福特汽車-品質(zhì)系統(tǒng)介紹

品質(zhì)系統(tǒng)

天馬行空官方博客：://；；QQ群：1755696321Agenda–QualitySystemTotalQualityExcellence–CompanyPolicyLetterNo.1.BriefHistoryofFLHQualityManagementQualityArrow(QualityisJob#1)QS-9000/ISO14001System/QualityOperatingSystemTGWReduction/VRT/SAQTGR/KanoModel21.FordTotalQualityExcellenceCompanyPolicyLetterNo.1Qualityisdefinedbythecustomer;thecustomerwantsproductsandservicesthat,throughouttheirlife,meethisorherneedsandexpectationsatacostthatrepresentsvalue.品質(zhì)是由顧客所定義Qualityexcellencecanbestbeachievedbypreventingproblemsratherthanbydetectingandcorrectingthemaftertheyoccur.達(dá)成卓越的品質(zhì)必須注重在問題的預(yù)防AllworkthatisdonebyCompanyemployees,suppliers,anddealersispartofaprocessthatcreatesaproductorserviceforacustomer.Eachpersoncaninfluencesomepartofthatprocessand,therefore,affectthequalityofitsoutputandtheultimatecustomers’satisfactionwithourproductsandservices.

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)3FordTotalQualityExcellenceSustainedqualityexcellencerequirescontinuousprocessimprovement.Thismeans,regardlessofhowgoodpresentperformancemaybe,itcanbecomeevenbetter.

維持卓越的品質(zhì)必須持續(xù)作流程的改善Peopleprovidetheintelligenceandgeneratetheactionsthatarenecessarytorealizetheseimprovements. 改善的智識(shí)及行動(dòng)來自人Eachemployeeisacustomerforworkdonebyotheremployeesorsuppliers,witharighttoexpectgoodworkfromothersandanobligationtocontributeworkofhighcalibertothosewho,inturn,arehisorhercustomers.

後工程即是顧客;不接收不良,不傳送不良-Chairmanoftheboard(口徑;水準(zhǔn),程度)天馬行空官方博客：://；；QQ群福特六和品質(zhì)管理之發(fā)展演進(jìn)1/4~1986-Introduction/Localization引入福特原廠產(chǎn)品開發(fā)標(biāo)準(zhǔn)如WorldwideDesignRequirement及WorldwideProductAcceptanceSpecifications。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)UPAS-UniformProductAssessmentSystem-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。5福特六和品質(zhì)管理之發(fā)展演進(jìn) 2/4天馬行空官方博客：://；；QQ群：1755696326福特六和品質(zhì)管理之發(fā)展演進(jìn) 3/41991~1996Upgrading/Standardization建置QIS(QualityInformationSystem)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(NewOverallVehicleAssessment-Customer)。1996年起導(dǎo)入QOS品質(zhì)運(yùn)行系統(tǒng)。Achievement1994年獲得Q1再次驗(yàn)證肯定。

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)的肯定。

7福特六和品質(zhì)管理之發(fā)展演進(jìn) 4/41996~nowTransformation/Internationalization1996年起開始推動(dòng)福特生產(chǎn)系統(tǒng)-FPS(FordProductionSystem)。2000年起廠內(nèi)開始推動(dòng)SixSigma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)(FordConsumerProductAudit)。Achievement1997年榮獲國(guó)際環(huán)境管理系統(tǒng)ISO14001驗(yàn)證。

1998年獲得汽車業(yè)國(guó)際品質(zhì)系統(tǒng)QS-9000驗(yàn)證肯定。2001年福特六和引擎廠新人圈榮獲福特總部CDQA(CustomerDrivenQualityAward)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ISO9001/QS9000及ISO14001整合系統(tǒng)驗(yàn)證。83.Ford‘QualityisJob#1’ArrowDefine,Measure,Analyze,Improve,ControlDesignfor6-SigmaCommonProblemSolvingLanguage&ToolsHighQuality,HighVelocityImprovements inBusinessResults9LeadershipPrinciplesRewardandRecognitionTrainingandFeedbackPartnershipwithUnions,Dealersand SuppliersVehicleQuality(High&LowTime-In-Service)CustomerSatisfactionTGWWarrantyResidualValueSales&Service SatisfactionEliminationof WasteQ1QualityIsJob#1QUALITYLEADERSHIPINITIATIVEEngageAllEmployees6-SIGMADataDrivenDecisionMakingQUALITYOPERATINGSYSTEMPerformancetoStandardsDriveProcessDeliverResultsPlanDoCheckActFordMotorCompanyQOSProductCreationSales&ServiceCertificationSystemFPDSFutureCustomersCurrentCustomersOrdertoDeliverySuppliersLaunchCurrentModelFPS9QualityLeadershipInitiative9LeadershipPrinciplesValue:

QualityisJobOne.Itisourresponsibility,ourjobsecurityandourfuture.

