福特汽車品質(zhì)系統(tǒng)介紹ppt課件

1、品質(zhì)系統(tǒng)李柏超品質(zhì)部經(jīng)理Ford Lio Ho Motor Co., Ltd.2002.12.13.Agenda Quality SystemTotal Quality Excellence Company Policy Letter No.1. Brief History of FLH Quality ManagementQuality Arrow (Quality is Job#1)QS-9000/ISO 14001 System/Quality Operating SystemTGW Reduction / VRT / SAQTGR / Kano Model.1. Ford Total

2、Quality ExcellenceCompany Policy Letter No. 1Quality is defined by the customer; the customer wants products and services that, throughout their life, meet his or her needs and expectations at a cost that represents value. 品質(zhì)是由顧客所定義Quality excellence can best be achieved by preventing problems rathe

3、r than by detecting and correcting them after they occur. 達(dá)成杰出的品質(zhì)必須注重在問題的預(yù)防All work that is done by Company employees, suppliers, and dealers is part of a process that creates a product or service for a customer. Each person can influence some part of that process and, therefore, affect the quality

4、of its output and the ultimate customers satisfaction with our products and services. 每個(gè)公司員工對(duì)品質(zhì)及最終的顧客滿意都有貢獻(xiàn).Ford Total Quality ExcellenceSustained quality excellence requires continuous process improvement. This means, regardless of how good present performance may be, it can become even better.維持杰出

5、的品質(zhì)必須持續(xù)作流程的改善People provide the intelligence and generate the actions that are necessary to realize these improvements.改善的智識(shí)及行動(dòng)來自人Each employee is a customer for work done by other employees or suppliers, with a right to expect good work from others and an obligation to contribute work of high calib

6、er to those who, in turn, are his or her customers.後工程即是顧客;不接納不良,不傳送不良- Chairman of the board(口徑;水準(zhǔn),程度).2. 福特六和品質(zhì)管理之發(fā)展演進(jìn) 1/41986- Introduction/Localization引入福特原廠產(chǎn)品開發(fā)標(biāo)準(zhǔn)如Worldwide Design Requirement 及Worldwide Product Acceptance Specifications 。品管部門轄AP-QC (裝配及製造品管)及QA(品保) 。對(duì)供應(yīng)商推行福特Q-101全球性品質(zhì)管理規(guī)範(fàn)。廠內(nèi)推動(dòng)U

7、PAS-Uniform Product Assessment System-產(chǎn)品品質(zhì)統(tǒng)一稽核系統(tǒng)。 1984年起正式推動(dòng)品管圈(QCC)活動(dòng)。Achievement 1986年正式通過加拿大法規(guī)標(biāo)準(zhǔn)，成為臺(tái)灣第一個(gè)成車外銷的廠商。.福特六和品質(zhì)管理之發(fā)展演進(jìn)2/419861991 Self-development/Expansion1988年起福特六和採(cǎi)購(gòu)部門設(shè)立專責(zé)單位，全力輔導(dǎo)零組件廠商提昇品質(zhì)。導(dǎo)入先期品質(zhì)規(guī)劃觀念A(yù)PQP(Advanced Product Quality Planning)及品質(zhì)基礎(chǔ)教育如團(tuán)隊(duì)導(dǎo)向問題解決手法-8D (Team Oriented Problem Solv

8、ing 8 Disciplines) 。Achievement全球福特總部品質(zhì)評(píng)鑑人員評(píng)定金全壘打車系為全球同車系品質(zhì)之冠。1990年引擎鑄造廠獲頒象徵福特品質(zhì)最高榮譽(yù)的Q1獎(jiǎng)1991年裝配廠獲頒象徵福特品質(zhì)最高榮譽(yù)的Q1獎(jiǎng) 。 .福特六和品質(zhì)管理之發(fā)展演進(jìn)3/419911996 Upgrading/ Standardization建置QIS(Quality Information System)系統(tǒng)，在生產(chǎn)線上直接反應(yīng)品質(zhì)問題並於第一時(shí)間即時(shí)改善。1994年導(dǎo)入顧客導(dǎo)向式車輛評(píng)價(jià)系統(tǒng) Nova-C (New Overall Vehicle Assessment- Customer)。1996

