通用大宇制造質(zhì)量課件

Built-InQuality

制造質(zhì)量GMS不斷改進(jìn)員工參與標(biāo)準(zhǔn)化縮短制造周期制造質(zhì)量Built-InQuality

制造質(zhì)量GMS不斷改進(jìn)員工Manufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementIn-Process

Control&VerificationQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementManufacturing

Process

Validation制造工藝認(rèn)證In-ProcessControl&Verification工藝控制與確認(rèn)Quality

System

Management質(zhì)量體系管理Quality

Feedback/

Feed-forward質(zhì)量反饋/前饋ProductQualityStandards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)Built-InQuality制造質(zhì)量Manufacturing

Process

ValidatBuilt-In-Quality

制造質(zhì)量WhatIsQuality?

什么是質(zhì)量？GroupDiscussion小組討論Built-In-Quality

制造質(zhì)量WhatIsQDefinitions定義Qualityiswhatthecustomerperceivestobeacceptabletoachievehis/herenthusiasm質(zhì)量是客戶感覺能夠接受并滿足其熱忱的東西Definitions定義QualityiswhatMadCow瘋牛(DiseasedMeat病牛肉)PoorQualityMeansLostSales質(zhì)量差意味著失去客戶Firestone燧石(UnintendedAccidents)意外事故uninstalledshiftlock漏裝移位鎖定(SuddenAcceleration)突然加速M(fèi)adCow瘋牛PoorQualityMeansPP100:NotReportedDueToInsufficientSample樣品不足不匯報(bào)()J.D.PowerIQSTrendByBrand

PP100:NotReportedDueToIns

NCSIByMakers-2002

2002????NCSICustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客戶期望值感知質(zhì)量感知價(jià)值客戶埋怨客戶忠誠客戶保持力NCSIByMakers-2002Custo通用大宇制造質(zhì)量課件VoiceofCustomer

客戶意見VoiceofCustomer客戶意見VoiceofCustomer客戶意見??????????????1.停車方便(Convenienceofparking)2.外觀式樣(Exteriorstyling)3.內(nèi)部空間(Interiorroominess)4.節(jié)能(Fueleconomy)5.安全(Safety)1.外觀式樣

(Exteriorstyling)2.內(nèi)部空間(Interiorroominess)3.噪音與靜音(Noiseandquietness)4.節(jié)能(Fueleconomy)5.空調(diào)性能(Airconditionerperformance)???1.發(fā)動(dòng)機(jī)性能(EnginePerformance)2.發(fā)動(dòng)機(jī)噪音(EngineNoise)3.外觀式樣

(Exteriorstyling)4.噪音與靜音(Noiseandquietness)5.坐騎(Ride)L6????1.節(jié)能(Fueleconomy)2.噪音與靜音(Noiseandquietness)3.內(nèi)部空間(Interiorroominess)4.坐騎(Ride)5.外觀式樣

(Exteriorstyling)??1節(jié)能(Fueleconomy)2.空調(diào)(Airconditioner)3.噪音(Noise)4.發(fā)動(dòng)機(jī)噪音(EngineNoise)5.M/T轉(zhuǎn)換

(M/TShift)1.節(jié)能(Fueleconomy)2.OSRVM手工控制(ManualOSRVM

control)3.發(fā)動(dòng)機(jī)噪音(Enginenoise)4.檢查發(fā)動(dòng)機(jī)點(diǎn)火(CheckEnginelight)5.法人形象(CorporateImage)1.節(jié)能(Fueleconomy)2.制動(dòng)性能(Brakeperformance)3.喇叭性能(Speakerperformance)4.內(nèi)飾品質(zhì)(Interiorquality)5.噴涂質(zhì)量差(Poorpaintquality)1.3排坐椅相稱(Seatscomport:3rdline)2.節(jié)能(Fueleconomy)3.發(fā)動(dòng)機(jī)啟動(dòng)(Poorenginestart)4.法人形象(CorporateImage)5.級別(Gradablity)VoiceofCustomer客戶意見????Built-in-Quality

制造質(zhì)量WhatisBuilt-In-Quality?

