夾具重復性試驗轉(zhuǎn)孔TOMOANAEnglish-Chinese課件

1、全員參與標準化作業(yè)持續(xù)改進縮短制造周期造入質(zhì)量通用-全球制造系統(tǒng)Principle: Built In Quality 原則： 造入質(zhì)量Element: 14 Manufacturing Process Validation 元素： 14個制造工藝驗證GM-GMS Operating Tool 通用-全球制造系統(tǒng)操作工具14.5 TOMOANA僅供通用內(nèi)部使用 2010年8月全員參與標準化作業(yè)持續(xù)改進縮短制造周期造入質(zhì)量通用-全球制造Copyright Notice版權(quán)聲明 August, 2000 General Motors Corporation (GM). 2000年8月，通用汽車公司

2、All rights reserved. 版權(quán)所有No part of this material may be reproduced in any form or by any method (photocopy, microfilm, digital, etc.) without the written permission of General Motors Corporation, educational purposes included.本資料中的任何部分在沒有通用汽車公司書面許可證的情況下不得以任何形式或任何方式（復印，縮微拍攝，數(shù)碼拍照等等）復制，包括教育用途。Copyrigh

3、t NoticeScope 范圍This operating tool defines roles & responsibilities for TOMOANA activities applied to all GM South America and African Assembly Plants.本操作工具為應用于所有通用南美和非洲的組裝工廠的TOMOANA活動定義了角色和責任。Definition 定義TOMOANA is a method to ensure the process repeatability in welding fixtures for welded subass

4、emblies and reduce dimensional variation in Body-in-white build up process.TOMOANA是一種確認焊接夾具工藝復現(xiàn)性和在白車身制造過程中減少尺寸變化的方法。Purpose 目的 Support GM-GMS principle : Built-in-Quality; 支持通用-全球制造系統(tǒng)原則：制造質(zhì)量； Support deliverable execution as required in MQRR ( Manufacturing Quality Readiness Review); 支持根據(jù)MQRR（制造質(zhì)量準備

5、評審）要求的交付運行； Define the standardized process for validation and control and verification ofstability for welding fixture. 確定驗證和控制標準化程序和焊接夾具穩(wěn)定性驗證。Scope 范圍Responsibility 責任The Manufacturing Engineering ( Dimensional Engineering) is the process owner for implementation of this process during the Launch.

6、 The Body Shop Manager is the process owner for execution of this procedure in regular production. 工藝（尺寸工程師）是負責在產(chǎn)品啟動過程中實施流程。車身車間經(jīng)理是在量產(chǎn)時運行這個過程的負責人。Introduction TOMOANA is a tool applied to ensure the dimensional repeatability in welded subassemblies and it is effective preventive tool to support the

7、Quality Motto; Do not accept, build and ship Defects.TOMOANA是適用于焊接總成部件時相關尺寸的確認，是一種預防性的工具，它是有效來支持質(zhì)量格言的預防工具：絕不接受，制造，傳遞缺陷。It is a methodology applied to reduce dimensional variation in Body Shop and continuously improve the Dimensional Quality of BIW and Assemblies ( A rate and 6 Sigma).它是適用于在車身車間減少尺寸變

8、化和持續(xù)改進白車身和裝配的尺寸質(zhì)量的方法論（等級A和6 Sigma）。Do not Defects絕不接受制造傳遞缺陷Responsibility 責任Do not Enablers 要素Standard parts; 標準件；Welding fixtures; 焊接夾具；Measurement system ( Gauge Pass-no-Pass); 測量系統(tǒng)（測量及格不及格）Standardize Work; 標準化工作；Records ( validation and daily record); 記錄（確認及日記錄）Enablers 要素TOMOANA: PDCA cycle6. P

9、roblem Solving; 7. Effectiveness & Efficiency. 1. TOMOANA planning; 2. TOMOANA validation 5. Alarm & Escalation; 3. Daily Control ( Production core)4. Weekly Monitoring ( Quality core)PDCA 周期計劃驗證問題解決效力與效率報警升級日常管理（生產(chǎn)核心）周監(jiān)督（質(zhì)量核心）TOMOANA: PDCA cycle6. Problem 1- Planning: Launch process 計劃：流程啟動 The TOM