9、年起導(dǎo)入QOS品質(zhì)運(yùn)行系統(tǒng)。Achievement1994年獲得Q1再次驗(yàn)證一定。 1996年成為國(guó)內(nèi)首家汽車業(yè)者通過 ISO-9001國(guó)際標(biāo)準(zhǔn)驗(yàn)證，得到世界品質(zhì)系統(tǒng)標(biāo)準(zhǔn)的一定。 .福特六和品質(zhì)管理之發(fā)展演進(jìn)4/41996now Transformation/ Internationalization1996年起開始推動(dòng)福特生產(chǎn)系統(tǒng)-FPS(Ford Production System)。2000年起廠內(nèi)開始推動(dòng)Six Sigma品質(zhì)改善專案活動(dòng)。2002年導(dǎo)入新版QOS品質(zhì)運(yùn)作系統(tǒng)及FCPA消費(fèi)者導(dǎo)向產(chǎn)品稽核系統(tǒng) (Ford Consumer Product Audit)。Achieveme

10、nt1997年榮獲國(guó)際環(huán)境管理系統(tǒng)ISO 14001驗(yàn)證 。 1998年獲得汽車業(yè)國(guó)際品質(zhì)系統(tǒng)QS-9000驗(yàn)證一定。2001年福特六和引擎廠新人圈榮獲福特總部CDQA(Customer Driven Quality Award)總裁獎(jiǎng)。2001及2002年獲得福特FPS全球評(píng)比最高層級(jí)之榮耀。2002年獲得ISO 9001/QS 9000及ISO 14001整合系統(tǒng)驗(yàn)證。.3. Ford Quality is Job#1 ArrowDefine, Measure, Analyze, Improve, ControlDesign for 6-SigmaCommon Problem Solvin

11、g Language & ToolsHigh Quality, High Velocity Improvements in Business Results9 Leadership PrinciplesReward and RecognitionTraining and FeedbackPartnership with Unions, Dealers and SuppliersVehicle Quality(High & Low Time-In-Service)Customer SatisfactionTGWWarrantyResidual ValueSales & Service Satis

12、factionElimination of Waste Q1QualityIsJob #1QUALITY LEADERSHIP INITIATIVE Engage All Employees6-SIGMAData Driven Decision MakingQUALITY OPERATING SYSTEMPerformance to StandardsDrive ProcessDeliver ResultsPlanDoCheckActFord Motor Company QOSProductCreationSales & Service Certification SystemFPDSFutu

13、reCustomersCurrentCustomersOrder toDeliverySuppliersLaunchCurrentModelFPS.Quality Leadership Initiative9 Leadership PrinciplesValue: Quality is Job One. It is our responsibility, our job security and our future. Attitude: Zero Defect Mindset. Dont take it, dont make it and dont pass it on. Culture:

14、A relentless daily focus on quality. Training: Ensuring people have the necessary skills and tools to do their jobs. Accountability: Effective measurement and feedback for continuous improvement - accountability and performance metrics.Cooperation: Help suppliers help us succeed. Joint Leadership Co

15、mmitment: Effective Quality Leadership at all levels. Disciplined Execution: Changes never compromise quality. Enterprising Approach: The customer is our shared concern. .4. ISO 9001/QS-9000及ISO 14001整合系統(tǒng)ISO 9001(96)/QS-9000(98)內(nèi)部稽核: 2 times/yearISO 14001(97)內(nèi)部稽核: 1 times/yearISO 9001(96)/QS-9000(98

16、)外部稽核: 1 times/yearISO 14001(97)外部稽核: 1 times/year2 systems, 2 sets of procedures, 30% overlap Integration整合程序書，整併減少30%重疊。建立整合內(nèi)部網(wǎng)站以e化管理，減少紙張及增進(jìn)效率。整合內(nèi)部稽核: 2 times/year整合外部稽核: 1 times/year不僅整合集中內(nèi)部資源人力，連外部稽核費(fèi)用都可降低! Next Step轉(zhuǎn)換QS-9000至TS 16949ISO 18000.QOS-Quality Operating System品質(zhì)運(yùn)行系統(tǒng)由福特總部發(fā)行之一致性生產(chǎn)品質(zhì)運(yùn)行

