福特汽車頭燈六西格瑪改進(jìn)案例

福特汽車頭燈六西格瑪改進(jìn)案例6-PANELApril13,2010STANDARDREPORTINGMETHOD

FORPROBLEMSOLVING6-PANELTEAMMEMBERS

PROJECTCHAMPION:StephenFan

TeamLeader:

SunnyRen/JaneDemaria

TEAMMEMBERS:CFMAOPD:GrayYaoProcessOwner:WangDongCFMAequipment:ZhangHongCFMAmanufacture:SuJianguoVTYCoperation:EricWangProjectLocation:ChongqingCFMA/supplierVTYCDMAICR6-PANELVRT–ExteriorOrnamentationVFG–V77LightingL22–HeadlampAlignmentVehicle:CD345ICA2halogenPROJECTCLASSIFICATION:VOICEOFTHECUSTOMER:From2010ECGGQRS:C307/CD345Headlampaimingdeflectionandnotbrightenough.Detailsseeverbatimasattached.CTQSTATEMENT(CustomerRequirement):

CustomersexpectHeadlightstogiveaccurateaimingandadequate

brightvisionwithoutcausingglareforoncomingtraffic.DEFECTDEFINITIONforY(EngineeringMetric):

Headlampbeamdeflecttoonesideandbothsideheadlampnotaligned,andluminancenotbrightenough.PROBLEMSTATEMENT,SCOPE,ANDGOAL

Customer’sperceptionisthatCD345Headlampsarenotalignedproperlyandnotbrightenough.ThegoalistoreducetheL223MISTGWby70%.Where:Chinesemarket,notEUmarket;what:Aimingorluminanceunsatisfiedbycust;When:aftersalesanddrivingatnight,notfoundinplant;Howbig:In2010/3/8ECBGQRSreport,21complaintsonaimingandbrightnessissue,whilealmostallthenightdriversdissatisfytheheadlampbrightnessofFocusandMondeo.DMAICRCD345MY10GQRSPareto:10MYuptoMar27Note:GenkplantTGWareallcomplainedbeamtoohigh.Genkwarrantyareforimproperoperation.C307MY10GQRSPareto:6-PANELVRT–ExteriorOrnamentationVFG–V77LightingL22–HeadlampAlignmentVehicle:C307MCAhalogenPROJECTCLASSIFICATION:VOICEOFTHECUSTOMER:From2010ECGGQRS:C307Headlampaimingdeflectionandnotbrightenough.Detailsseeattachedverbatimlist.CTQSTATEMENT(CustomerRequirement):

CustomersexpectHeadlightstogiveaccurateaimingandadequate

brightvisionwithoutcausingglareforoncomingtraffic.DEFECTDEFINITIONforY(EngineeringMetric):

Headlampbeamdeflecttoonesideandbothsideheadlampnotaligned,andluminancenotbrightenough.PROBLEMSTATEMENT,SCOPE,ANDGOAL

Customer’sperceptionisthatC307Headlampsarenotalignedproperlyandnotbrightenough.ThegoalistoreducetheL223MISTGWby70%.Where:Chinesemarket,notEUmarket;what:Aimingorluminanceunsatisfiedbycust;When:aftersalesanddrivingatnight,notfoundinplant;Howbig:In2010/3/8ECBGQRSreport,21complaintsonaimingandbrightnessissue,whilealmostallthenightdriversdissatisfytheheadlampbrightnessofFocusandMondeo.DMAICR10MYuptoMar27Note:Sar.plantTGWandwarrantyaremainlyforHeadlampaimtoohigh.6-PANELHeadlampaimandbrightnessMeasurementsManpart-Insufficientadjustmentspace-Reflector/lenssurfaceimperfections/distortedHeadlampbulbvariation

Bulb

departurefromfocusAutomaticadjustment-AimequipmentcalibrationEnvironmentMachinesDesignUnitcodebarscanningforpara.load-Operatorsskillandusage-Dealerreplacedheadlampwithoutaimadjustment-

Lampworkingvoltage-Headlampbeamreadingbyaligner-Acceptablerangesetup-Torquegunspeedsetup-Fixmethodofheadlamp-BulbselectedCause&EffectDiagram:

DMAICR-Vehiclepositionadjustbeforeaimalignment-Reflectorsurfacedesign-

Lamphorizontal&verticalmountedposition(bodyvariation)evaluateinbodyshop-

Processincontrol-Cust.Changebulb/lampthemself6-PANELHeadlampworkingvoltage:Verification:Checkvoltageloadedonheadlamp,toexcludetoomuchcontactresistance'simpactonlampbrightness;Teston1complainedMondeoandcomplainedFocusDMAICRPerdesign,headlampworknormallyatvoltage12~13.5VConclusion:voltageisnottherootcauseforbrightnessissue.6-PANELCFMAheadlampalignmentadjustDMAICRAdjustgunVehicleheadlamp

shineintotheLightBox.TheLightBoxLensthenconvergesthelighttoformthebeampattern.Thegun

adjustbeampatterntoacceptablerange.LightBox6-PANELDMAICRCFMAheadlampalignmentcalibrationweeklyLaserfromlightboxgothroughtheholeLaserthroughthefrontholeandlayonthispointToadjust4wheelsorientationsystemtoachieve3pointsononeline.6-PANELAcceptablerangesetup(comparewithGenkandSararlouisplant):Verification:DMAICRSararlouisplanthorizontally0+/-70mm(10m)vertically