什么是制造質(zhì)量？GroupDiscussion

小組討論Built-in-Quality

制造質(zhì)量WhatisBWhatisBuilt-InQuality?什么是制造質(zhì)量？Definition定義Methodbywhichqualityisbuiltintothemanufacturingprocess,sothatdefectsareprevented,detected,andcountermeasuresareimplementedtopreventreoccurrence.指質(zhì)量在生產(chǎn)過程中產(chǎn)生，因此可以預(yù)防、發(fā)現(xiàn)缺陷，以及采取措施防止缺陷再發(fā)生的方法。Purpose意圖

Ensuresdefectsarenotpassedtothecustomer.確保不傳遞缺陷。WhatisBuilt-InQuality?DefinDesigners設(shè)計(jì)師Suppliers供應(yīng)商Production生產(chǎn)人員Dealers經(jīng)銷商Buyers采購員Sales&Marketing銷售人員TheCustomerChain...CompanyPerspective客戶鏈…公司遠(yuǎn)景Built-In-Quality

制造質(zhì)量DesignersSuppliersProductionDAssembly總裝Supplier供應(yīng)商Paint涂裝Body車身TheCustomerChain...ProductionPerspective客戶鏈…公司遠(yuǎn)景EachProcessHasatLeastOne“Customer”andOne“Supplier”每個(gè)階段至少有一個(gè)客戶和一個(gè)供應(yīng)商Built-In-Quality

制造質(zhì)量AssemblySupplierPaintBodyTheCDonot不要Accept接受Build制造Ship傳遞aDefect!缺陷SolveProblemsThroughTeamwork!團(tuán)隊(duì)合作解決問題！Built-In-QualityMotto

制造質(zhì)量口號SatisfyYourCustomer…滿足你的客戶DonotAcceptaDefect!SolveProQualityThroughTeamwork–KnowYourCustomer!Whatwaterleaks?Idon’tseeanywaterleaks什么漏雨？我沒發(fā)現(xiàn)漏雨。Thiscarwasn’tmadeonmyshiftTheproblemisPressShop.Theflangeistoolong.問題出自沖壓，邊緣過長Iwon’trunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower.Theproblemisthatthepiecesarebadfromthesupplier.問題在于供應(yīng)商的材料不好。Itisnotfrommyarea,maybeit’sthesealer這輛車不是我輪班造的。在沒有工業(yè)工程裝配方法及人力的情況下，我不做任何試驗(yàn)。這不是我負(fù)責(zé)的地方，也許是粘膠負(fù)責(zé)Don’trunawayfromtheproblem!

不要逃避問題!QualityThroughTeamwork–KnoLivinguptotheMotto...符合口號...-

WhatIsaDefect?

什么是缺陷？GroupDiscussion

小組討論

Defect缺陷LivinguptotheMotto...DeAdefectisaproductthatdoesnotmeettheestablishedqualitystandard.缺陷是不合已定標(biāo)準(zhǔn)的產(chǎn)品。Measurementofaqualitycharacteristic質(zhì)量性能測量Vehicle#車輛

號UpperSpecificationLimit規(guī)格上限LowerSpecificationLimit規(guī)格下限QualityStandard質(zhì)量標(biāo)準(zhǔn)Defect缺陷Defect缺陷xxAdefectisaproductthatdoeWhyaredefectsundesirable?為什么缺陷不受歡迎？Defectsmayalsoresultin…

缺陷還可能導(dǎo)致Highwarrantycosts過高保修成本

Lostcustomersale失去客戶DefectsRequireCorrection=CorrectionisWaste

缺陷需要糾正—糾正就是浪費(fèi)Whyaredefectsundesirable?De

QUALITYISEVERYONE’S

RESPONSIBILITY

質(zhì)量是每個(gè)人的職責(zé)Design,Engineering,Production,Quality,SupportDepartmentsandSuppliers.