17、系統(tǒng)，涵蓋一切生產(chǎn)廠區(qū)(車身、塗裝、完成車、新車驗(yàn)放部)之要求。以ISO 9001/QS 9000為基礎(chǔ)，連結(jié)FPS, Six-sigma, FPDS等企業(yè)之組織系統(tǒng)工具。目的在推行一致性的福特組裝廠最正確品質(zhì)系統(tǒng)，以達(dá)到監(jiān)控並持續(xù)改善新車的出廠品質(zhì)。共27個(gè)QOS單元要求，62個(gè)評(píng)分項(xiàng)目。 (R/Y/G).QOS-Quality Operating SystemTime and Data ManagementRequired meeting scheduled at designated frequencies to communicate and evaluate Plant Qualit

18、y System Output, total 18 meetings. A tool for plants to communicate information back to the base departments addressing customer concerns.VOPQUG-001FLH PracticesDescriptionFrequencyParticipantsMetricsDescriptionFrequencyParticipantsMetricsNOVA-C and Quality system Performance OverviewsDailyPlant Mg

19、r.Area Mgr.Quality Mgr.Area SupervisorArea CIWG LeadersNova-cWrap reviewChips & ScratchesSqueaks / RattlesFAI/CAI review Roll TestConvoy Yard reviewDailyPlant Mgr.Area Mgr.Quality Mgr.Area SupervisorArea CIWG LeadersNova-c Wrap review Chips & ScratchesSqueaks / Rattles FAI/CAI review Road Test, Exce

20、l, PDI, FTT.Convoy Yard Review-每日品質(zhì)會(huì)議Review Vehicle QualityReview Concern & Actions.QOS-Quality Operating SystemVariability Reduction VRT/VFGa structured process to drive quality improvement focused on customer expectations. It ensures that plant controllable customer concerns are acted upon quickly

21、 and permanently. Tool Verificationensure regular inspection and certification of plant test equipment, tools, and gages is being conducted per the corporate guidelines. .QOS-Quality Operating SystemIncoming Materialmeasures plant effectiveness in improving and controlling the quality of material en

22、tering the plant. A working relationship with the plant, suppliers, purchasing, and other key activities is essential for quality improvement. Process Control / Build & Inspection Process identify requirements for controlling specific operations and inspections. Those requirements come from practice

23、s and/or procedures that are the infrastructure of the assembly Vehicle Operations QOS. CCs, SCs, CTQ.QOS-Quality Operating SystemRepair Systema formalized repair process assuring the preparation, repair, material, and tooling/equipment used are in accordance with established/approved repair standar

24、ds. Quality Acceptance Criteria established level of standards to be used for inspection. the criteria must then be cascaded throughout the plants.to assure that every inspection/check/test is performed to the same standards throughout the entire system.QOS-Quality Operating SystemWeld SurveillanceI

25、n process checks of welded assemblies, when coupled with periodic tear down of welded bodies and assemblies, provide a positive method of determining weld quality.ensure that all weld production operations are being effectively performed. Dimensional Control a comprehensive body sheet metal construc

26、tion strategy that takes into account all key body sheet metal components and their relationships to each other and bodylines. to identify, track, and reduce dimensional variation from component to component and vehicle to vehicle .QOS-Quality Operating SystemTorque Assuranceto assure that Fastening

27、 Control System implementation is standardized and effective across all assembly plants.FCPAto identify manufacturing imperfections through a series of a Static/Dynamic/Full (combination of static & dynamic) audits of finished units.使顧客導(dǎo)向所發(fā)現(xiàn)的問題直接回饋到生產(chǎn)線，以求獲得迅速對(duì)策及改善方案。 .FCPA(Ford Consumer Product Audi

