文本分析案例en

1、QMT-Netzwerk MQ-1Process series.QMT training.QMT-Netzwerk MQ-1Seite 2Process series.AgendaProcess summary sheetStarting situation / Aim of the processBenefits / Brief description / BasicsThe processResponsibility, deadlines - timetableRole / contribution of QMTTCR - Tasks, competencies, responsibili

2、ties, description of activityUpstream and downstream processesFurther documents (forms & links)Tips & tricksReal-life experience or applying methodsBack-up (details)BMW GroupSummary sheet MQ-9, L. Simon 20.05.2011Process series.Aim and brief description:The process series is a test of the production

3、 systems, tools and the logistics processes under series conditions.The aim of the process series for the supplier is to demonstrate early on that the supplier is able to manufacture the required quantities with the available resources (equipment and manpower) under series conditions and to a high q

4、uality standard, and deliver on schedule.Input:Component launch capability assessmentFrom.QMTQMT activities:Process series evaluation in line with the following key criteria:Preliminary process capability of particular product and process featuresTechnical status of complete production systemQuality

5、 status of manufactured parts (especially functional dimensions, installation dimensions, Q features)Process (error susceptibility)Material flow of OK and not OK partsQuantity manufactured and proportion of scrapCompetence of operatorsTimeline:9 MBSProcess series3 MBSProcess owner:QMT employee (SLA)

6、Others involved / process partners:Clover leaf members (development, purchasing, logistics)Output:Production process and product approvalTo.Clover leaf / supplierProcess maturity:The process series is defined in PI 4.1.3/4 and described in more detail in the referenced documents.Documents / links:VD

7、A Volume 2 on product & process approval (PPF) - chapter 4, p. 24 ff. (not subject to change management)PI4.1.3./4 Product and Process Development at the Supplier, Production Process and Product ApprovalProcess series guidelines Documents on process series PZS formsPrevious areas of application:The

8、supplier is obliged to perform a process series. In exceptional cases, the PZS may be omitted by agreement with QMT. However, the supplier must provide adequate evidence of capability.Experience and summary:The process series generates parts for sample testing, which are sent to the QSB at BMW with

9、the initial sample test report.The findings from the process series are used to plan process monitoring in volume production and requalification.Documentation:Contact person:Lorand SimonQMT-Netzwerk MQ-1Seite 4Upstream and downstream processes.Position of PZS on QMT process map.Timing:The process se

10、ries must be carried out as soon as parts and processes are regards to series condition, at least prior to DOC.QMT-Netzwerk MQ-1Seite 5Aim of the process.Definition, aims & evaluation criteria.An unsuccessful process series(result RED) prevents the launch from proceeding!Launch capability should be

11、confirmed before/through PZS (8- 5 MBS)Initial samples are taken from PZS production (6-3 MBS)Initial sample status amber/2 (up to 2 MBS) initial sample status green/1 (up to 3 MAS)QMT-Netzwerk MQ-1Seite 6The process.Responsibility, requirements & implementation.The supplier is responsible for imple

12、mentationIf BMW is not involved (PZS omitted), the supplier mustprovide adequate evidence of capabilityProcess is usually documented in the PZS module in RMT or PZS formsQMT-Netzwerk MQ-1Seite 7The process.Deadlines & timetableProcess of PEP re. PZS:Supplier nomination (up to 30 MBS)Agree on schedul

13、e with supplier with regard to BMW milestones + PZS(after supplier nomination, at least once per month)Approx. 14 10 MBSQMT releases questions (PZS module in RMT) / sends PZS forms (approx. 9 6 MBS)Confirm launch capability (8 5 MBS)Approx. 6 3 MBSOrder and evaluate initial samples from PZS (initial

14、 sample status amber/2 up to 2 MBS and initial sample status green/1 up to 3MAS)SOPEnsure that PZS deadline is scheduled/met before/in time for awarding At early stage: define deadlines, send documents, order initial samplesAll measures arising from PZS must be completed in time for DOC (SOP -46AT)Q