Attitude:

ZeroDefectMindset.Don'ttakeit,don'tmakeitanddon'tpassiton.

Culture:

Arelentlessdailyfocusonquality.

Training:

Ensuringpeoplehavethenecessaryskillsandtoolstodotheirjobs.

Accountability:

Effectivemeasurementandfeedbackforcontinuousimprovement-accountabilityandperformancemetrics.Cooperation:

Helpsuppliershelpussucceed.

JointLeadershipCommitment:

EffectiveQualityLeadershipatalllevels.

DisciplinedExecution:

Changesnevercompromisequality.

EnterprisingApproach:

Thecustomerisoursharedconcern.

104.ISO9001/QS-9000及ISO14001整合系統(tǒng)ISO9001(’96)/QS-9000(’98)內(nèi)部稽核:2times/yearISO14001(’97)內(nèi)部稽核:1times/yearISO9001(’96)/QS-9000(’98)外部稽核:1times/yearISO14001(’97)外部稽核:1times/year2systems,2setsofprocedures,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:2times/year整合外部稽核:1times/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!

NextStep轉(zhuǎn)換QS-9000至TS16949ISO1800011QOS-QualityOperatingSystem品質(zhì)運(yùn)行系統(tǒng)12QOS-QualityOperatingSystemTimeandDataManagementRequiredmeetingscheduledatdesignatedfrequenciestocommunicateandevaluatePlantQualitySystemOutput,total18meetings.

Atoolforplantstocommunicateinformationbacktothebasedepartmentsaddressingcustomerconcerns.VOPQUG-001FLHPracticesDescriptionFrequencyParticipantsMetricsDescriptionFrequencyParticipantsMetricsNOVA-CandQualitysystemPerformanceOverviewsDailyPlantMgr.AreaMgr.QualityMgr.AreaSupervisorAreaCIWGLeaders…Nova-cWrapreviewChips&ScratchesSqueaks/RattlesFAI/CAIreviewRollTest…ConvoyYardreviewDailyPlantMgr.AreaMgr.QualityMgr.AreaSupervisorAreaCIWGLeaders…Nova-cWrapreviewChips&ScratchesSqueaks/RattlesFAI/CAIreviewRoadTest,Excel,PDI,FTT…

13ConvoyYardReview-每日品質(zhì)會(huì)議ReviewVehicleQualityReviewConcern&Actions14QOS-QualityOperatingSystemVariabilityReductionVRT/VFGastructuredprocesstodrivequalityimprovementfocusedoncustomerexpectations.Itensuresthatplantcontrollablecustomerconcernsareacteduponquicklyandpermanently.ToolVerificationensureregularinspectionandcertificationofplanttestequipment,tools,andgagesisbeingconductedperthecorporateguidelines.

15QOS-QualityOperatingSystemIncomingMaterialmeasuresplanteffectivenessinimprovingandcontrollingthequalityofmaterialenteringtheplant.Aworkingrelationshipwiththeplant,suppliers,purchasing,andotherkeyactivitiesisessentialforqualityimprovement.

ProcessControl/Build&InspectionProcess

identifyrequirementsforcontrollingspecificoperationsandinspections.Thoserequirementscomefrompracticesand/orproceduresthataretheinfrastructureoftheassemblyVehicleOperationsQOS.

CC’s,SC’s,CTQ…16QOS-QualityOperatingSystemRepairSystemaformalizedrepairprocessassuringthepreparation,repair,material,andtooling/equipmentusedareinaccordancewithestablished/approvedrepairstandards.

QualityAcceptanceCriteria

establishedlevelofstandardstobeusedforinspection.

thecriteriamustthenbecascadedthroughouttheplants.toassurethateveryinspection/check/testisperformedtothesamestandardsthroughouttheentiresystem.17QOS-QualityOperatingSystemWeldSurveillanceInprocesschecksofweldedassemblies,whencoupledwithperiodicteardownofweldedbodiesandassemblies,provideapositivemethodofdeterminingweldquality.ensurethatallweldproductionoperationsarebeingeffectivelyperformed.