10、OANA must be developed for all the in the Body Shop Process. Geo-stations means any sub-assembled parts that impact the geometry of the vehicle and still can be applicable for any sub-assembled part that is causing downstream quality issues (noise, water intrusion, fits) or that is known as critical

11、. TOMOANA 必須在車身車間程序中為所有 GEO-STATIONS 發(fā)展。Geo-stations 意味著任何影響車輛幾何學的初級裝配零件并且仍然適用于引起質(zhì)量問題（異響，水浸，匹配問題）或者是危險的初級裝配零件。 During the Body Shop Readiness this tool should be initiated together with Iterative matching activities ( 53 weeks prior to SORP) and achieve 100% approved by End of MVBns. 在車身車間準備期間，此工具應該

12、和反復的匹配活動一起啟動（在SORP階段53周前）并且在MVBns結(jié)束時得到100%通過。TOMOANA Timeline 時間軸技術(shù)規(guī)格檢驗感覺特性設計研究生產(chǎn)裝配文件下發(fā)100%通過第一圈1- Planning: Launch process 計1- Planning: Current process 計劃：目前工藝TOMOANA is also applied in dimensional continuous improvement process for current programs. Based on the GCA, Verification Station and CMM

13、feedbacks TOMOANA can support a method to eliminate the variability existing on welded subassembly fixture after the root caused analyzed.TOMOANA也適用于目前項目的空間持續(xù)改進程序。根據(jù)GCA、檢驗站和CMM回饋，TOMOAMA可以在分析根本原因之后，支持消除存在于焊接部件夾具變異性的方式。偏差1- Planning: Current process TOMOANA Planning 計劃 The TOMOANA must have a deploym

14、ent plan developed, which includes four key attributes (4Ms) to ensure the adequate execution level from the TOMOANA activities:TOMOANA必須發(fā)展部署計劃，包括4個保證TOMOANA行為適當運行水平的關鍵屬性：1.Man: 人員 1.1 Define team to perform the validation process; 明確小組實施驗證程序； Dimensional expert should lead or support team; 空間專家應該領導

15、或支持小組； 1.2 Define by whom the Daily Control will be conducted; 明確誰來執(zhí)行日常管理； 1.3 Develop training for the different levels of people involvement and deploy it; 為各階層的參與人員開展并部署培訓；2. Material: 材料 2.1 Define how standard parts will be available; 明確標準件如何可用； 2.2 Define where and how the standard parts will

16、be storage, include who is make the supports; 明確標準件應該如何存放并存放在哪里，包括誰來支持； 2.3 Define when the standard parts should be exchanged ( date); 明確何時交換標準件（日期）；3. Machine: 機器 3.1 Define which welding fixture will be implemented and when; 明確適用哪個焊接夾具，何時適用；4. Method: 方案 4.1 Deploy measurement process and pin gag

17、e must be enough for all the areas; 部署測量程序，全部地區(qū)的定位銷板必須充足； 4.2 Develop Standardized Work ( STS/TIS) and apply JIT. 開展標準化工作（STS/TIS）并且應用JIT.TOMOANA Planning 計劃1.Man: 人員 1. TOMOANA Planning 計劃Measurement System; 測量系統(tǒng)Gauges in 3.0 - 3.5 and 4.0 mm are applied to measure the diameters of holes previously

18、 identified.3.0-3.5mm和4.0mm的測量儀器應用于以前確定的孔的直徑。測量儀器測量系統(tǒng)1. TOMOANA Planning 計劃Measurem驗證流程：TOMOANA驗證標記并打4.0mm的孔打開夾鉗，移動零件，放下零件，關閉夾鉗測量孔的直徑并記錄每10個重復項目3和4結(jié)果是依據(jù)標準的嗎？分析并做調(diào)整?；氐巾椖?階段1階段2打開夾鉗，移動零件，放下零件，夾緊夾鉗測量孔的直徑并記錄每5個重復項目7和8結(jié)果是依據(jù)標準的嗎？打開夾鉗，移動零件，放下零件，關閉夾鉗測量孔的直徑并記錄階段3結(jié)果是依據(jù)標準的嗎？結(jié)束驗證。存檔文件驗證流程：TOMOANA驗證標記并打4.0mm的孔打開