設(shè)計(jì)，工程，生產(chǎn)，質(zhì)量，相關(guān)部門及供應(yīng)商OURBestResources:我們最好的資源:→

PEOPLE

員工OURGoal:我們的目標(biāo)：

→

EveryoneisaQualityInspector

人人都是質(zhì)檢員

→

EveryoneisaProblemSolver

人人都是問題解決者QUALITYISEVERYONE’S

RESPOWHOISRESPONSIBLEFORQUALITY?誰對質(zhì)量負(fù)責(zé)？WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITYME!!!我！ME!!!Healthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessControlled

ExternalTransportationManufacturing

Process

ValidationIn-ProcessControl&VerificationQuality

System

ManagementScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementValuesVision/MissionShopFloor

ManagementInternalPull/DeliveryAndon

ConceptProblem

SolvingSimple

Process

FlowProductQualityStandardsStandardized

WorkSmallLot

PackagingTemporary

Material

StorageQuality

Feedback/

Feed-forwardVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

Maintenance

FixedPeriod

Ordering

System/OrderPartsProductQualityStandards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)Healthand

SafetyPriorityQualReflectvoiceofthecustomer反映顧客的心聲Simple,clear&supportuser簡單、清晰，有利操作者ClearlyMeasurableatpointofuse在使用上可明確測量KeyPointsofGoodQualityStandards:

質(zhì)量標(biāo)準(zhǔn)的要點(diǎn)：

Inuser’sStd.Work&postedvisual在操作者的標(biāo)準(zhǔn)化工作或張貼出來StandardsMustSupporttheOperator,too–NotonlytheEngineer!!!標(biāo)準(zhǔn)不僅有益于設(shè)計(jì)者，也有益于操作工人ReflectvoiceSimple,clearCleaNottighterthanthoseappliedatthepreviousprocess

不要比前道工序的更嚴(yán)格KeyPointsofGoodQualityStandards:

質(zhì)量標(biāo)準(zhǔn)的要點(diǎn)：

FinalInspectionStandard:Gap+/-1mmFINALINSPECTIONBODYSHOPBodyShopStandard:Gap+/-2mmNottighterthanKeyPointsofUsemasterpartsandboundarysamplesasrequiredtomakevisual標(biāo)準(zhǔn)件與邊界樣件需要目視化KeyPointsofGoodQualityStandards:

質(zhì)量標(biāo)準(zhǔn)的要點(diǎn)：

BoundarySamplesshouldvisuallyindicateOK–NotOKconditiontohelpoperatorsmakequick,gooddecisions邊界樣件應(yīng)該標(biāo)明好或不好，以便操作人員迅速且更好地下決定。Visually“describing”thedefectisNotaBoundarySample!目視化標(biāo)明缺陷不是邊界樣件！Cratermorethanthissizeisnotacceptable不接受焊口大于此尺寸ExampleofaBoundarySample邊界樣品的范例UsemasterpartsandKeyPointsCreatea“Standards-Based”Culture

創(chuàng)造一個(gè)以標(biāo)準(zhǔn)為基點(diǎn)的文化氛圍Iwouldn’tbuythis!Doesn’tlookgoodtome!Myopinionis…Thisdoesnotmeetthestandard..TalkintermsofTheStandard,notopinions!以標(biāo)準(zhǔn)為基點(diǎn)，而非觀點(diǎn)！Createa“Standards-Based”CulManufacturing

Process

ValidationQuality

System

ManagementProductQualityStandardsQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&VerificationManufacturing

Process

Validation制造工序認(rèn)證Manufacturing

Process

ValidatWhatisaprocess?

什么是工序？Inputs投入Outputs輸出Aprocessisasetofinter-relatedresourcesandactivitieswhichtransformsinputsintooutputs.工序是集中相關(guān)的資源進(jìn)行一系列活動(dòng)，把投入轉(zhuǎn)換成輸出！Environment環(huán)境Process工序Man

MachinesMethodMaterialsWhatisaprocess?