15、MT-Netzwerk MQ-1Seite 8Role / contribution of QMT.Tasks, competencies, responsibilities.Check supplier project schedule with regard to BMW milestones before / in time for awardingAgree at early stage on deadline, scope and participants for process seriesRequest measures / initiate escalations in eve

16、nt of deviations from planAgree and define particular product and process featuresCreate, prepare and release in good time the PZS module in RMT / send PZS formsParticipate in and evaluate process series (supplier isresponsible for implementation)Define initial sampling date and number of samples to

17、 be taken from PZSDistribute final report to BMW teams or refer them to documentation on RMTQMT-Netzwerk MQ-1Seite 9Role / contribution of QMT.Tasks, competencies, responsibilities.LSV 3.0 Quality tabQMT-Netzwerk MQ-1Seite 10BMW QMTBMW QMT activities:Process series evaluation in line with the follow

18、ing criteria:Preliminary process capability of particular product and process featuresTechnical status of complete production systemQuality status of manufactured parts (especially functional / installationdimensions, Q features)Process (error susceptibility)Material flow of OK and not OK partsQuant

19、ity manufactured and proportion of scrapCompetence of operatorsSupplier activities:Demonstrate provisional product and process quality in accordance with agreed conditions up to 3 MBS.Document results in process series data sheet.Plan and prepare process series (incl. scope of parts) in accordance w

20、ithagreed project schedule.Agree (in advance) on special process features to be checkedSupplierRole / contribution of QMT.Tasks, competencies, responsibilities.QMT-Netzwerk MQ-1Seite 11Role / contribution of QMT.Description of activity.PZS module in RMTCreate PZS module (scope must have confirmed st

21、atus)PZSQMT-Netzwerk MQ-1Seite 12300 parts (serial no. xxxxxxx-xx) and 200 parts (serial no. xxxxxxx-xx) are produced in 2 shifts The parts are destined for vehicle construction VS1 and VS2 (assuming parts from PZS are OK)5 parts should be taken from the PZS for initial sample testing and presented

22、to BMW by DD.MM.YYYY.DD.MM.YYYYRole / contribution of QMT.Description of activity.PZS module in RMTEnter PZS planned deadline and define additional agreementsQMT-Netzwerk MQ-1Seite 13PZS module in RMTEnable supplier self-disclosure in good time before PZSRole / contribution of QMT.Description of act

23、ivity.300 parts (serial no. xxxxxxx-xx) and 200 parts (serial no. xxxxxxx-xx) are produced in 2 shifts The parts are destined for vehicle construction VS1 and VS2 (assuming parts from PZS are OK)5 parts should be taken from the PZS for initial sample testing and presented to BMW by DD.MM.YYYY.DD.MM.

24、YYYYQMT-Netzwerk MQ-1Seite 14PZS module in RMTProduction / processing of form sheetsCreate module report300 parts (serial no. xxxxxxx-xx) and 200 parts (serial no. xxxxxxx-xx) are produced in 2 shifts The parts are destined for vehicle construction VS1 and VS2 (assuming parts from PZS are OK)5 parts

25、 should be taken from the PZS for initial sample testing and presented to BMW by DD.MM.YYYY.Role / contribution of QMT.Description of activity.Show agreements (print, sign, distribute)corresponds to 2nd tab in PZS formsShow cover sheet (print, sign, distribute)corresponds to 3rd tab in PZS formsShow

26、 data sheets (features + quantity)corresponds to 4th/5th tabs in PZS formsQMT-Netzwerk MQ-1Seite 15PZS formsProcess series project data (1st tab)RMT comparisonPartly in scope configuration (responsibility), partly in additional agreements in PZS moduleRole / contribution of QMT.Description of activi

27、ty.QMT-Netzwerk MQ-1Seite 16PZS formsAgreements on process series (2nd tab)RMT comparisonAdditional agreements / parts free text onlyRole / contribution of QMT.Description of activity.Sign and distribute document after process series!QMT-Netzwerk MQ-1Seite 17RMT comparisonThe evaluation is the resul

