生產(chǎn)制造概論

1、生產(chǎn)製造概論 By Ringo D. L. Lin Ford Lio Ho Motor Co., Ltd. 生產(chǎn)製造概論生產(chǎn)製造概論 品質(zhì)系統(tǒng)品質(zhì)系統(tǒng) 新車上市控制計畫新車上市控制計畫 環(huán)境保護(hù)環(huán)境保護(hù) Six Sigma 物料規(guī)劃與運(yùn)籌物料規(guī)劃與運(yùn)籌 福特生產(chǎn)系統(tǒng)福特生產(chǎn)系統(tǒng)/工廠工程工廠工程 & 維護(hù)維護(hù) 顧客滿意顧客滿意品 質(zhì) 系 統(tǒng) Total Quality Excellence Company Policy Letter No.1. Brief History of FLH Quality Management Quality Arrow (Quality is Job#1

2、) QS-9000/ISO 14001 System / Quality Operating System TGW Reduction / VRT / SAQ TGR / Kano Model (to be covered by Knight in detail) Define, Measure, Analyze, Improve, Control Design for 6-Sigma Common Problem Solving Language & Tools High Quality, High Velocity Improvements in Business Results

3、9 Leadership Principles Reward and Recognition Training and Feedback Partnership with Unions, Dealers and SuppliersQualityQualityIs IsJob #1Job #1QUALITY LEADERSHIP INITIATIVE Engage All Employees6-SIGMAData Driven Decision MakingQUALITY OPERATING SYSTEMPerformance to StandardsDrive ProcessDeliver R

4、esultsPlanDoCheckActFord Motor Company QOSProductCreationSales & Service Certification SystemFPDSFutureCustomersCurrentCustomersOrder toDeliverySuppliersLaunchCurrentModelFPS3 Pillars of Ford Quality Is Job#1 StrategyFord Lio Ho Quality Resolution Flow DiagramRYGRYGRYGRYG1Time & Data Mgmt. G

5、 G G G2Variability ReductionVRT/VFG G G G G3Tool Verification G G G G4Incoming Material Y G 5Process Control /Build & InspectionProcess G G G G6Repair System Y G Y G7Quality AcceptanceCriteria G8Weld Surveillance G9Dimensional Control G10Torque Assurance Y11FCPA G12Wind Noise GQOS Area / Element

6、 R/Y/G RatingsVO QOS / QITDArea / ElementsBodyPaintFinalPDA / NOVA-CQOS 總表- 1/3RYGRYGRYGRYG13Squeak & Rattle G14Water (20 minutesoak) G15M-10 Program G16CBT (PDI or Final) 17PIC (ProductInformation Center) G18QVS Quick VIMS G19Control Pt/Tip LevelR R 20Ultra Sonic21Air Leakage Test22Joint Qualit

7、yComm./Mgmt. QualityComm.23 6-SigmaMethodologyQOS Area / Element R/Y/G RatingsVO QOS / QITDArea / ElementsBodyPaintFinalPDA / NOVA-CNew QITDArea / Elements GTBDTBDTBDQOS 總表- 2/3RYGRYGRYGRYGTime & Data Mgmt. G G G GVariability ReductionVRT/VFG GTool Verification GIncoming Material Y Process Contr

8、ol /Build & InspectionProcess G G Repair System GQuality AcceptanceCriteria G GQOS Activity / Element R/Y/G Rating24252627VO e-QOSElementAPQPMCPVTRecg / InspQOS 總表- 3/3新車上市控制計劃新車上市控制計劃課程內(nèi)容課程內(nèi)容1.1.製造處製造處 “ “前瞻工程部前瞻工程部” ” 新車導(dǎo)入職掌新車導(dǎo)入職掌介紹現(xiàn)行車輛生產(chǎn)流程暨製程管制介紹現(xiàn)行車輛生產(chǎn)流程暨製程管制2.2.新車上市前生產(chǎn)可行性評估及成本分析新車上市前生產(chǎn)可行性評估及