什么是工序？InputWherecanErrorsOccur?

問題會出在哪？Defects缺陷Materials:材料Partsoutofstandard不符標(biāo)準(zhǔn)的零件Wrongparts錯(cuò)誤零件Poordesign設(shè)計(jì)不當(dāng)

Method:方法Poorstd.Work不好的標(biāo)準(zhǔn)工作LackofTraining缺乏培訓(xùn)

Machine/Process:機(jī)器/工序NoTPM沒有TPMProcessnotcapable工序不好Improperspecification規(guī)格不當(dāng)

Man:人力Notfollowstd.Work不遵循標(biāo)準(zhǔn)化工作Distractions,Forgetfulness分心、遺忘LackofExperience缺乏經(jīng)驗(yàn)ErrorsResultInWherecanErrorsOccur?

問題會出在哪ValidatethemanufacturingprocesspriortoStartofProduction!在生產(chǎn)啟動(dòng)前認(rèn)證制造工藝！Donot切勿Accept

接受Build

制造Ship傳遞aDefect!

缺陷！LivingUptotheMotto…達(dá)到口號“EliminatetheNeedforInspectiononaMassBasisbyBuildingQualityintotheProductintheFirstPlace”-Dr.Deming PFMEAWorkstationReadiness工位準(zhǔn)備ProcessControlPlan工藝控制計(jì)劃Error-proofingPlan防錯(cuò)計(jì)劃ValidatethemanufacturingproErrorProofingHierarchy防錯(cuò)層次Prevention預(yù)防Detection

檢測HumanJudgment人為判斷None無Product/ProcessDesignChange產(chǎn)品/工藝設(shè)計(jì)改變DFM/A&D/PFMEARobustDesigns&CapableProcesses機(jī)器設(shè)計(jì)及可行工藝One-WayAssembly同一裝配ProcessControls工藝控制LocatingPins&Stops固定點(diǎn)及停點(diǎn)Sensors&ProcessMonitors傳感器及工藝監(jiān)控Electro-MechanicalDevices電子機(jī)械儀器ColorCoding顏色信號VisualControls直觀控制AndonSystems暗燈系統(tǒng)StandardizedWork標(biāo)準(zhǔn)化工作ErrorsCan’tHappenSmallImprovement小改進(jìn)SignificantImprovement重大改進(jìn)IntroductiontoErrorProofing防錯(cuò)介紹ErrorProofingHierarchy防錯(cuò)層次P0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:VisualControlExampleHumanJudgment0515100396OLHM51020150151012457810115Better:0515100396OLHM5102015015101245ABExample:VehicleIdentification車輛認(rèn)證

(MutilationCoverColor)(蓋板顏色毀損)HumanJudgment人為判斷VisualControlExampleABExample:VehicleIdentificatVerticalPlate垂直板BatteryPost電池接頭ProcessControlExampleDetection檢測VerticalPlateBatteryPostProcXWorkPiece加工件WorkPiece加工件Fixture夾具Fixture夾具ProcessControlExamplePrevention預(yù)防XWorkPiece加工件WorkPiece加工ProductDesignExample(Before)REC<<>>>STOPPAUSEREC<<>>>STOPPAUSEOLDDESIGN老設(shè)計(jì)CanbeInstalledUpsideDown可以反安裝ApplicationofLabelsonCassetteDecks.門板標(biāo)簽Prevention預(yù)防ProductDesignExample(BeforeREC<<>>>STOPPAUSENEWDESIGN新設(shè)計(jì)ApplicationofLabelsonCassetteDecks.門板標(biāo)簽CanOnlyBeInstalledCorrectly!ProductDesignExample(After)PreventionREC<<>>>STOPLeftHandLocatorTabRightHandLocatorTabExample--ProductErrorProofing(OneWaytoInstallSeatBelt)防錯(cuò)樣品—只有一種安全帶安裝方法ProductDesignExample產(chǎn)品設(shè)計(jì)范例PreventionLeftHandLocatorTabRightHanSimpleEverydayExamples1)ErrorPrevention????Automaticshut-off自動(dòng)斷電SimpleEverydayExamples1)ErrErrorProofingExerciseThinkofanexampleatworkorathomewhereerrorproofingcanpreventanundesirablethingfromhappening想想工作或生活中使用防錯(cuò)措施避免不好事情發(fā)生的例子Discussasateamandreport–Take5minutes小組討論、匯報(bào)—5分鐘ErrorProofingExerciseThinkManufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&Verification工序控制與認(rèn)證ProductQualityStandardsManufacturing

