QIP V2.0介紹

1、Presentation of the QIP V2.0QIP V2.0介紹介紹Manufacturing Performance Assessment生產(chǎn)績效評估生產(chǎn)績效評估May 20132INTRODUCTION 介介紹紹ContentsEVALUATION WORKSHEET& SCORING MATRIX 評評價工作表價工作表 & 打分矩打分矩陣陣EVALUATIONPROCESS 評評價價過過程程REQUIREMENTSOVERVIEW 要求要求預覽預覽EXAMPLES OFSCORING 打分打分實實例例3INTRODUCTION 介介紹紹Assessment t

2、ools Present Situation 評估工具評估工具 現(xiàn)狀現(xiàn)狀4Enterprise PerformanceChecklist& Process audit5Main Specifications 主要說明主要說明(1/2)The key principles 關鍵原則關鍵原則 One single assessment referential 3 differents tools 一個審核標準 - 3個不同的工具92 Requirements76 / 92 Requirements59 / 92 Requirements50 / 92 RequirementsCertifi

3、cation認證認證6Main Specifications 主要說明主要說明(2/2)Common characteristics 共同的特性共同的特性 which can be used on every manufacturing site & every process ，可以用在所有的生產(chǎn)現(xiàn)場，可以用在所有的生產(chǎn)現(xiàn)場&生產(chǎn)過程生產(chǎn)過程 Evaluation covers the entire manufacturing scope () 審核覆蓋了整個生產(chǎn)領域（審核覆蓋了整個生產(chǎn)領域（）What is the difference between ISO/TS and

4、 QIP V2.0 ? ISO/TS is the high level review performed by an independent 3rd party.QIP V2.0 is a much closer look performed by the Customer.GM & PSA check on the shop floor how systems are being used whereas ISO/TS checks that there are Quality Systems in place.ISO/TS 和和QIP V2.0的區(qū)別是什么？的區(qū)別是什么？ISO/

5、TS是由獨立的第三方做的高水平的審核QIP V2.0是客戶做的更加細致的審核GM&PSA在車間水平檢查體系是如何運行的而ISO/TS則是檢查現(xiàn)場是否有質(zhì)量體系Part & Process零件零件&過程過程Project項目項目ManufacturingSystem生產(chǎn)體系生產(chǎn)體系 The new tool to replace the Assessment 代替QIP V1.0的新工具 associated with an 有相關的 Scope: 范圍：范圍：Purpose 目的目的: Evaluate the of processes on site: Manufac

6、turing System requirements are fully met and work effectively 審核工廠 的過程：生產(chǎn)體系要求全部滿足并且有效運行Drive the (identification of weak points & axes of improvement) 促進（識別薄弱環(huán)節(jié)& 改善重心） Operational Requirements 操作操作要求要求Maximum duration of the evaluation on site: 審核最長不超過： can be done by supplier himself 供應商做 t

7、o integrate the impact of the events in the relationship ，考慮突發(fā)的問題776 / 92 Requirements76 / 76Nb of Requirements要求數(shù)目0 / 70 / 9859 / 92 Requirements The new tool to replace the 代替的新工具 Scope: 范圍：范圍：Purpose 目的目的: Evaluate the Basics are in place審核質(zhì)量基礎達到At the beginning of a project, evaluate the on supp

8、lier site 項目開始階段，在供應商現(xiàn)場評估其的有效性 Operational Requirements 操作要求操作要求Maximum duration of the evaluation on site: 審核時間：Self-assessment by supplier before evaluation: 審核之前由供應商做自評：48 / 76Nb of Requirements7 / 74 / 9Project項目項目949 / 92 Requirements Scope: 范圍：范圍：Purpose 目的目的: At the end of a project, of the p

9、rocess: Parts & Process controls are in place to ensure final product quality 項目結(jié)束階段，：有零件&產(chǎn)品控制，確保成品質(zhì)量During mass production phase after major issues, 在現(xiàn)生產(chǎn)發(fā)生重大問題后， Operational Requirements 操作要求操作要求Maximum duration of the evaluation on site: 現(xiàn)場審核最長不超過：Self-assessment by supplier before evaluat