19、夾鉗，2- Validation Process;驗證程序The initial validation process must be conducted in four steps as follows:最初的驗證程序必須按照以下四個步驟執(zhí)行：3.1 Define hole positions and make the holes; 確定孔位并打孔；3.2 Repeatability of the welding fixture clamping; 焊接夾具鉗位重復定位；3.3 Repeatability with “cold” welding; 用冷焊重復定位；3.4 Study in w

20、elded substructure; 研究焊接底層結(jié)構(gòu)；During the validation process is important to mention;驗證程序的重點：The same subassembly parts will be used for all phase ( I, II and III); 相同組件應該應用于各個階段（ I, II 和 III ）After runs process validation the welded subassemblies shall be disposal for scrap or if no damage was done,

21、can be used as normal production parts, as long product engineering approves. 運行驗證程序之后，焊接組件應該處理廢料，或者如果沒有損壞，可以作為正常生產(chǎn)零件使用，只要產(chǎn)品工程批準。2- Validation Process;驗證程序2- Validation Process; 驗證程序3.1 Define hole positions and make the holes; 確定孔位并打孔；Its the first step for the Tomoana validation. Ensure that weldi

22、ng fixture is OK and there is not potential variation related to fixtures. Make sure that all holes defined are able to identify any variation on subassembly process and:這是Tomoana驗證的第一步。確保焊接夾具沒問題，并且沒有涉及到夾具的潛在變化。確保所有確定的孔都能夠在分部裝配過程中鑒定任何變化并且： analyze all the variation to be studied ( x, y and z axles)

23、between two or more parts; 分析全部要研究的兩個或多個零件之間的變化（x, y和z軸）； define a minimum of two points that guarantee this variation; 確定最小的保證這個變化的兩點； define the location of the perforation considering: 確定穿孔位置時考慮到： must not coincide with welding spot position; 一定不要和焊點位置一致； must be accessible for measuring on the w

24、elding fixture; 一定在焊接夾具上能夠測量； eliminate the burrs on the holes; 去除孔邊的毛刺； identify the holes with numbers; 確定孔的編號；見附件A2- Validation Process; 驗證程序3.1確定孔位并打孔（繼續(xù)部分）例如：基準面注意孔的質(zhì)量！穿孔直徑：4mm確定孔位并打孔（繼續(xù)部分）例如：基準面注意孔的質(zhì)量！穿孔直徑確定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外部部件聯(lián)合區(qū)域右邊左邊確定零件上的部件聯(lián)合區(qū)域以確保適當?shù)拇┛状_定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外

25、部2.2 Repeatability of Welding Fixtures Clamping (phase I) 焊接夾具鉗位的重復性（第一階段）Once made the holes the repeatability process on welding fixtures clamping is initiated (phase I). If the Clamping does not able to provide repeatability the welding fixture has to be adjusted or/and re-define new holes positi

26、ons. The previous step redone.一旦打孔了，焊接夾具鉗位的重復性程序就啟動了（第一階段）。如果鉗位不能提供重復性，必須調(diào)整焊接夾具或者重新確定孔位。然后重復前面的步驟。2.2.1 Perform Clamping Process; 執(zhí)行夾緊步驟Repeat 10 times the following sequence; 重復10次以下序列；a) remove pieces and relocate them; 移動并重新安置零件；b) clamp the fixture; 夾緊夾具；c) measure the diameter of the holes and

27、register ( appendix B).測量孔的直徑并記錄下來（附件B）。 需要測量的孔見附件B2.2 Repeatability of Welding FFor the Validation Process is recommended to validate with every holes diameter minor than 0.5mm. Conditional accept should be avoided to not impact the next phases of the process.建議的驗證程序檢驗每個孔的直徑小于0.5mm。有條件的接受應避免影響程序的下一