28、t of the answers to the questionnaire and can also be manually overruledPZS formsProcess series cover sheet (3rd tab)Manual evaluationRole / contribution of QMT.Description of activity.Sign and distribute document after process series!QMT-Netzwerk MQ-1Seite 18RMT comparisonidenticalPZS formsProcess

29、series data sheet Quantity (4th tab)Role / contribution of QMT.Description of activity.QMT-Netzwerk MQ-1Seite 19PZS formsProcess series data sheet Features (5th tab)RMT comparisonidenticalRole / contribution of QMT.Description of activity.QMT-Netzwerk MQ-1Seite 20PZS formsMeasures derived from proce

30、ss series (6th tab)RMT comparisonMeasures are generated from unresolved issues via the questionnaire answersRole / contribution of QMT.Description of activity.QMT-Netzwerk MQ-1Seite 21Define PZS deadline/scope1a Note quantitiesProvisional PZS (optional, approx. process precursor)Completion of tool r

31、elocation /production systems 100% function (VS1)100% launch capability (AT)Process series (PZS)Complete all measures from PZS in time for DOC7100% MUP (sample testing) = 2/amber (2 MBS)100% MUP = 1/green (3 MAS)161a2334564573Upstream and downstream processes.Position of PZS in supplier timetable.88

32、QMT-Netzwerk MQ-1Seite 22Further documents.Questionnaire PZS module in RMT.Question BlockQuestionresponsible1 Product and Process1 Have the principle of fail-safing (e.g. Poka Yoke) and/or the automation options beenplanned?Q(uality)2 Can the relevant product characteristics be verified?Q(uality)3 C

33、an the relevant process characteristics be verified?Q(uality)4 Have the validation volumes required for the process series been successfully verified?Q(uality)5 Have the reliability-related characteristics (reliability indicators) been integrated in the process steps and are they monitored regularly

34、?Q(uality)6 Is the system for corroborating non-capable product and process characteristics introduced and effective?Q(uality)7 Is product-specific traceability of the units implemented?Q(uality)8 Are the required, complete and unchanged customer specifications available?Q(uality)9 Is a current proc

35、ess FMEA available? Is the action stipulated implemented in the test and inspection plan and in the process?Q(uality)10 Has pre-production under series terms been necessary for todays process series?Q(uality)11 Are process parameters monitored and controlled on-site and as stipulated in the test pla

36、n?Q(uality)12 Are the internal Q goals and the respective action limit determined for all assembly steps?Q(uality)13 Do the containers and packaging correspond to the final series status and are they coordinated with and tested by the respective BMW units?Q(uality)14 Are all containers available in

37、adequate quantity?Q(uality)15 Is there a system for handling damaged packaging?Q(uality)16 Do the transport containers undergo a maintenance interval?Q(uality)17 Does the identification of the containers and parts correspond to the requirements of the packaging manual and the agreements with BMW?Q(u

38、ality)18 Is the flow of material and parts secured against mixing/mix-up?Q(uality)19 Can rework be avoided continuously?Q(uality)QMT-Netzwerk MQ-1Seite 23Further documents.Questionnaire PZS module in RMT.Question BlockQuestionresponsible2 Resources and Facilities1 Will there be an initial sample rel

39、ease and, if applicable, a last sample release?Q(uality)2 Is spare parts supply ensured for maintenance?Q(uality)3 Is a plan for maintenance available?Q(uality)4 Have the required MCSs been conducted and has machine capability been verified for the agreed characteristics?Q(uality)5 Are all required

40、online measurement systems or offline measurement concepts installed inthe production process?Q(uality)6 Has the capability for the measurement and test equipment used been verified?Q(uality)7 Is regular measurement and test equipment control ensured?Q(uality)8 Is a contingency strategy available fo

41、r technical systems?Q(uality)9 Do the current production conditions correspond to future series conditions?Q(uality)10 Are production, test and inspection documents available and up-to-date?Q(uality)11 Is adequate capacity for the in-series tests and inspections available?Q(uality)12 Do the producti

42、on facilities and tools correspond to the series status?Q(uality)13 Are all production facilities and tools in accordance with launch curve available and unrestrictedly operational?Q(uality)14 Is the production facility qualified for the required cycle time and is a performance verification availabl