10、ion: 審核之前供應商要自評：41 / 76Nb of Requirements0 / 79 / 910One Single assessment referential 唯一一個審核標準唯一一個審核標準 (same requirements) used for all the 3 types of audit 3種審核使用（同樣的要求） of suppliers manufacturing system via audits 通過審核對供應商的生產(chǎn)體系作 All the audit results affect to Bidlist performance (supplier plant

11、scoring)ManufacturingSystem生產(chǎn)體系生產(chǎn)體系Project項目項目 Part & Process 產(chǎn)品產(chǎn)品&過程過程41948776Bidlist (supplier plant scoring)Bidlist(供應商工廠得分)411BIDLIST Vision (Supplier Plant Scoring) Bidlist愿愿景（供應商工廠得分）景（供應商工廠得分）Details of impacts (implemented in 2014) 詳細影響（詳細影響（2014年實施）年實施）Points deduction扣分扣分 Certified

12、 (QSB+ Pass Green: Score 85%) Waiver and Not Applicable認證（QSB+通過通過 - 綠：綠：得分85%）棄權(quán)或不適用 Not Certified (not evaluated or QSB+ failed Red: Score 紅：紅：得分 85% with no red key element 最終結(jié)果最終結(jié)果85%，沒有紅色關鍵要素，沒有紅色關鍵要素 Note: Self-assessment can be refused if the scoring is not robust (important gap between custo

13、mer evaluation & supplier self-ass.) 注意：如果得分不可靠，自評結(jié)果會被回絕（供應商自評注意：如果得分不可靠，自評結(jié)果會被回絕（供應商自評&客戶評審之間差距很大）客戶評審之間差距很大）19 Training 培訓培訓Intent 目的Understand Audit Requirements & expectations 理解QSB+的要求，期望Review & implement examples to supplier system檢查，并對供應商體系建立標桿Process 過程Supplier self-training

14、 based on QIP V2.0 material package供應商根據(jù)QIP V2.0文件包做自培訓Service provider training (approved 3rd party) Available in 2014 第三方服務機構(gòu)進行培訓（認證的第三方服務機構(gòu)） - 2014年實施年實施 Complete Action Plan 完整的行動計劃完整的行動計劃Intent 目的Cover Gap between supplier current system & QIP V2.0 requirements. 覆蓋供應商當前體系和QIP V2.0要求之間的差距Bas

15、e for close follow up of implementation 跟蹤實施情況Process 過程Maximum leadtime for full implementation is 完整的實施時間最多6In due dates it needs to be considered that system has to operate, not only implemented 在期限內(nèi)，要考慮到，體系不只是建立了還要正常運行Hint 注意事項Verify action plan after receiving (actions definition, due dates are

16、 realistic) 收到行動計劃后進行檢查（行動定義，期限合理可行）Organize regular calls for checking completion of action plan and guide supplier to right direction 經(jīng)常電話溝通了解行動計劃的完成情況并給供應商正確的指導20 Intent 目的目的On-site customer assessment to verify that all the Requirements are met 客戶現(xiàn)場評估，檢查是否所有要求都滿足Result in Certified status for ne

17、xt 3 years 有效期3年的認證狀態(tài)Process 過程過程It can be done auditor () 只能是（）Maximum 1.5 - 2 days assessment 時間最長1.5-2天Result is reported out in the Audit Sheet 在QSB+審核表中記錄結(jié)果21 Intent 目的目的To ensure that QIP v2.0 system works after audit 確保審核之后，QIP v2.0體系正常運行To ensure awareness of QIP v2.0 requirement in case of

18、new staff 確保新員工了解QSB+的要求Process 過程過程Supplier need to send self-assessment with associated action plan 供應商要發(fā)送自評結(jié)果，附帶行動計劃after initial certification, 初次認證后 (Plant manager, Quality Manager or Operation Manager) or repeat Quality issue. （工廠經(jīng)理，質(zhì)量經(jīng)理或者生產(chǎn)經(jīng)理）或出現(xiàn)重復的質(zhì)量問題If self-assessment is missed to submit,

19、certification can be revoked 如果未能提交自評結(jié)果，認證可能會被吊銷If PCPA meanwhile performed, not necessarily need to submit self-assessment 如果期間做了PCPA，自評提交不是必須的。22 Intent 目的目的To complete all certification process to ensure that QIP V2.0 system is operating and work effectively again 完成整個認證過程，保證QIP V2.0體系有效運行Process