Process

ValidatIn-ProcessControl&Verification–(3)Elements工序控制與認(rèn)證1.PreventionOutputs輸出Inputs投入NOK2.DetectionOKNextProcess下道工序Feedback反饋Donot不要Accept

接受Build

制造Ship

傳遞aDefect!

缺陷！LivingUptotheMotto…符合標(biāo)準(zhǔn)3.Containment包容In-ProcessControl&Verificat1)StandardizedWork標(biāo)準(zhǔn)化工作FollowandContinuouslyImproveStandardizedWork!!!遵守及不斷改進(jìn)標(biāo)準(zhǔn)化工作?。n-ProcessControl&Verification–1)PREVENTIONPreventionVehicleManifestManual2-DoorSunroof1)StandardizedFollowandIn-P2)FocusonOperation集中精力生產(chǎn)KeepYourConcentration&RespectStandardizedWorkofOthers!注意及尊重他人的標(biāo)準(zhǔn)化工作In-ProcessControl&Verification–1)PREVENTIONPrevention2)FocusonKeepYourIn-Proces3)ErrorProofingPrevention&OperatorAids防錯(cuò)預(yù)防與操作者支持TheBestProcessisOneThatCannotFail!最好工序就是不會失敗的！In-ProcessControl&Verification–1)PREVENTIONPreventionDAEWOO3)ErrorProofingTheBestProc4)RegularChecksofSystems&Processes定時(shí)檢查系統(tǒng)與工藝Std.WorkChecks!檢查標(biāo)準(zhǔn)化工作In-ProcessControl&Verification–1)PREVENTIONPreventionCHECKCHECK???????CHECKProcessControlChecks!檢查工序控制！TPMChecks!檢查TPMSafety/5SChecks!檢查安全/5S4)RegularChecksStd.WorkIn-PSelf-Checks自檢IncludeQualityChecksinStandardizedWork!把質(zhì)檢作為標(biāo)準(zhǔn)化工作的一部分In-ProcessControl&Verification–2)DETECTIONDetectionCheckMethods:POINTTOUCHLISTENCOUNTSelf-ChecksIncludeQualityChe2)ErrorProofingDetection檢測防錯(cuò)UseVisualandAudioSignals!使用視覺、聽覺信號！In-ProcessControl&Verification–2)DETECTIONDetectionStoptheLine,or停線或UseAlarms,or使用警報(bào)或CombinationofBoth,dependingonCriticality根據(jù)危險(xiǎn)程度兼用兩種方法2)ErrorProofingUseVisualan3)In-ProcessVerification工序認(rèn)證Inspectorsarenotthereasapoliceman,theysupportproductionbyconfirmingtheprocess!檢察員不充當(dāng)警察角色，而是作為確定工序的生產(chǎn)支持者In-ProcessControl&Verification–2)DETECTIONDetectionVerificationStationsFinalLineC.A.R.E.3)In-ProcessInspectorsareno3a)FocusonCriticalitems集中注意重大問題FrequencyofcheckstonotallowCriticaldefectstoleavetheshop!經(jīng)常檢查，不讓重大缺陷走出車間！In-ProcessControl&Verification–2)DETECTIONDetectionSafetyItems“Walk-Home”ItemsMajorCustomerDissatisfierS/CF/F3a)FocusonFrequencyofcheck4)DefectEscalation缺陷逐層匯報(bào)Escalatedefectstoleadershipforsupportdependingonfrequencyandcriticality!根據(jù)缺陷出現(xiàn)頻率與嚴(yán)重程度逐層向領(lǐng)導(dǎo)匯報(bào)以尋求支持！In-ProcessControl&Verification–2)DETECTIONDetectionExample:TeamLeaderSectionLeaderGroupLeader2defects/1hour4defects/1hour4)DefectEscalatedefectstoIn1)UseAndon(taughtmorelater)使用暗燈Makeproblemsvisual&pullinsupport!問題直觀，拉線尋求幫助！In-ProcessControl&Verification–3)CONTAINMENTAlwaysRememberthePriorities:一定要牢記：1)Safety安全2)Quality質(zhì)量3)Responsiveness(Throughput)響應(yīng)Containment包容1)UseAndonMakeproblemsvisu2)FollowContainmentProcess遵循包容程序Extraordinaryactionstopreventdefectsfrombeingpassed!采取特別行動(dòng)防止缺陷傳遞！In-ProcessControl&Verification–3)CONTAINMENTSomeexamples:1)Stoptheline停線2)100%checks100%檢查3)On-linerepair線上維修4)Reworks返工5)Sorting整理Containment包容2)FollowExtraordinaryactionsHowDoesourQualityMottorelatetoContainment?Donot不要Accept