X+/-50mm(10m)Xasinspec,averagereleased117mmGenkplanthorizontally0+/-50mm(10m),vertically

X+/-50mm(10m)Xasinspec,averagereleased117mmCFMAplant:horizontally(-100,100)/

10m,vertically

X+/-0.1h/10m,whichequals581.5+/-72.7mm.H-bulbheight,set727mm.GB4599-2007reqt:horizontally+/-1°(0+/-175mm/10m),Vertically

thehorizontallinenohigherthanbulbheight.TwicethanEUsetup6-PANELLampphotometricfailure:Verification:HeadlampsupplierVTYCtodophotometrictestoncomplainedheadlamps.

DMAICRTestresult:complywithGBhomologation.Allpass.Conclusion：Homologationofphotometricistoolargetomeetcustomersatisfaction6-PANELBulbluminancenotcompetitive:Verification:SendsamplestoFoEtodothephotometricmeasurement,andgettheluminancedatafromFoE.Getthecompetitors’datafromVisteonandFoE,andcomparetheluminancedatabetweendifferentmarketsanddifferentsuppliers.DMAICRConclusion:BeampatternspreadwideronFordvehicles.ToyotaCorollaandHondaCivicaremore"spotty",thereforehighermaximumvalue.Fromtestresult,thetotallluminiscompetive,thebrightnesscomplaintsmainlyforaimingnotwell.6-PANELCustomercomplainedheadlampcheck:DMAICRTestlayout-birdview6-PANELCustomercomplainedheadlampcheck:DMAICRTestlayout-sideview1stfocusyz11bultpositionprojectedtowall(0,710)2onlyLHlampHVonwall(60,600)3onlyRHlampHVonwall(99,450)4combineHVonwall(60,600)Alldatawithmmunit2;43z13y2ndfocus1bultpositionprojectedtowall(0,710)2onlyLHlampHVonwall(-60,480)3onlyRHlampHVonwall(970,490)4combineHVonwall(-120,500)Alldatawithmmunit42Homologationreqt:y:-170~350;z:414~621Sararlouisplantreqt:y:-50~50;z:640~720The2vehiclescouldmeetGBreqtbutfailtomeetSararlouisplantacceptablerange.6-PANELDMAICRFixmethodcheck:

CD345HeadlampsarefastenedtoGORnearbyhoodcushion.HeadlampfastenerHoodcushionHLadjusterHeadlampadjusterisdesignedsonearbyhoodcushion.Duringcustomerusage,thehoodcushionisbumpedfrequently,soasimpactHLadjuster,soasimpactheadlampaimpoint.6-PANELDMAICRHeadlampbulbpositioncheck:

Bulbshouldbefixedatfocusofreflectortoachievedesign-intentbeamprofile.Asshownabove,thePic1istakenatnatualstate;Pic2istakenwithsocketpressed.Conclusion:SinceC307socketloose,lwobeambulbdeparturefromfocuspoint.Pic2C307HLwithsocketpressedtofocusPic1C307HLbulbsocketinnaturestate6-PANELDMAICRCD345/C307lensqualitycheck:

C307lenstoolingcorrodedseriously.CD345Lenstoolingcorroded,andwarpageseen.Corrodedstainscouldbeclearlyseen.C307AutopalheadlampC307VTYCheadlamp-Cust.Changebulb/lampbythemselvesUnitcodebarscanningforpara.load-Operatorsskillandaimequipmentusage-Dealerreplacedheadlampwithoutaimadjustment6-PANELHeadlampaimandbrightnessMeasurementsOperatorpart-Spaceforadjustment-Reflector/lenswarpage/surfacecorroded-Headlampbulbvariation-BulbdeparturefromfocusAutomaticadjustment-AimequipmentcalibrationEnvironmentMachinesDesign-

Lampworkingvoltage-Headlampbeamreadingbyaligner-Acceptablerangesetupandevaluation-Torquegunspeedsetup-Fixmethodofheadlamp-Bulbselected--Vehiclepositionadjustbeforeaimalignment-Reflectorsurfacedesign-

ProcessincontrolDMAICRCause&EffectDiagram:

Aftermeasuringandanalysis,theredcircledarerootcausesorescapepointsandneedactions.

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Lamphorizontal&verticalmountedposition(bodyvariation)evaluateinbodyshop6-PANELNextstepsDMAICR

PlannedactionResp.