20、 過程過程In case of major issue, repetitive failed PCPA or degradation of supplier performance, SD site initiate revoke process with agreement of management 如發(fā)生重大問題，如PCPA反復不通過或者供應商績效惡化，在征得管理層同意后，SQD啟動認證吊銷過程According to vision, audit result will have on-line link with Bidlist 我們的愿景是，審核結(jié)果同Bidlist聯(lián)系起來。23EV

21、ALUATION WORKSHEET& SCORING MATRIX 評評價工作表價工作表&打分打分矩矩陣陣 Instructions 說明Description of usage of QIP questionnaire. QIP調(diào)查表介紹 QSB+ process QSB+過程Special instruction for QSB+ evaluation. QSB+的特殊說明 Glossary 術(shù)語表Complete list of abbreviations used in audit list. 審核清單中的縮寫清單 Header 表頭Input of basic in

22、formation and selection of audit scope. 基本信息的輸入和審核類型的選擇 Summary 總結(jié)Result of audit/self assessment calculated automatically. 審核/自評結(jié)果的自動計算 Audit 審核Common questionnaire list. 通用問卷表 Action plan 行動計劃Supplier action plan to close gaps identified during self assessment or audit. 供應商為關閉審核或自評中發(fā)現(xiàn)的問題而制定的行動計劃 C

23、hange request 更改申請Proposal for changes/suggestions to be considered for next review 更改/建議反饋單2425General DefinitionSummary of the intent of requirement要求的概述要求的概述Detailed deployment of Requirement in bullet pointsSupplier has to operate a system to meet listed expectations分條詳細說明分條詳細說明“要求要求”。供應商必須運行某個體

24、系來。供應商必須運行某個體系來達到列出的標準達到列出的標準Auditor hints and techniques how and what need to be checked besides Criteria of Requirement審核員注意事項和技巧審核員注意事項和技巧 - 除除“要要求標準求標準”之外還需要審核什么和之外還需要審核什么和怎樣怎樣審核審核Two types of Criteria of the Requirement are identified: 要求中包含要求中包含2種標準種標準basic criteria are identified with , cover

25、 basic key requirements additional criteria are identified with unbold type, cover additional requirements . 附加要求為附加要求為非粗體字，涵蓋了附加要求非粗體字，涵蓋了附加要求（推薦的最佳實踐）（推薦的最佳實踐）Furthermore it is used for collecting evidences and setting up scoring 另外，還用作另外，還用作收集收集證據(jù)和設置打分證據(jù)和設置打分ItemRequirement 要求要求Criteria of Requir

26、ement 要求標準要求標準Look for 查找查找Fast Response FR1Daily leadership meeting held with cross-functional, multilevel attendees to address significant external and internal concerns.1) There is a daily Fast Response (FR) meeting with cross-functional attendees and led by manufacturing.2) The FR meeting is a c

27、ommunication meeting and a precise timing is respected.3) All the significant external and internal issues are addressed.4) Natural owners are assigned to problems, next report out date is assigned.5) Take into account the production forecast and the quantity produced.6) Safety and near miss acciden

28、t issues are reported out.Attend FR meeting. Observe:- lead by manufacturing with cross -functional attendees,- how leader controls the FR meeting (keep timing max 10-20 minutes, focus on subject, not going to the details.),- environment is suitable (everyone can hear and see the meeting),- how issu

29、es reported out.- Problem Solving report format is used for report out and document the status of the issue. Axiom #1: all your activities & your standards 所有的活動 & 按標準實施 Axiom #2: your real effectiveness to achieve customer expectations & it 真實的有效性，滿足客戶期望& 進行2627Quality manuals Proce

30、dures質(zhì)量手冊程序質(zhì)量手冊程序Work Instructions 作業(yè)指導書Guides 指南Flowchart 流程圖Requirements要求Implementation scoringEffectiveness scoringProcessMetrics過程指標ResultMetrics結(jié)果指標To evaluate standardization and implementation of requirement評價要求的評價要求的實施和實施和標準化標準化情況情況To evaluate real effectiveness to achieve customer expectat