接受Build

制造Ship

傳遞aDefect!

缺陷！Itmeansempoweredleadersmakejudgmentshowtocontrolqualitywhiletryingtokeepthelinerunning!!意味著領(lǐng)導(dǎo)有權(quán)作出決定：在盡量不停線的情況下，怎樣控制好質(zhì)量！Doesthismeanwestopthelineeverytimewehaveaproblem?這是不是意味著一有問題就停線呢？HowDoesourQualityMottorelHowDoesourQualityMottorelatetoContainment?Sometimesthebestdecisionmaybetoletadefectpasstothenextprocess,but…有時(shí)最好的辦法是讓差錯(cuò)轉(zhuǎn)到下工序，但是……ItisaconsciousdecisionmadebytheappropriatelevelActionmustbecommunicatedtonext“customer”DefectmustbeclearlyidentifiedonvehicleContainmentmustbeinplacetopreventfurtherdefects

ExamplesofSomeAndonGuidelines:暗燈使用的指導(dǎo)方針1)Willtheproblemaffectthenextprocess?問題會不會影響下道工序？2)CanIeffectivelyrepairthedefectoutofstation?能不能在工位外有效解決問題？3)Whatisthestatusofmydecouplers?自己的切斷器是什么狀態(tài)？4)Others…其他……HowDoesourQualityMottorelAndonDiscussion–HoodsSituation:AttheBodyShopend-of-lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods.AfterworkingthelinebackweknowthateverycarinthesystemhastheconditionallthewaytoHoodInstall.Aftersortingtherawhoods,itisfoundthatthereareenoughgoodhoodstokeepproducingcars,howevertherearenotenoughgoodhoodstorepairthedefectivecarson-line.Thesupplersaysnewhoodswillarrivein6hours.TheoperatorsatendoflinehavepulledtheAndonandtheescalationprocesshaspulledintheBodyShopManagerandQualityManager.Considerationsare:1)ThedecouplerbetweenBodyandPaintisalmostempty,2)Hoodswithcrackedmetalwillnotaffectanyofthesubsequentprocesses,and3)Hoodscanbechangedoutofstationrelativelyeasily.Discussion:YouarethePlantQualityManager–whatisyourdecision?Discussasagroup!