DimensionalControl

acomprehensivebodysheetmetalconstructionstrategythattakesintoaccountallkeybodysheetmetalcomponentsandtheirrelationshipstoeachotherandbodylines.toidentify,track,andreducedimensionalvariationfromcomponenttocomponentandvehicletovehicle18QOS-QualityOperatingSystemTorqueAssurancetoassurethatFasteningControlSystemimplementationisstandardizedandeffectiveacrossallassemblyplants.FCPAtoidentifymanufacturingimperfectionsthroughaseriesofaStatic/Dynamic/Full(combinationofstatic&dynamic)auditsoffinishedunits.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。

19FCPA(FordConsumerProductAudit)

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)品的問題及潛在可能造成顧客/消費(fèi)者不滿意的地方。採用全球一致的車輛作業(yè)評(píng)價(jià)流程於所有量產(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。使用顧客/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)〕。20FCPA(FordConsumerProductAudit)

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21CCRS(CustomerConcernRatingSystem)

顧客導(dǎo)向式評(píng)分系統(tǒng)22QOS-QualityOperatingSystemWindNoiseevaluatesthenoiseacceptabilityofvehicles,aswouldanaveragecustomer.Duringthedriveevaluation,thetrainedauditorlistenswithanunaidedearandrateswindnoiseperformance,onascalefrom1to10,usingthe"WindNoiseRatingCriteria"formSqueak&Rattletoeffectivelydetectassemblyorcomponentsqueakandrattleconcernspriortotheunitsleavingtheplant.23Squeak&RattleRoadTestSqueak&RattleTestTrackUpgradeLength: 100ftUniformViennaBlock,100ftSteppedViennaBlockWidth: 104〞40”40”24”TrackWidth~66”40〞40〞24〞100’UniformViennaBlockSteppedViennaBlock24Squeak&RattleRoadTestUniformViennaBlockSteppedViennaBlock(~1〞StepinHeight)25QOS-QualityOperatingSystemWater(20minutesoak)pre-determinedcriticalwaterentryareas,whichmaynotshowupduringthenormal100%productionwatertest.This20–Minutetestisaverificationofprocess/designactionstakentocorrectanyrepetitivewaterleakconcerns.FinishVehicleEvaluationProgram(M-10Program)

adailyevaluationofcompletedproductionlevelvehicles.Theseunitsaredrivenover-night,overtheroadbyauthorizedplantpersonnel.Itsfunctionistoidentifyissuesearlyanddevelopimmediateprocess/productcontainmentandimprovementactions.26QOS-QualityOperatingSystemPIC(ProductInformationCenter)includesexternalandinternalqualityindicators,givingtheplantsastandardizedmeansofdisplayingqualitydata,description,andvisualrepresentation.PICallowsinformationflowtopresentqualityefforts,whichfactuallydemonstrateperformanceovertime.ControlPoint/TipLevel

utilizeseithercurrentoraddedinspectionasatooltodriveIn-Station-Process-Control(ISPC)andtofacilitatecommunicationwiththeBaseOperatortodevelopcountermeasurestocontainqualityconcernswithinthezone.27QOS-QualityOperatingSystemUltrasonicamethodtoevaluatewindnoise.Theprocessisperformedbyattachinganultrasonictonegeneratortothecenterofthewindshieldandmovingadetectioninstrumentaroundthepotentialleakareas(glassruns,windshield,dooropenings,etc.).WindNoiseleaksaremeasuredindecibels(dB)andcomparedtopredeterminedlimits.Predeterminedlimitsareestablishedbycorrelationofleaksandcustomerdata.AirLeakageTest

anevaluationofsealedpaintedvehiclebodiesandcompletedproductionvehiclesforobjectivemeasurementsofbodyairleakage.28UltrasonicTestEquipment29QOS

總表-1/330QOS

總表-2/331QOS

總表-3/332QOSFAPAssessmentResultFLHelementlevel:2.75(FullLevel:4)U.S.VOtotalplantsummarystatusforreference:ThelevelofFLHisbetterthanVOplantsintheUS.33FordLioHoQualityImprovementFlowDiagram345.TGWReduction–VRT/SAQTGW(ThingsGoneWrong):問題點(diǎn),故障情況VRT(VariabilityReductionTeam)astructuredprocesstodrivequalityimprovementfocusedoncustomerexpectations.SAQ(SingleAgendaforQuality)asystematicmatrixtoprioritizeCustomerConcernsbasedoninternalandexternalindicators.35VRTOrganizationMeetingDateChampionTeamLeaderSub-System/GQRSCategoryJ.D.PowerCategoryTue.RingoLinMikeChang

ExteriorPaint&Corrosion

Vehicleexterior,(Paintissues)

JamesWang

Body&ExteriorTrim/Bumper

Vehicleexterior(ExcludeWindnoise,Waterleaks)

SteveTangInteriorTrim,Waterleakage,Squeaksandrattles

VehicleinteriorWaterleaksSqk&Rat

Wed.RichardChenS.M.Lee

Mirror,Seating&Restraints

Mirror