31、ion and continous improvement評價評價滿足客戶期望和滿足客戶期望和持續(xù)改善的有效性持續(xù)改善的有效性28Key Element #1Key Element #2Implementation scoring of each individual requirement 每項要求的實施得分Effectiveness scoring at the end of each key element 每個關鍵要素最后的有效性得分29Implementation scoringPtsElement Scoring 要素得分要素得分0No basic criteria are in

32、place. 沒有落實任何評價標準沒有落實任何評價標準1Several basic criteria are not in place. 一些基本標準沒有實施一些基本標準沒有實施2Majority of basic criteria are in place and followed。 Or basic criteria are not in place or followed at all areas of company. 大部分的基礎標準建立并遵守。或者基礎標準沒有在公司所有的區(qū)域建立或遵守大部分的基礎標準建立并遵守。或者基礎標準沒有在公司所有的區(qū)域建立或遵守3All basic cri

33、teria are in place but not followed at each job or all the timeOr additional criteria which have impact to the customer are not in place or followed所有的基礎標準建立了但是沒有在每個工位或者沒有時刻遵守?；蛘邔蛻粲杏绊懙母郊訕藴蕸]有建立或遵守所有的基礎標準建立了但是沒有在每個工位或者沒有時刻遵守。或者對客戶有影響的附加標準沒有建立或遵守4All basic criteria and additional criteria which may ha

34、ve impact to the customer are in place and followed所有可能對客戶有影響的基礎和附加標準都建立并遵守所有可能對客戶有影響的基礎和附加標準都建立并遵守NRNot Reviewed: Requirement not audited at this time (Not part of audit scope, Training Required, Follow-Up Required). Plan to review in future. Give future review date in Comment box. 未審核：該項要求本次未審核（不再

35、審核范圍內(nèi)，需要培訓，需要跟蹤）。做以后的審核計劃，在意見欄中給出計劃審核日期NANot Applicable: Question does not apply and not calculated to overall result. Note to explain why question is not applicable is needed in Comment box. 不適用：問題不適用并且不計入總體結(jié)果中。需要在評價欄中解釋為什么問題不適用 Fast Response fully implemented, but there are several long lasting cu

36、stomer complaints, 全面實施快速反映，但是存在一些全面實施快速反映，但是存在一些長期的客戶抱怨長期的客戶抱怨 Non-conforming materials are controlled, but operating with high scrap rate without any improvement activities, 不合格材料受控，但是實際操作中不合格材料受控，但是實際操作中報廢率較高報廢率較高且沒有改進且沒有改進行動行動 LPA is performed in all level according to schedule , concerns docume

37、nted and action defined, but there are lots of repetitive finding on LPA 所有層次人員按計劃實施所有層次人員按計劃實施LPA,問題記錄，制定了行動計劃問題記錄，制定了行動計劃,但是在但是在LPA中發(fā)現(xiàn)中發(fā)現(xiàn)很多很多的的反復反復問問題題System is in place, but not working effectively!體系建立了，但是運行效率低體系建立了，但是運行效率低303131 the Key notions 主要概念主要概念Effectiveness is evaluated through a speci

38、fic requirement at the end of each section 通過每段結(jié)尾的特殊要求來評估有效性通過每段結(jié)尾的特殊要求來評估有效性Effectiveness scoringLPA effectiveness are continuously monitored and analysed via LPA results1) Tracking of audit results with visualization to share status on affected area (nb of non conformances per LPA, pareto of non c

39、onformances, repetitive findings, nb of customer issues caused by non respect of standardized work - it should have been found by LPA).2) Tracking of keeping audit schedule & e f f e c t i v e n e s s o f a c t i o n p l a n implementation(average ti m e to treat deviations/effectiveness).PtsEff

40、ectiveness Scoring 有效性得分有效性得分0No basic metrics are in place to evaluate key element effectiveness 沒有建立評價關鍵要素有效性的基礎指標沒有建立評價關鍵要素有效性的基礎指標1Some metrics are in place but basic metrics are not defined 建立了某些指標，但是沒有建立基礎指標建立了某些指標，但是沒有建立基礎指標2Basic metrics are in place and followed with targets however deviati