AndonDiscussion–HoodsSituaBackground:Inthiscase,thedecisionisisshutdownthelinefor(6)hoursandwaitforpartsorrunthelineandmakeacontainmentplan.SincethedecouplerbetweenBodyandPaintisalmostempty,thismeansallBody,PaintandGAwillalleventuallyshutdown.PotentialDecision:Inthiscase,QualitycanstillbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethehoodsdonotaffectthenextprocess.TheCostofstoppingthelinewillnotresultinbetterQualityorResponsiveness.Thus,agooddecisionwouldprobablybetorunthelineandmakeacontainmentplan:Allcarswithbadhoodstobespeciallyidentified.ProductionandQualityinPaintandGAnotifiedofthesituation,knowthevehiclenumbersandidentificationmethod.100%checkatHoodInstalloperationuntilprocesscapabilityisassured.PaintandFinalProcessnotifiedthatnewhoodstobepaintedinPaintandwillbeswappedinFinalProcessareaandhavetimetomakeaplanhowtoaccommodatethat.AndonDiscussion-HoodsBackground:Inthiscase,theSituation:AttheCockpitLoadstationinGAitisdiscoveredthatthereisaproblemwithoneoftheelectricalharnesseswithinthecockpit.Thecockpitsarebuiltasamodulebyanoutsidesupplier.Afterworkingthelinebackweknowthatseveralcockpitsinthesystemhavethecondition.TheoperatorsatCockpitLoadhavepulledtheAndonandtheescalationprocesshaspulledintheTrimLineSectionLeader,whoconsultswiththeChassisLineSectionLeader.Considerationsare:1)ThedecouplerbetweenTrimandChassisabouthalffull,2)Theelectricalharnesswillaffectthenextassemblyprocess,3)Repairingtheharnesseson-linewilltakeapproximatelyonehour,and4)RepairingtheCockpitlaterintheprocessisdifficultandverytimeconsuming.Discussion:YouaretheTrimSectionLeader–whatisyourdecision?Discussasagroup!

AndonDiscussion-CockpitsSituation:Discussion:AndonDiBackground:Inthiscase,thedecisionisisshutdownthelinefor(1)hourandrepairtheharnessespriortoCockpitLoadorrunthelineandrepairthecockpitsout-of-station.SincethedecouplerbetweenTrimandChassisisabouthalffull,thismeansthatChassiscancontinuerunningforashortwhileandtheneventuallyshutdown.PotentialDecision:Inthiscase,QualitycannotbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethebadcockpitsaffectthenextprocessandareextremelydifficulttorepairlater.TheCostofstoppingthelineismoredesirablethanthecostofrepairingthemlaterandthepotentialtocreatemoredefects.Inthiscase,thedecouplerstatusdoesnotreallyimpactthefinaldecisiontoomuch.Thus,agooddecisionwouldprobablybetostopthelineandfixtheharnessespriortoCockpitInstall.TheTrimLineSectionLeaderwillinformtheGAAreaManagerofthisdecisionandtheimpactonourResponsivenesstarget.AndonDiscussion-CockpitsBackground:Inthiscase,theManufacturing

Process

ValidationQuality

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ManagementQuality

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WorkVisual

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Feedforward質(zhì)量反饋與前饋ProductQualityStandardsIn-ProcessControl&VerificationManufacturing

Process

Validat

“Customer”客戶QualityInformationFeedback/Feedforward

質(zhì)量反饋與前饋“Suppliers”供應(yīng)商You你ProcessAProcessBProcessCbackDefectflowingfromAtoB

缺陷從A流到B

StatusonProblemResolution

問題解決狀態(tài)forwardEscapeddefectflowingtoProcessC避免缺陷流到CTemporaryprocessbeingusedinProcessB

過程B的暫時(shí)方案Process/productchangewithtime

工藝/產(chǎn)品隨時(shí)間改變StatusonProblemResolution

問題解決狀態(tài)“Customer”QualityInformationMotivationforTimelyFeedback

及時(shí)反饋的動(dòng)機(jī)Immediate1Day1YearHighMediumLow1s100s1000sTimetoDiscoverDefect發(fā)現(xiàn)缺陷的時(shí)間AbilitytoDiscoverRootCause發(fā)現(xiàn)根源的能力NumberofDefectiveVehiclesBuilt已經(jīng)生產(chǎn)的缺陷產(chǎn)品MotivationforTimelyFeedbackExample--DailyReportingMetrics(DirectRun)

每天匯報(bào)制度DefinitionPercentageofvehiclesthatmadeitthroughtotheEnd-of-Lineinspectionprocesseswithnodefects.Thisisacommon,globalmetricthatiscomputeddailybyallAssemblyPlants.