28、階段。焊接夾具鉗位的重復性（第一階段）評價夾緊步驟；驗證程序的標準（一、二、三階段）接受：直徑變化：小于0.5mm有條件的接受：直徑變化：0.5到1.0mm拒絕：直徑變化：大于1.0mmFor the Validation Process is 2.3 Repeatability with “cold”welding; 冷焊的重復性This step will ensure whatever variation between welding fixtures and welding process ( phase II) does not occur. 這一步驟確保焊接夾具和焊接程序間是否存

29、在變化（第二階段）。2.3.1 Apply Cold welding;應用冷焊-Repeat 5 times the following sequence:重復5次以下序列：a) remove pieces and relocate them;移動并重新安置零件；b) Apply cold welding ( with pressure and without current);應用冷焊（用壓力不用電流）c) measure the diameter of the holes and register ( appendix B)測量孔的直徑并記錄（附件B）2.3.2 Assess Cold w

30、elding process; 評價冷焊工藝；If cold welding process is acceptable under Validation criteria move for next phase. If not, understand welding fixture variation and eliminate it. Then start the validation process again (phase I). 如果在驗證標準下冷焊工藝是可接受的就進行下一階段。如果不可接受，了解焊接夾具變化并且消除。然后再次開始驗證程序（第一階段）。焊鉗冷點焊見附件B2.3 Rep

31、eatability with “cold”w2.4 Study in welded subassemblies; 研究焊接組件This is the last step of TOMOANA Validation with welded subassemblies ( phase III).這是焊接組件TOMOANA驗證的最后一步。2.4.1 Welding; 焊接Repeat once the following sequence: 重復一次以下序列：remove pieces and relocate them; 移動并切重新安置零件；b) clamping the welding fi

32、xtures;夾緊焊接夾具；c) weld the parts; 焊接零件；d) measure the diameter of the holes and register ( appendix B).測量孔的直徑并做記錄（附件B）。 2.4.2 Assess Welding Process; If welding process is acceptable under Validation criteria the phase is over and the documents can be archived. If not, understand welding fixture vari

33、ation and eliminate it. Then start the validation process again (phase I). 如果焊接工藝在驗證標準下是可以接受的，此階段結(jié)束并且文件可以歸檔。如果不是，了解焊接夾具變化并消除。然后再次開始驗證程序（第一階段）。焊鉗點焊見附件B2.4 Study in welded subassembl2- Validation Process;驗證程序2.5- Re-Validation process;再驗證程序 The TOMOANA process must be re-validated always that: TOMOANA

34、程序必須再次驗證：- Change the standard parts for:改變標準件為： -Product changes;產(chǎn)品改變 -Welding fixture intervention/ change;焊接夾具介入/改變-Any transfer weld fixtures: 焊接夾具轉(zhuǎn)移： - Movement between areas;區(qū)域之間移動 - Plant to Plant公廠之間移動When the standard parts are changed due:當更改標準件由于： -Premature abrasion of the holes;孔的前期磨損 -

35、Damaged;損壞 - Corrosion points;銹蝕點There is no need to re-validated the TOMOANA, only change the parts.沒有必要再驗證TOMOANA，只是改變零件即可。2- Validation Process;驗證程序3- Daily control:日常管理 Production team is accountable for execute the TOMOANA daily control and maintain Standard Part in capable condition. 生產(chǎn)小組在允許條件

36、下負責允許TOMOANA日常管理并威脅標準件。3.1. Standard Part;標準件 After TOMOANA process approved a new subassembly part shall be created and available as Standard Part. 在TOMOANA程序通過后，應造新的組件并且可以作為標準件使用。 Standard Part has to follow the characteristics below: 標準件必須符合以下特點： keep the same figure as the holes and positions th

37、at used during the validation process ( step 2 of flow); 保證在驗證程序中使用的孔和位置一致（步驟2的流程）； Recommended to submit in Elpo Process; If the decision is submit in Elpo the parts have to be processed prior to holes perforated. If the decision is not Elpo process the parts have to be applied with protective oil

