努力达致接近目标值的最小差异而不增加本钱。,他将损失定为：“从产品装运时流失的那局部损失“这种损失包括：,customer dissatisfaction,客戶不滿意,added warr

8、anty cost to the producer,生产商增加担保本钱,loss due the companys bad reputation,公司信譽恶劣引致的损失,which would lead to eventual loss of market share.,这种损失终將导致市场份额的丧失。,Why?,Taguchi Quality Loss Function(QLF),Taguchi,品质,损失运算,(,QLF),Quality cost are usually quantified in terms of tangible cost such as rework and scr

9、ap cost,and customer warranty.These losses constitute only the tip of the iceberg.,品质本钱通常以有形本钱如翻工,报废,给客户提供担保等等而被量化,这些损失只是冰山一角。,What about the intangible costs such as management/engineering time,inventory,customer,dissatisfaction,and loss market share?,那些无形的本钱代价如管理/设计时间,存货,客户的失望,市场份额损失等,又怎样呢？,QLF is

10、 a method used to approximate these hidden and long term losses.QLF 是用于估算这些隐藏的而且是长期损失的方法。,Why?,Taguchi Quality Loss Function(QLF),Taguchi,品质损失,运,算,(,QLF),The way QLF is established depends on the type of quality characteristics involved.A quality characteristics is whatever we measure to judge perfo

11、rmance(quality).,QLF的建立有赖于有关的品质特性。,品质特性是用来判断性能(品质)而进行的一切量度。,There are five types of quality characteristics.,有五种品质特性.,Nominal the best.Achieving a desired target value with minimal variations,such as,dimensions&output voltage.,名义上的最好 达致理想的目标值,差异最小,如尺寸和输出电压。,Smaller the better.Minimizing a response,s

12、uch as shrinkage and wear.,越小越好 如收缩和磨损,Larger the better.Maximizing a response,such as pull off force and tensile strength.,越大越好 如拉力和张力,Attribute.Classifying and/or counting data,such as appearance.,属性澄清并且/或者清点数据,如外观,Dynamic.Response varies depending on input,such as a fan drive speed,should vary wi

13、th engine temperature.,动态 回复有賴於輸入,如風扇的變速必須根据引擎溫度而變化。,Why?,Taguchi Quality Loss Function(QLF),Taguchi,品质,损失运算,(,QLF,Value of quality characteristics,品质,特性值,Loss$,y,L=k(y-T),L =Loss in$s以美元计的损失,k =Cost coefficient 本钱系数,y =Value of quality characteristics 品质特性值,T =Target value.目标值,LSL,USL,Why?,Basic Pr

14、emises for Quality Cost:,品质本钱根本前提:,1.It is less expensive to prevent rather than detect nonconformity,预防比检测更省钱。,2.Process and product performance can be appraised(measured),工序和产品性能可以评估(量度),3.The causes for nonconformance can be identified and their effects can be reduced or eliminated,产品不符的原因可以确认,其影

15、响可以减小或消除,Why?,Why Examine the Cost of Quality?,为何要审视品质本钱?,1.Get management attention引起管理层的关注,2.Change the way employee think about errors,改变雇员看待错误的方法,3.Provide better return on the quality improvement program,提供更好的回报,4.Provide a tool to measure impact of corrective actions,为改正行动提供量度的工具,5.Provide a t

16、ool to measure the impact of poor-quality on profits,为恶劣品质对利润的影响提供量度的工具,Why?,Prevention,Scrap,预,防,报,废,1.Prevention Cost預防本钱,-Cost of all activities specifically designed to prevent poor quality in products.,專門設計用于防止產品惡劣品質的一切活動本钱。,2.Appraisal Costs.評估本钱,-Cost associated with measuring,evaluating or auditing products to ensure,conformance to quality standards.,為確保符合品質標準所進行的與產品量度、評估或審核等有關的本钱。,3.Internal Failure Costs.內部失效本钱,-Failure costs occurring prior to delivery or shipment of the product.,在產品交