下線檢查合格的車輛百分比，這是全球統(tǒng)一在所有總裝廠每天用電腦記錄的制度。FinalInspection(End-of-Line)下線檢測DynamicVehicleTestorequivalent動(dòng)態(tài)測試Other100%Inspections**其他10%檢測(i.e.U/BCheck)TotalDirectRun=(92%*98%*96%*99%)

=86%vehicleswithnodefectRepairCARELine#offirsttimevehicleswithatleastonedefect至少有一個(gè)缺陷的第一次認(rèn)證

80204010%FirstTimeQuality一次質(zhì)量認(rèn)證百分比92%98%96%99%Totalfirsttimevehiclesthroughthestationonagivenday在特定時(shí)間工位的第一次認(rèn)證1000100010001000RepairRepairRepair**100%WaterTestand100%SqueakandRattleTestresultsarenotcurrently(3/2000)includedinDirectRun**100%的漏雨測試與異響測試并不包含在DirectRunExample--DailyReportingMetManufacturing

Process

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OrderSchedulesSupply

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OperatingStandards+CorporateQualityProceduresAssemblyPlantProceduresWorkInstructionsRecordsandOtherDocumentationISOPlantQualityManualISO工廠質(zhì)量手冊QualitySystem質(zhì)量體系GMS

制造標(biāo)準(zhǔn)+公司質(zhì)量程序總裝工廠程序工作指導(dǎo)記錄及其他文件GMS

OperatingStandards+CorpQualitySystemModelDon’t

adefectAcceptBuildShipMANUFACTURINGAREAQUALITYDPT.CUSTOMERProductionProductionQualityControlSIPStandardizedInspectionProcessDIQS/GCAContinuousImprovementsFeedbackResponsibleforproducingfirsttimequalityConfirmprocessandproduct.Providetechnicalsupport.Supportproblemresolution.ExpectationGDSIPTVJDPetc.ProcessStandard(StandardizedWork)ProductQualityStandards(CVIS)DAILYMANAGEMENT&MANAGEMENTBYBUSINESSPLANDEPLOYMENTPrinciple:QualitySystemModelDon’tad質(zhì)量體系樣式不

缺陷!接收制造傳遞生產(chǎn)部門質(zhì)量部門顧客生產(chǎn)生產(chǎn)質(zhì)量控制SIP標(biāo)準(zhǔn)檢測程序DIQS/GCACIPFeedback負(fù)責(zé)首次質(zhì)量檢查確定工藝及產(chǎn)品提供技術(shù)支持幫助解決問題期望GDSIPTVJDPetc.工藝標(biāo)準(zhǔn)（標(biāo)準(zhǔn)化操作）生產(chǎn)質(zhì)量標(biāo)準(zhǔn)CVIS業(yè)務(wù)計(jì)劃實(shí)施的日常管理與維護(hù)原則:質(zhì)量體系樣式不缺陷!接收生產(chǎn)部門質(zhì)量部門顧客生產(chǎn)SIPDIHowdoesBuilt-InQualityapply

totheotherGMSPrinciples?

制造質(zhì)量與其他GMS原則的關(guān)系Standardization:Pre-requisiteforachievingbuilt-inqualityContinuousImprovement:StabilizestheprocesssothatContinuousImprovementscantakeplace.ShortLeadTime:Drivesfirsttimequality,thereby,enablingshorterleadtimestodelivervehicletothecustomer

PeopleInvolvement:Everyoneisr