41、ons from targets are not managed 建立了基礎指標并遵建立了基礎指標并遵守，有目標跟蹤。但是與目標的偏差沒有管理守，有目標跟蹤。但是與目標的偏差沒有管理3Basic Metrics are followed and deviations are managed by action plans, but additional metrics are not defined 遵守基礎遵守基礎指標并且偏差有行動計劃管理，但是沒有建立附加指標指標并且偏差有行動計劃管理，但是沒有建立附加指標4Continuous improvement for basic metrics

42、are in place and most of additional metrics are managed 建立了基礎指標的持建立了基礎指標的持續(xù)改善并且大部分附加指標有管理續(xù)改善并且大部分附加指標有管理32 Red / Yellow / Green visualization applied 紅/黃/綠狀態(tài)可視化 Thresholds are defined on 2 levels 門檻定義在2個水平On each Requirement: score = Overall result goes Red 每個要求：得分= 總體結(jié)果為紅On each Key Element: score

43、= Overall result goes Red 每個關鍵要素：得分= 總體結(jié)果為紅 Conditions to be certified 認證條件No Red item (Key Element or Requirement)沒有紅色項（關鍵要素或要求）Overall result 總體結(jié)果33 QIP V2.0 Requirements QIP V1.0 Requirements QIP V2.0 要求 QIP V1.0要求 QIP V1.0 Requirements QIP V2.0 Requirements QIP V1.0 要求 QIP V2.0要求 Old Scoring New

44、 Scoring 舊打分 新打分34REQUIREMENTSOVERVIEW 要求要求預覽預覽35Key Element 關鍵要素關鍵要素Nb OfRequirements要求數(shù)目要求數(shù)目1FRFast Response 快速反應 62CNCControl of Non-conforming Product 不合格品管理73VS & EPVerification Station & Error proof Verification檢查工位&防錯檢查64SWStandardized Work 標準化工作75TRTraining 培訓66LPALayered Process

45、 Audit 分層審核47RRRisk Reduction 風險消除68CCContamination Control 污染控制59SCMSupply Chain Management 供應鏈管理510MCManaging Change 變更管理611MAIMaintenance 維護612MMFMMaterial Flow Management 材料流管理713ELGExternal Logistic 外部物流514SPMStrategy & Project management 戰(zhàn)略&項目管理715PPCPart & Process Control 零件&過

46、程控制9 92 Detection & Tracking of the internal/external major issues 內(nèi)外部問題識別&跟蹤Daily production meeting 每日生產(chǎn)會議Fast response Board 快速反應展板 Problem solving standardize methodology 問題解決標準化方法Used for all type of concerns 適用于所有類型的問題6 steps: define, contain, root cause id, correction, validation, ins

47、titutionalization 6步：定義，遏制，識別根本原因，糾正，驗證，制度化 System to manage lessons learned 經(jīng)驗反饋管理體系Organization 組織Procedure / forms 程序/表格36 Traceability 追溯性Compliance to specific customer requirements 符合客戶的特殊要求Equipments & Organization associated 相關設備&組織FIFO Management FIFO管理 Identification mode of the no

48、n-conforming or suspect material 識別不符合模式或可疑材料 Alert issue 報警問題Upstream: Tier N 向上追溯：N級供應商Downstream: Customer 向下追溯：客戶 Containment process 遏制過程 Rework process 返修過程 Management of the deviations (customer “derogations”) 偏差管理（客戶“質(zhì)損”）37 Final Checking 終檢Organization 組織Standards 標準 Alarm system 報警系統(tǒng)Thresh

49、olds definition 確定門檻Escalation process 升級過程 Error proofing systems 防錯系統(tǒng)Management of the EPS EPS管理Management of the malfunctionning / failures 生產(chǎn)異常/缺陷管理38 Workplace organization 工作場所組織Standardize Layout 標準化的布局5S management 5S管理 Ergonomics & Painfulness concerns 人機工程 & 勞累度問題Rules related to e

50、rgonomics 人機工程相關的規(guī)則Assessment of the workstation 工位的評估Operator involvement 操作人員參與 Working instructions (production process operations & logistics) 作業(yè)指導書（生產(chǎn)過程操作&物流）Standards 標準Procedure to validate start of production 認可生產(chǎn)啟動的程序 Visual & appearance items (boundary samples) 看得見的&表面問題（極限

51、樣件）Procedure 程序Management of the boundary samples 極限樣件管理 Control devices Calibration & Capability 檢具 標定 & 能力Management of the devices (identification) 設備管理（標識）Capability & Calibration 能力 & 標定39 Training organization 培訓組織Needs identification / Organization 需要鑒定/ 組織Infrastructures &

52、; skills for training activity 培訓活動所需的技能&基礎設施 Training material 培訓材料 Safety Policy 安全制度Safety handbook 安全手冊Training on safety 安全培訓 Employees Qualification / Flexibility Chart 員工資質(zhì)/柔性圖Qualification process / follow up qualification status 資質(zhì)鑒定過程/跟蹤資質(zhì)狀態(tài)Calibration process for the quality control a

53、ctivity 質(zhì)量控制活動的標定過程 Training refreshment 新人培訓 Motivation of Staff 調(diào)動員工積極性 Process of motivation 積極性激發(fā)過程Individual interviews 個人談話40Generic layered process audit 通用的分層審核Procedure and working standards 程序和操作標準Auditors training 審核員培訓 LPA on operational activities (under manufacturing dep. responsabilit

54、y) 生產(chǎn)活動LPA(生產(chǎn)部門責任) Master planning 總計劃Complete coverage with relevant frequency 完全覆蓋，頻次合理Involvement of the different level of management 各管理層參與 LPA results follow-up LPA結(jié)果跟蹤Deviations record 偏差記錄Action plans associated 相關的行動計劃Countermeasures sheet 措施表Continuous improvement 持續(xù)改善41 PFMEA management P

55、FMEA管理Periodical reviews 定期檢查Cross-functional approach跨職能方法 Management of the highest risk items 最高風險問題管理Identification & analysis 識別 & 分析Action plans follow-up 跟蹤行動計劃 Reverse PFMEA 逆向PFMEAReal and effective risks verification at the workstation 對工位的風險進行真實有效的檢查Findings taken into account to

56、improve process 發(fā)現(xiàn)問題，改善過程 General Risks management to guarantee manufacturing activity 風險管理，保證生產(chǎn)活動Natural risks (floods, fire,) 自然風險（洪水，火災）“Supply chain” risks (loss of energy, loss of supply) “供應鏈風險” （能源不足，供應不足）42 Main topic: cleanliness of the process 主要是：過程的清潔 Risk analysis on the complete shopfl

57、oor 整個車間的風險分析 Compliance to customer specifications when needed 需要時，順從客戶的要求 Management of the sensible areas (clean rooms, paintshop,) 敏感區(qū)域管理（清潔室，油漆車間） Management of the foreign material in parts 零件中的異物管理 Management of the dirts in parts or paint 零件或油漆中的污垢管理43 Management of the Tier N suppliers N級供應

58、商管理 Procedures to evaluate & select supplier 供應商評價&選擇程序 Cascading of the customer requirements to the Tier N 傳遞客戶要求到N級供應商CSE tranfer CSE傳遞Traceability requirements 追溯性要求Product change management 產(chǎn)品變更管理 Escalation process 升級程序Management of the single issues 單一問題管理 Audit policy 審核政策Target defi

59、nition and performance review 目標定義和效果檢查Bidlist and business hold Bidlist和業(yè)務中止 Incoming inspection process 來料檢查過程Components Control plan 零部件控制計劃Sampling rules 抽樣規(guī)則Records 記錄44 All type of changes (planned & unexpected) 所有類型的變更（計劃的&計劃外的） Procedure for monitoring product/process changes 產(chǎn)品/過程變更

60、監(jiān)控計劃Project management 項目管理Communication with the customer 客戶溝通Management of the deliverables (documents) 交付物管理（文獻。） Risk analysis before any change 變更之前做風險分析 Production Trial Run (PTR) process 生產(chǎn)試運行過程 Banking process 存儲過程Planning 計劃Stock build-up 建立倉儲Management of the long term storage 長期倉儲的管理 Alternative processes / Bypass processes 備用過程Identified alternative processes 識別的備用過程Authorizing process 認可過程Specific countermeasures 特殊的對策45 Maintenance organization & strategy 維護組織&策略Perimeter covered 覆蓋相關領域Available ressources & facilities 資源&設施可用Communication with manufac