43、e?Q(uality)15 Have all production facilities and tools been accepted by the responsible areas?Q(uality)16 Are special operating resources marked as BMW property?Q(uality)17 Are the respective work stations ergonomically designed in relation to the worker?Q(uality)18 Is the space ratio reasonably des

44、igned for the maximum number of production items?Q(uality)QMT-Netzwerk MQ-1Seite 24Question BlockQuestionresponsible3 Problem analysis / correctionContinuous improvement1 Is a process for handling series parts returned by the customer (delivery and field quality)defined in writing and known?Q(uality

45、)2 Is the procedure for control of nonconforming units implemented in the process?Q(uality)3 Is the current reject share or rework share acceptable for subsequent series production?Q(uality)4 Has the quality and process data (statistically) been evaluated and filed?Q(uality)5 In case of deviations f

46、rom product/process requirements: Are the causes analyzed and thecorrection measures checked for effectiveness?Q(uality)6 Are processes and products audited frequently?Q(uality)7 Are there defined defective parts which are to be identified and used in the scope of the first piece clearance?Q(uality)

47、8 Is the process for handling damaged parts (delivery and field quality) sent back by customers determined in writing and known?Q(uality)Further documents.Questionnaire PZS module in RMT.QMT-Netzwerk MQ-1Seite 25Question BlockQuestionresponsible4 Sub-suppliers / Primary Material (Sub-supplier-Manage

48、ment)1 Is it ensured that all parts to be processed (in-house parts and out-source parts) comply with the valid release/change status?Q(uality)2 Is the regulation for the flow of material applied for finished products and is compliance with FIFO guaranteed?Q(uality)3 Are the current demand figures a

49、nd delivery deadlines available and have they been forwarded to sub-suppliers?Q(uality)4 Have process series been completed on the parts used?Q(uality)5 Have the required clearance tests been completed for the parts used?Q(uality)6 Are exceptions regulated in case of a missing/negative initial sampl

50、ing inspection?Q(uality)7 Is the delivery quality of supplier parts guaranteed?Q(uality)8 Is the change management of the sub-supplier regulated and proved?Q(uality)9 Is the product-specific traceability of the units implemented at sub-suppliers?Q(uality)10 Is there a receipt of goods process?Q(uali

51、ty)Further documents.Questionnaire PZS module in RMT.Question BlockQuestionresponsible5 Personnel1 Is the production line manned in accordance with series production? (Capacity)Q(uality)2 Are the required production staff demonstrably adequately trained?Q(uality)3 Are maintenance staff available for

52、 plant malfunctions?Q(uality)4 Are the maintenance staff adequately trained for all product-related production facilities?Q(uality)5 Is there an HR plan with deputy regulations?Q(uality)QMT-Netzwerk MQ-1Seite 26Further documents.Questionnaire PZS module in RMT.Question BlockQuestionresponsible17 Log

53、istics Concept1 How is the result of the logistics concept evaluation?L(ogistics)2 Changes to product and process have been communicated and approved within the supply chain. (e.g. location changes, assembly process changes, service providers, IT- changes, assembly measures (internal supply process

54、changes)L(ogistics)3 Do the containers and packaging correspond to the final series status and are they coordinated with and tested by the respective BMW units?L(ogistics)4 Are all containers available in adequate quantity? Container quantity and the number of components that will fit in the contain

55、ers is defined? Spare part and alternative solution packing has been taken into account in the planning and has been coordinated with packaging planning.L(ogistics)5 The required capicity bandwidth is available and in the framework of the process series ensured under production conditions. An overvi

56、ew of the capacity flexibility is available. A tool for rolling capacity planning is available.L(ogistics)6 Are the current demand figures and delivery deadlines available and have they been forwarded to sub-suppliers?L(ogistics)7 Supply chain is defined. Identification of critical subcontractors.L(ogistics)8 Proof of safeguards against mixing / confusion in the material and parts flow in WE, production and shipping is available. A mislabeling in production and shipping is not possible.L(ogistics)9 The 10-day flash design is implemented, the process was verified in the pre-series.L(ogisti