28、t)福特消費(fèi)性產(chǎn)品評(píng)價(jià)是完成車的稽核流程，用以指出產(chǎn)品的問題及潛在能夠呵斥顧客/消費(fèi)者不滿意的地方。採(cǎi)用全球一致的車輛作業(yè)評(píng)價(jià)流程於一切量產(chǎn)車種。驅(qū)使製造精緻工藝的提昇以期在車輛交貨與初期服務(wù)時(shí)達(dá)成高度顧客滿意度。強(qiáng)調(diào)顧客/消費(fèi)者的回饋及反應(yīng)。強(qiáng)調(diào)會(huì)影響顧客滿意度的設(shè)計(jì)意圖及製程限制。運(yùn)用顧客/消費(fèi)者導(dǎo)向的評(píng)分系統(tǒng)CCRS稽核時(shí)間約為每輛車三個(gè)小時(shí)。.FCPA(Ford Consumer Product Audit)福特消費(fèi)性產(chǎn)品評(píng)價(jià)檢查項(xiàng)目包括：內(nèi)外部裝配情形塗裝情形電機(jī)及各部機(jī)械功能引擎室及底盤漏水，風(fēng)音及異音情形車輛動(dòng)態(tài)及道路駕駛.CCRS(Customer Concern Rating

29、 System)顧客導(dǎo)向式評(píng)分系統(tǒng).QOS-Quality Operating SystemWind Noiseevaluates the noise acceptability of vehicles, as would an average customer. During the drive evaluation, the trained auditor listens with an unaided ear and rates wind noise performance, on a scale from 1 to 10, using the Wind Noise Rating Cri

30、teria form Squeak & Rattleto effectively detect assembly or component squeak and rattle concerns prior to the units leaving the plant. .Squeak & Rattle Road TestSqueak & Rattle Test Track UpgradeLength:100 ft Uniform Vienna Block, 100 ft Stepped Vienna BlockWidth:104404024Track Width 66404024100Unif

31、orm Vienna BlockStepped Vienna Block.Squeak & Rattle Road TestUniform Vienna BlockStepped Vienna Block(1 Step in Height).QOS-Quality Operating SystemWater (20 minute soak)pre-determined critical water entry areas, which may not show up during the normal 100% production water test. This 20 Minute tes

32、t is a verification of process/design actions taken to correct any repetitive water leak concerns. Finish Vehicle Evaluation Program (M-10 Program) a daily evaluation of completed production level vehicles. These units are driven over-night, over the road by authorized plant personnel. Its function

33、is to identify issues early and develop immediate process/product containment and improvement actions. .QOS-Quality Operating SystemPIC (Product Information Center)includes external and internal quality indicators, giving the plants a standardized means of displaying quality data, description, and v

34、isual representation. PIC allows information flow to present quality efforts, which factually demonstrate performance over time.Control Point/Tip Level utilizes either current or added inspection as a tool to drive In-Station-Process-Control (ISPC) and to facilitate communication with the Base Opera

35、tor to develop countermeasures to contain quality concerns within the zone. .QOS-Quality Operating SystemUltrasonica method to evaluate wind noise. The process is performed by attaching an ultra sonic tone generator to the center of the windshield and moving a detection instrument around the potenti

36、al leak areas (glass runs, windshield, door openings, etc.). Wind Noise leaks are measured in decibels (dB) and compared to predetermined limits. Predetermined limits are established by correlation of leaks and customer data. Air Leakage Test an evaluation of sealed painted vehicle bodies and comple

37、ted production vehicles for objective measurements of body air leakage. .Ultrasonic Test Equipment.QOS 總表- 1/3.QOS 總表- 2/3.QOS 總表- 3/3.QOS FAP Assessment ResultFLH element level: 2.75 (Full Level: 4)U.S. VO total plant summary status for reference:The level of FLH is better than VO plants in the US.

38、Ford Lio Ho Quality Improvement Flow Diagram.5. TGW Reduction VRT / SAQTGW (Things Gone Wrong): 問題點(diǎn),缺點(diǎn)情況VRT (Variability Reduction Team)a structured process to drive quality improvement focused on customer expectations.SAQ (Single Agenda for Quality)a systematic matrix to prioritize Customer Concern

39、s based on internal and external indicators. .VRT OrganizationMeeting DateChampionTeam LeaderSub-System /GQRS CategoryJ.D. Power CategoryTue.Ringo LinMike Chang Exterior Paint & Corrosion Vehicle exterior, (Paint issues) James Wang Body & Exterior Trim / Bumper Vehicle exterior (Exclude Wind noise, Water leaks) Steve TangInterior Trim, Water leakage, Squeaks and rattles Vehicle int