38、in order to avoid premature corrosion; 建議在電泳工藝中提交；如果在電泳過程中提交決定，在打孔之前必須加工零件。如果不在電泳過程中做決定，在零件上必須涂上防護油以避免前期銹蝕。3- Daily control:日常管理3.1. Standard Part; ( continuation) 標準件（繼續(xù)部分）All the measurable points identified; 確定所有測量點Part identification; 確認零件allocate in properly area; 在適當區(qū)域分配validate date & exchang

39、e part definition ( without: damages, corrosion points, premature abrasion of the holes). 檢驗日期& 交換零件明確（沒有：損壞、銹蝕點、孔的前期磨損）見附件E3.1. Standard Part; ( continua3- Daily control: 日常管理3.2 Execution; 執(zhí)行 The TOMOANA must be execute in beginning of the each shift. TOMOANA必須在每輪開始執(zhí)行。 To initiate the TOMOANA the

40、standard parts must be according, with no damages and the holes must not be wider or closed. Otherwise call the Team Leader and wait for his decision. 啟動TOMOANA時，標準件必須符合要求，沒有損壞，孔不能過大或者關閉。否則通知小組領導等待他的決定。 The Tomoana daily control consist in allocate the standard parts in the welding fixture and close

41、 the clamps and then measure the holes specified. (phase I of validation process) TOMOANA日常管理包括在焊接夾具中分配標準件，關閉夾鉗然后測量具體的孔（驗證程序的第一階段）。 The welding fixture will be evaluate under criteria below to be release for production 焊接夾具將按照下面生產(chǎn)中發(fā)放的標準來評估。 If the result is OK, record it on TOMOANA register and rele

42、ase the production. On the other hand if the result is NOK, record it and initiate the reaction plan according to Alarm & Escalation process. 如果結(jié)果是合格的，將它記錄在TOMOANA登記簿上并且發(fā)放生產(chǎn)。另一方面如果結(jié)果是不合格的，將它記錄下來并且根據(jù)警報和升級程序啟動反應計劃。見附件C開始標準件合格嗎？為焊接夾具分配標準件打電話給小組組長，等待他的授權(quán)來開始生產(chǎn)關閉焊接夾具夾鉗測量并登記每個指定的孔結(jié)果合格嗎？根據(jù)警告 & 升級流程啟動反應計劃準備生

43、產(chǎn)開始3- Daily control: 日常管理 If 4- Weekly Monitoring: Quality team is accountable for TOMOANA monitoring. It means perform weekly the following requirements; 質(zhì)量小組負責TOMOANA監(jiān)督。這意味著每周按照以下要求執(zhí)行：1- must ensure documentation is in place ( STS/TIS); 必須確保文件到位（STS/TIS）；2- must verify the Standard Part integrity:

44、 quality, identification; 必須檢驗標準件的完整性：質(zhì)量、確認；3- must verify the gauge, pin; 必須檢驗標準尺寸、識別碼；4- must confirm the Daily control execution: frequency and criteria; 必須確認日常管理執(zhí)行：頻率和標準；5- must ensure any process variation related to measurements have a reaction plan; 必須確保任何與測量有關的程序變化有反應計劃；6- must request weldi

45、ng fixture adjustment when necessary; 必須在必要時要求焊接夾具調(diào)整； There are others requirements that are recommended as: 還建議以下其他要求：7- could verify the TOMOANA area and allocation; clean up, organized and safety; 可以檢驗TOMOANA區(qū)域和分配；清潔；組織和安全；8- could check the TOMOANA board if all documentation proposed is availabl

46、e; 如果所有提交的文件都是可用的，可以檢查TOMOANA看板；見附件D4- Weekly Monitoring:見附件D5- Alarm & Escalation Process: 警告與升級程序 The reaction plan must be initiated based on Alarm & Escalation process defined when non-standard condition occurs. 反應計劃必須根據(jù)在不標準條件發(fā)生是確認的警告和升級程序啟動。The subassembly production must stop on first NOK hole and corrective action done. 組件生產(chǎn)必須在第一個不合格的孔時就停止，做校正工作。If remain 3 consecutive days in Alarm 1, the production should stop and corrective