解决问题型A3 建议型A3 状况型A3
12/7/2015
Aleris Restricted & Confidential
2
A3的优点
结构化思考
PDCA，帮助员工深 刻理解并掌握问题解决方法，实践 于工作中。
凝练问题
把握问题的本质，用一 张A3纸即可清晰明了地展现问题解决 整体“过程 ”。
沟通平台
A3 报告培训教材
Dec 2015
12/7/2015
Aleris Restricted & Confidential
1
什么是A3
A3报告（A3 Report）是一种由丰田公司开创的方法，通常用 图形把问题、分析、改正措施、以及执行计划囊括在一张大的 （A3）纸上。
在丰田公司，A3报告已经成为一个标准方法，用来总结解决 问题的方案，进行状态报告，以及绘制价值流图。 A3分类： - Problem solving A3 - Proposal A3 - Status A3
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▲ ● ▲ ● ▲ ● ▲
● ● ●
△預計完成時間 ▲實際完成時間
○ 符合目標 △優良目標
×出現問題
12/7/2015
Aleris Restricted & Confidential
11
7.检查/确认效果
努力地理解问题发生的因果关系，不要仅仅实施一些使问题消失的的方法
要验证方案总体的有效性 使用与目标设置中的相同标准 选定验证有效性的方法，尽量逐一实施 预先计划要收集的数据 明确数据的收集人和收集的频次
4. Actions follow up
Item Objectives # 1.1 1 Heat up factor opetimazation 1.2 1.3 High Level Action Additional data processing in order to compare the various tests Compare the recent TUS test results Wu Yin Arrange additional heat up factor trials based on the current results and the discussion outcome Evaluation of the 6061 test results-check BT calculation Preparation of 7075 trials within the next campaigns -Go on test Pre trial with an empty furnace for segment 1-4 fan speed to 90%-SAT Heat up factor test in order to evaluate the fan speed effect for the heat up factor, energy consumption and temperature accuracy Tracking of the “growing plate effect” at the exit door light barrier and after the quench section-Xiqun check how the program calculate length Tracking of the actual safety distance at the kick out position Take a picture of every deviating plate group at the end of the roller table and record the plate positions by the operators Registration of every event causing any kind of scrap ( even partial scrap) with all relevant data and counter measures (like the 2nd annealing file). Incl. later scrapings at the stretcher, CT testing or inspection. Registration of every event causing or could cause any kind of scrap, 2nd annealing or standstill. With the relevant data, root cause, short time actions and long time actions. Align with the 2nd annealing and scrap file Improvement of the issue reporting form. Needs to be filled in with proper information's by production and maintenance.- meeting with Mike&frank Development of temp mitigation activities for all issues which can’t be solved immediately. Communication via controlled documents to all relevant production or maintenance employees Sales training in order to raise the awareness for this issue. Integrate Dave in this process. Consequent loading of every possible combination. Loading preparation by pre-stacking of batches Can combinations be better supported (annealing time tolerances? Stronger quench code?) -Test plan review next week Sufficient number of qualified operators available Manning pattern ideal? Shift improvements (best practice) Pre treatment of the plates (Cleaning, sorting, stacking) Are based on the so far collected cases general activities defined? Pareto? Adjustment of the max load volume according the annealing temperature-trail for 5000mm2 to verify heat up capbility(prepare the plate)-Libing provide demension 470C, 475C, 480C 4400mm2 (4200mm2) 495C 4200mm2 530C, 535C 4000mm2-4200 mm2 for all Need to find the balance between delivery dates and throughput. Consequent “thick to thin “ and “long to short” campaigns Simulation of the planned sequences and alternatives up front Consequent combination of all kind of tasks at the furnace. Various maintenance departments, QA, Production. Should be covered by a detailed maintenance planner schedule. Collect the pipeline activities continuously Change of the current practice – edge trim the head and the tail according to the BT Plate length optimization (the shorter the better) Fast unloading tool for the transportation plates and test plates or cooling down of the test plates in the quench-try in next TUS Can the SAT be carried out with a partially emptied furnace Zhang Libing Zhang Libing Pang Liang Wu Yin Pang Liang Frank Sun Responsible Start Finish Mar date date W13 3/25 3/25 3/25 3/25 3/25 3/25 3/25 3/25 3/25 3/25 5/20 5/15 4/30 Done Done Done 5/13 5/29 On going. 4/10 5/3 Apr
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