【正文】 ure Costs 真正的失效成本 ? Scrap報(bào)廢 ?Rework 翻工 ?Warranty保證 ? Engineering time 工程設(shè)計(jì)時(shí)間 ? Management time管理時(shí)間 ? Shop and field downtime工場(chǎng)壞機(jī)時(shí)間 ? Increased inventory增加存貨 ?Decreased capacity 削弱生產(chǎn)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. 通常量度的失效成本只是真正失效成本中的冰山一角。 Quality cost is a measure of the achievement and non achievement of product quality. Tip of the Ice Berg 冰山一角 The Cost Pyramid 成本金字塔 Process Control 工藝控制 Inspection 檢 查 Field Service 服 務(wù) Design 設(shè)計(jì) Cost of Quality QFD SPC DOE Money spend to fix an issue at different stages: 不同階段修正某個(gè)問 題所花的金錢： Design: 1 $ 設(shè)計(jì) : 1 $ Production: 100$ 生產(chǎn) : 100$ Customer: 1000$ 到客戶手中 : 1000$ Resultant Cost 結(jié)果成本 = Failure Cost 失效成本， Defect Cost 次品成本 . Controllable Cost 可控成本 = Prevention and Appraisal Cost. 預(yù)防和評(píng)估成本 . Poor Quality is Poor Business 品質(zhì)差即是生意差 0 10 20 30 40 50 60 Controllable Effort Cost Total Cost 總成本 Controllable Cost可控成本 Resultant Cost 結(jié)果成本 A Low High Effect of Good Preventive Activities 良好的預(yù)防活動(dòng)產(chǎn)生的效果 0 10 20 30 40 50 60 Controllable Effort Cost A B Old Total 舊的總成本 Controllable Cost 可控成本 Resultant Cost 結(jié)果成本 Low High New Tota 新的總成本 l Good Preventive activities usually begin at front end of process with better effect on resultant cost. 良好的預(yù)防活動(dòng)通常開始于工序前沿，對(duì)結(jié)果成本產(chǎn)生較好的影響。 他將損失定為： “ 從 產(chǎn)品裝運(yùn)時(shí)流失的那部分損失“這種損失包括 ： customer dissatisfaction, 客戶不滿意 added warranty cost to the producer, 生 產(chǎn)商增加擔(dān)保成本 loss due the pany’s bad reputation, 公司信譽(yù) 惡劣引致的損失 which would lead to eventual loss of market share. 這 種損失終 將 導(dǎo)致市場(chǎng)份額的喪失。 What about the intangible costs such as management/engineering time, inventory, customer dissatisfaction, and loss market share? 那些無形的成本代價(jià)如管理 /設(shè)計(jì)時(shí)間，存貨，客戶的失望，市場(chǎng)份額損失等，又怎樣呢？ QLF is a method used to approximate these hidden and long term losses. QLF 是 用于估算這些隱藏的而且是長(zhǎng)期損失的方法。 品質(zhì)特性是用來判斷性能 (品質(zhì) )而進(jìn)行的一切量度。 Smaller the better. Minimizing a response, such as shrinkage and wear. 越 小越好 如 收縮和磨損 Larger the better. Maximizing a response, such as pull off force and tensile strength. 越 大越好 如 拉力和張力 Attribute. Classifying and/or counting data, such as appearance. 屬 性 澄清并且 /或 者 清點(diǎn)數(shù)據(jù)，如外觀 Dynamic. Response varies depending on input, such as a fan drive speed should vary with engine temperature. 動(dòng) 態(tài) 回復(fù)有賴於輸入，如風(fēng)扇的變速必須根據(jù)引擎溫度而變化。 L = Loss in $’s以 美元計(jì)的損失 k = Cost coefficient 成本 系數(shù) y = Value of quality characteristics 品質(zhì) 特性值 T = Target value. 目標(biāo) 值 LSL USL Basic Premises for Quality Cost: 品質(zhì) 成本基本前提 : 1. It is less expensive to prevent rather than detect nonconformity 預(yù) 防比檢測(cè)更省錢。 2. Appraisal Costs. . 評(píng)估成本 Cost associated with measuring, evaluating or auditing products to ensure conformance to quality standards . 為確保符合品質(zhì)標(biāo)準(zhǔn)所進(jìn)行的與產(chǎn)品量度、評(píng)估或?qū)徍说扔嘘P(guān)的成本。 ? Appraisal Cost associated with measuring conformance 評(píng)估 與符合標(biāo)準(zhǔn)量度有關(guān) 的成本。 Apparent Supplier Quality Cost 明顯的供應(yīng)商品質(zhì)成本 Cost of Supplier Quality Surveys. 供應(yīng)商品質(zhì)調(diào)查成本 Cost of Receiving and Source Inspection. 接收和源頭檢查成本 Cost of dispositioning nonconformance purchased materials. 采購錯(cuò)位與不符的物料 Cost of scrap and rework of supplier caused nonconformance. 供應(yīng)商的原因引起的報(bào)廢和翻工 Cost of site visit to correct supplier service problems. 走訪供應(yīng)商改正問題所需的成本 Hidden Supplier Costs隱含的供應(yīng)商成本 Cost incurred by supplier at the supplier’s facility供應(yīng)商設(shè)備引致的成本 Cost incurred by buyer in solving problems at the supplier’s facility 采購人員用供應(yīng)商設(shè)備解決問題時(shí)發(fā)生的成本 Supplier Quality Cost供應(yīng)商品質(zhì)成本 Index 指標(biāo) (QCPI) Excellent卓越 Good 良好 Fair一般 Poor差 + Immediate corrective action required. 要即刻采取改正行動(dòng) Supplier Rating Program Using Quality Cost. 用品質(zhì)成本評(píng)估供應(yīng)商程序 . First Portion Traditional price and delivery tracking. 第一部分 傳統(tǒng)價(jià)格與發(fā)貨跟蹤 Second Portion Evaluates supplier Quality Cost Performance using an Index 第二部分 用指數(shù)表示供應(yīng)商品質(zhì)成本表現(xiàn) Supplier Quality Cost + Purchased Cost 供應(yīng)商品質(zhì)成本 +采購成本 Purchased Cost 采購成本 QCPI = Example : Supplier having two rejected lot for month of June: 舉例：供應(yīng)商六月份有二批退貨 1. Cost of processing ining rejection (documentation, return expenses) : Study show that each rejected lot would require $100 to process 處理退貨成本 (記錄，退費(fèi) )處理一批貨要 100元 ($) Two rejected lots = 2 Lots X $100/Lot = $200 (2批需要 200元 ) 2. Cost of plaint investigation ( BUQE) 投訴原因調(diào)查成本 Man hours required to investigate the root cause. Study show cost per man hour is $20 調(diào)查根本原因需要的工