9、成本分析 ( (feasibility study & cost analysis)feasibility study & cost analysis)3.3.新車上市之製造計劃新車上市之製造計劃 ( (Manufacturing Manufacturing Launch Plan)Launch Plan)4.4.新車試作階段之流程管制新車試作階段之流程管制成功大學(xué)EMBA經(jīng)營管理企業(yè)永續(xù)經(jīng)營追求永續(xù)利潤由環(huán)境保護(hù)創(chuàng)造利基qQuality levelqWhat is Six sigma? qWhy we need Six sigma?qDevelopment and Deplo

10、yment strategyqHow Six sigma merges into our daily business? OutlineSigma Level 與合格率的關(guān)係與合格率的關(guān)係每百萬不良數(shù)每百萬不良數(shù)合格率合格率2308,53769.15%366,80793.32%46,21099.38%523399.98%63.499.99966%SigmaLevel在在1.5s s 的長期偏移量下的長期偏移量下挑戰(zhàn)挑戰(zhàn)為什麼大多數(shù)的企業(yè)在為什麼大多數(shù)的企業(yè)在 34 Sigma?3 sigma 4 sigma 5 sigma 6 sigma 大多數(shù)的企大多數(shù)的企業(yè)能力業(yè)能力障障礙礙沉醉過去的成就

11、沉醉過去的成就(不再挑戰(zhàn)不再挑戰(zhàn))靠檢驗(yàn)及檢修靠檢驗(yàn)及檢修依賴嘗試錯誤法依賴嘗試錯誤法(經(jīng)驗(yàn)經(jīng)驗(yàn))救火式的解決問題救火式的解決問題(頭痛醫(yī)頭頭痛醫(yī)頭)缺乏數(shù)據(jù)缺乏數(shù)據(jù)部門間互相的推卸部門間互相的推卸官大學(xué)問大官大學(xué)問大挑戰(zhàn)挑戰(zhàn)超越障礙超越障礙3 sigma 4 sigma 5 sigma 6 sigma 那些動力可以躍越障礙那些動力可以躍越障礙?深信我們還有進(jìn)步的機(jī)會深信我們還有進(jìn)步的機(jī)會相信方法論相信方法論接受挑戰(zhàn)現(xiàn)況接受挑戰(zhàn)現(xiàn)況導(dǎo)入新的技術(shù)導(dǎo)入新的技術(shù),工具及手法工具及手法領(lǐng)導(dǎo)管理階層的態(tài)度領(lǐng)導(dǎo)管理階層的態(tài)度改變改變實(shí)事求是的行為表現(xiàn)實(shí)事求是的行為表現(xiàn)障障礙礙我們的機(jī)會我們的機(jī)會獲利減少獲

12、利減少哪一種比較有利哪一種比較有利?行政,製造,或運(yùn)輸?shù)某杀纠麧櫪碚撋系某杀纠麧?COPQ理論上的成本COPQ理論上的成本利潤C(jī)OPQ*COPQ: Cost Of Poor Quality(劣質(zhì)成本劣質(zhì)成本)利潤售價降低目標(biāo)目標(biāo) Year20012002CurrentObjProjects from S.A.Q12%83%80%Green Belts188530600Green Belt projects opened29151137Green Belt projects closed036120Projects on hands per Black belt1.23.43Black Belt

13、 projects opened218163Black Belt Projects closed443884Each Black Belt Projects closed2.92.24 Ford Production System and Vision, MP&L Mission, Role and Responsibility Model Line-Up Complexity Production Schedule and Release MP&L Exterior and Internal Logistics Common Material Management SystemIntroduction of FLH MP&L 介紹內(nèi)容 福特生產(chǎn)系統(tǒng)福特生產(chǎn)系統(tǒng)內(nèi)容大綱內(nèi)容大綱1. 企業(yè)競爭與觀念變革企業(yè)競爭與觀念變革2. 福特生產(chǎn)系統(tǒng)之概念福特生產(chǎn)系統(tǒng)之概念3. 精實(shí)製造基本觀念精實(shí)製造基本觀念4. FPS 系統(tǒng)介紹與展開系統(tǒng)介紹與展開5. FPS小組活動小組活動6. FPS小組活動推行績效小組活動推行績效7. 結(jié)語結(jié)語工廠工程工廠工程 &