长安福特马自达Module 6 - Program Management.ppt

ProgramManagement,Purpose,Utilizingastandardizedprocess,STAisabletoensureaproductionSuppliersmanufacturingprocessesarecapableofproducingpartsthatdemonstratethecapabilitytomeetproductspecificationspriortoprogrammilestones.,Goal,ThegoalofthiscourseistoprovideSTAEngineerswiththeabilitytoperformwithinastandardizedprocessinsupportofaflawlesslaunchoftheprogram.,Objectives,ProvideprogramsupportwithinthetimeframesofFPDSDescribetheroles,responsibilities,andrelationshipsofSTAProgram,Site,andResidentEngineersandotherteammembersthroughoutaprogramProvideinitialprogramsupportCreate,implement,andmanagetheHighImpactandFocusSupplierlistsProvideprototypebuildsupportPrepareforandconductLaunchReadinessReviewsProvideassemblyplantbuildsupport,Background1,ReviewofinformationfromTheSTAJobandFPDScourses:STAWorkloadFPDSTypesofBuildsSTAResponsibilitiesinProgram,Background2,Finaltopicsupportsthecourseobjectiveto“provideinitialprogramsupport”by:ExplaininghowandwhenSTAintegrateswiththeprogramteamIdentifyingsourcesofprograminformationimportanttoSTADescribingrelationshipsnecessaryforthedeliveryofaprogramIdentifyingSTAresponsibilitiesforinitialprogramsupport,STAWorkload,STAProgramEngineersmayhaveupto400sitesthattheyareworkingwithatanyonetime.STASiteEngineersmayhaveupto50differentprogramsthattheyareinterfacingwith,inadditiontothesitestheyareresponsibleformanaging.STAResidentEngineersmaybedealingwithmultipleprogramsandupto500sites.,FPDSMilestones,TimingofSTAinFPDS,STAProgramManagermaystartonaprogramanywherefrom48tosixmonthspriortoJ1.Onmajorprograms,STAResidentManagersstarttransitioningatapproximately1PPtobecomefamiliarwiththenewprogramandassumeresponsibilities.Onminorprograms,STAResidentManagers/Engineershavetheleadforlaunchsupportattheassemblyplant.STAProgramEngineersworkwiththeprogramteamfrominitialassignmentuntiladefinedperiodafterJ1.STAResidentManager/Engineerresponsibilitiesmayoverlap(currentmodelandnewmodelprograms).STASiteEngineerwillbeinvolvedatmilestonesandbuildsandtoresolveSupplierissues.,STAProgramFunctions1,WorkwiththePMTsVerifySupplierneeddatesareappropriateforcommodityCreatetheHighImpact/FocusSupplierListCoordinateAPQPreportingstatusreportsCoordinateSupplierLRRs/SupplierSponsorshipReviewsCollectanddistributeLRRSummaryreportsthroughJ1,STAProgramFunctions2,SupportIQwithdevelopmentoftheincomingproductsamplingplanforhigh-riskSuppliersCoordinatelistofSuppliersrequiredonsiteattheassemblyplantforvehiclebuildsWorkwithSTASiteEngineerstocompletePPAPandrun-at-rateexercisesbeginningatAttendSupplier/FordmanagementmeetingsasrequiredSupportFreshEyesReviewsatSuppliersitesasrequiredResolvequality-relatedbuildissuesandverifycorrectiveactions,TypesofBuilds1,APs:Usedtosupportthetarget-settingprocessTypicallybuiltfromcobbledpartsNotrequiredtobebuilttoproduction-intentprocessesCPs:BuilttoconformtobothproductdesignandtheproductionprocessThefirsttimetheprogramteammayseeproductiontoolingMayincludeCPFandCPC,TypesofBuilds2,HTFBs:Approximatelythreemonthsbefore1PPWhentheprogramteamfirstseesthesheetmetaltooltryout1PP:Approximatelythreetofour-and-a-halfmonthsbeforeJ1andaftertheLaunchReadinessassessmentFullproductionattheplantwithproductiontoolingTheinitialphaseofEngineeringhandofftotheplant,TypesofBuilds3,FEU:Thirtyto60daysafter1PPSaleableunitsbuiltonproductiontoolingthatallowaslowramp-upofSuppliersandtheplantprocessprove-outIB:AlsoknownasContinuousBuild(CB)or4P(pre-productionprocessprove-out),STAProgramManager/EngineerResponsibilities1,SupportPurchasingwithnewSuppliersourcingSupporttheProgramteaminidentifyingHighImpact/FocusSuppliersReviewSegmentIIIandIVHighImpactAPQPstatusasdirectedCommunicateProgramrequirementsbetweentheappropriatePurchasingManagers,Buyers,andEngineersCommunicateHighImpactSupplierreadinessatrequiredprogrammilestones,STAProgramManager/EngineerResponsibilities2,Supportprogramandlaunchteamefforts,i.e.,PST,PAT,andPMTmeetingsSupportRun-at-Ratereviews,LRRs,anddispositionofPPAPpackagesforSegmentIIIandIVHighImpactSuppliersasdirectedParticipateinprototypebuildsProviderequiredon-sitelaunchsupportDriveresolutionofSupplierqualityissuesEnsuredatabasesareupdatedwithprogram-relatedinformation,STASiteEngineerResponsibilities1,STASiteEngineerSegmentIandII:SupportPurchasingwithnewSuppliersourcingReviewAPQP,establishPPAPlevel,anddispositionPPAPpackagesasrequiredResolveallbuildissuesusingtheG8Dfortheassignedsites,andverifycontainment/permanentcorrectiveactionsConductRun-at-RatereviewsandLRRsDrivenon-crisisbasedcommunicationsbetweenSuppliersandassemblyplantsServeasasinglepointofcontactforSuppliersiteperformance,STASiteEngineerResponsibilities2,STASiteEngineerSegmentIIIandIV:SupportPurchasingwithnewSuppliersourcingReviewAPQPstatusforHighImpact/FocusSuppliersasdirectedEstablishPPAPlevelanddispositionPPAPpackagesasrequiredConductRun-at-RatereviewsandLRRsatHighImpact/FocusSuppliersasdirectedDrivenon-crisisbasedcommunicationsbetweenSuppliersandassemblyplantsServeasasinglepointofcontactforSuppliersiteperformance,STAResidentManager/EngineerResponsibilities,Provideplantcoverageforallprogramsfrom1PPthroughlaunchSupportLRRsasrequiredandprovideinterfacewithPlantVehicleTeam(PVT)/plantAssistSTASiteEngineersasrequiredindispositionofPPAPpackagesAssistSTASiteEngineersasrequiredincompletionofSupplierRun-at-RatereviewsCommunicatebestpracticesandlessonslearnedacrossotherassociatedSTAprograms,IntegrationwiththeProgramTeam,STAProgramEngineers:BecomepartoftheprogramteamatthebeginningofaprogramapproximatelythreeyearsbeforelaunchContacttheprogrammanagementandPMTleadersto:GatherinformationabouttheprogramIdentifytheorganizationalstructureGainaccesstotheprogramteamswebsite,SourcesofProgramInformation1,PDL:PrimarycommunicationandofficialrecordannouncingandauthorizingprogramandcarlinecontentchangesProvides:TimingBuilddatesBudgetVehiclecontentWhotheprogramteamisIssuedbyaprogrambetweenkickoffandJ1UsedtocreatetheSTABusinessPlanforNewModelProgramSupport,SourcesofProgramInformation2,STABusinessPlanforNewModelProgramSupport:CreatedbySTAProgramManagement/EngineersfrominformationinthePDLTheoverallresourceplanforSTAforaprogramDemonstratestothePMThowSTAwillsupporttheprogram:TimingforallFPDSmilestonesandbuildsActivitiesIncludestheSupplierReadinessProcessTimeline:ReflectstheprocessforensuringSupplierreadinesswithinFPDStiming,SourcesofProgramInformation3,PPL:AlistofallpartsforaprogramincludingbothcarryoverandNTEIsIdentifiesPMTsforeachpartUsedbySTAProgramEngineerstoidentifyassociatedSuppliersandbeginselectionofSuppliersfortheHighImpact/FocusList:NotallSuppliersforNTEIswillbesourcedatthistime:STAsupportsthesourcingprocessasnecessary,SourcesofProgramInformation4,Lessonslearnedfrompreviousbuildeventsand/ormodelyear(MY)programs:MaybeobtainedfromtheSTADepartmentManagerReviewedbySTAProgramEngineersforallSTA-relateditemsandinitiativesandhowwelltheyworkedonpriorprograms:STAProgramEngineersshouldplantoincluderelevantlessonslearnedinthenewmodelprogram,SourcesofProgramInformation5,SIMandQR2Databases:UsedbySTAProgramEngineerstofindinformationoncurrentproductionqualityperformanceofSuppliersMeetingschedule:Basedonthisschedule,STAProgramEngineersbegintoattendmeetingsandcontributetodevelopmentactivities,LPhowever,additionalLRRsmaybenecessarypriortoeachbuildphaseforSupplierswithunresolvedissues,STAResponsibilityforLRRs1,TheSTAProgramEngineersupportsLRRsandisultimatelyresponsiblefortheircompletion:IdentifiestimeframeforschedulingInterfaceswithSTASiteEngineersAttendsLRRsastimeandworkloadpermitsFollows-uponLRRresultsMayconductLRRsforSegmentIIIandIVHighImpact/FocusSuppliersasnecessary,STAResponsibilityforLRRs2,ForSegmentIandIISuppliers,theassociatedSTASiteEngineersconducttheLRRs:STAProgramEngineersattendasnecessaryandfeasible.ForSegmentIIIandIVHighImpact/FocusSuppliers,STAmanagementnegotiateswhoisresponsible.,Scheduling1,STAProgramEngineers:DeterminetimeframeswithenddatesforLRRsbasedontheSTABusinessPlanforNewModelProgramSupportGivethisinformationtotheSTASiteEngineerswithasmuchleadtimeaspossibleforcompletionShouldalsoidentifyanyattendeesoutoftheordinarywhomtheSTASiteEngineersshouldinvitetotheLRRs,Scheduling2,STASiteEngineers:IdentifythemeetinglocationbasedonthemanufacturingcodeintheOpen-to-GoreportInmostcases,LRRstakeplaceatSuppliersitesworldwide.IftheSupplierispartoftheSupplierSponsorshipProgram,determinewhetherornottheassignedExecutiveSponsorwantstoattend:IftheExecutiveSponsorattends,theLRRbecomesaSupplierSponsorshipReview.CoordinatethedateoftheLRRwiththeSupplierandtheExecutiveSponsor,ifapplicable,Scheduling3,IdentifyotherpeoplewhoshouldparticipateintheLRRSendameetingnoticetoeveryoneidentifiedasLRRparticipantsincludingtheSTAProgramEngineer:Includearequestforconfirmationofattendance,Scheduling4,SendtheLRRAssessmentformtotheSupplier:AllowtheSupplieradequatetimetocompletetheformandspecifythattheformbecompletednolaterthanthreedaysbeforetheLRRCoordinatewithMP&LtomeetwiththeSupplierandcompleteSection7oftheassessment,TypicalTeamMakeup1,FordCoreTeam:STASiteEngineerSTAProgramEngineerBuyerPMTLeaderand/orPDEngineerManufacturingEngineerExecutiveSponsor(ifapplicable)MP<eamMember,FordSupportTeam(asrequired):STAProgramManagerSTACommodityManagerPurchasingProgramMgr.ManufacturingLaunchLeaderNewModelProgramMgr.ChiefVehicleProgramEngineerAssemblyPlantIQMgr.LP&TPersonnel,TypicalTeamMakeup2,SupplierCoreTeam:ProgramManagerManufacturingManagerQualityManagerCommercialManagerSupplierLaunchChampion(ifapplicable),SupplierSupportTeam(asrequired):CorporateOperationalMgnt.CorporateQualityMgnt.CorporateExpertsPlantManagerSub-SuppliersToolMakers,ThePre-Review1,TheSTAEngineer:Conductsthepre-reviewtoensuretheSupplieraccuratelycompletedtheassessmentIdentifiesthefollowing:IncompletesectionsRedoryellowratingswithnorecoveryplans/responsiblepartiesDuedatesincompatiblewithprogramneeddatesSummaryratingthatdoesnotagreewithdetailratingsCoordinatesatimelineforcorrectionbeforetheLRRFollowsuptoensuretheSuppliermakesthecorrectionsUpdatestheSTAProgram/SiteEngineer,dependingonwhoconductedthepre-review,ThePre-Review2,Byconductingapre-review,theSTAEngineerisensuring:TheSupplierspreparationfortheLRRTheparticipantsattheLRRwillbeabletoconductamoreefficientandthoroughreview,ConfirmAttendance,TheSTAEngineerconductingtheLRR:CompilesalistofpeopleattendingSendsoutconfirmationoftheirattendanceShouldensurethatthereisadequatecross-functionalteamparticipationforthereview,FacilitatingtheMeeting,TheSTAEngineer:LeadsthemeetingTurnsthemeetingovertotheSupplieraftertheintroductionforpresentationoftheassessmentTheSTAEngineer/teammembersaskquestionthroughoutto:Determinetheaccuracyofthered,yellow,andgreenratingsIdentifyissuesrelatedtoyellowandredratingsReviewrecoveryplansforredandyellowratingsEnsurerecoveryplansandtimingareinplaceandappropriatefortheissue,MeetingFollow-up1,TheSTAEngineerwhoconductedtheLRR:DocumentsthemeetingminutesEnsurestheSupplier,ExecutiveSponsor,ifinattendance,andSTAProgramEngineer,ifinattendance,agreeontheminutesDistributestheminutestotheLRRparticipants,launchteam,andmanagementofthelaunchteam,MeetingFollow-up2,TheSTAProgramEngineer:DeterminesifadditionalLRRsareneededbasedontheinitialLRRassessment:RequirescoordinationwiththeSTASiteEngineerUpdatestheAssessmentSummaryreportifapplicable,AssemblyPlantBuildSupport,Thissectionsupportstheobjectiveto“provideassemblyplantbuildsupport”by:DescribingpreparationneededtoparticipateinassemblyplantbuildsIdentifyingnumbersneededtotrackpartsandvehiclesExplainingSTAresponsibilityforparticipatinginOpen-to-GoExplaininghowOpen-to-GoandEASIarerelatedtoensurereadinessofpartsforproductionandmanagementofthePSWapprovalprocessDescribingproblemidentificationandresolutionExplainingtheiterativebuildprocess,whenvehiclesarereleasedtothecustomer,andwhenthelaunchteamsroleendsDescribinghowtocompile,document,distribute,andmaintainlessonslearned,WhereDoesItFitWithinFPDS?,PreparingforAssemblyPlantBuilds,STAProgramEngineers:ArrangewiththelaunchteamtoparticipateinthebuildIdentifyspecificneedsandtimingforon-sitesupportWorkwiththePMTtoidentifySuppliersrequiredonsiteContactSuppliersrequiredonsitetoensuretheyattendBecomefamiliarwiththelocationsetupifdifferentfrompreviousbuildsMakeappropriatecontactsattheplant,includingtheQualityControlOffice,PlantIQOffice,PVTOffice,andPlantLaunchCoordinatorsOffice,RotationNumbers,Internalcontrolnumberusedtoidentifyeachvehicleasitisbuiltattheassemblyplant:Vehiclesarenumberedsequentiallyfrom0000to9999andthenstartagainat0000.Shouldbeusedastheprimaryidentificationnumberforavehiclewhencommunicatingwithlaunchandplantpersonnel,VINNumbers,WasoriginallydefinedinISOStandard3779inFebruary1977andwasrevisedin1983Composedof17charactersIdentifiesmotorvehiclesofallkinds,BlendNumbers,AssignedtoaspecificpartforaspecificvehicleintheILVSsystemILVSistheprocessthroughwhichSuppliersgetadvancedinformationonFordproductionvehiclestoshipthepre-assignedpartsinsequencetomatchthevehicleproductionrotationnumbersLinkedtotherotationnumbersandinturntotheVINnumber,PartNumbers,IdentifypartsorassembliesusedintheproductionandserviceofFordvehiclesBasepartnumbersareassignedforspecificsystemfunctionsAcompletepartnumber(prefix,base,andsuffix)canonlyidentifyonepartunderallconditionsPartnumberschangeifthepartdesignaffectstheinterchangeabilityofthepart,LaunchTeamMeetingSupport,STAProgramEngineerssupportthelaunchbyattending:DailylaunchteammeetingsSub-systemteamleadermeetingsOpen-to-GomeetingsAIMissuesmeetings,DailyLaunchTeamMeetings,UsuallyheldinthemorningIncludelaunchteamleadersandkeyplantlaunchpersonnelMainpurposeistodiscussthestatusofmajorissuesand/orchangestothebuildscheduleresultingfromvariousissuesTeamleadersgiveabriefsummaryonthemainissues,andpartstatusisreported,Sub-systemTeamLeaderMeetings,Lower-levelmeetingsthatincludeindividualengineersinvolvedineachsub-systemBasicallyreplacesthePMTmeetingsanddealswithindividualAIMissuesandplanstoresolveeachissueThereareusuallyregularmeetingsforeachmajorsub-system,AIMIssuesMeetings,RegularmeetingsheldtoresolveopenbuildissuesUsuallyconductedinconjunctionwiththesub-systemteammeetingsSomeprogramsholdbuildissues(AIM)meetingsattheendofthedaytoreviewallissuesforthatday,Open-to-Go1,SupportlaunchteamtrackingofSupplierPSWtimingUsuallyoccurdailystartingjustbefore1PPandcontinueuntilallpartsmeetPSWrequirementsandarereleasedintoproduction,Open-to-Go2,TheOpen-to-GoReport:Primarydocumentusedtomanagetheday-to-daycontrolofpartavailabilityUsedtotrackandquantifypartreadinessgeneratedbyEASIIndicatespartstatusrelativetothe:Samplepromisedate(SPROM)Partidentification(partnumber)Suppliername(code)EngineeringreleaselevelPartapprovalstatus(PPAP)AlsoidentifiestheSupplierplantmanagerandqualitymanagerforcontactpurposes,SuppliersandtheEASISystem,DDLSuppliersareresponsibleforenteringthe:SamplepromisedatePSW(PPAPreadiness)date:PPAPLevel1Suppliersareself-certifyingandtheirPSWdatesareautomatically“rolledover”Non-PPAPLevel1SuppliersenterthePSWdatetoindicatetheirPPAPpackageisreadyforSTAreviewNon-DDLSuppliersareresponsibleforensuringthisinformationisenteredbytheFordPurchasingAnalyst,STAResponsibilityforOpen-to-Go,SupportOpen-to-GomeetingsEnsureallPPAPsareapprovedinEASI,ChangeControl,ThePMTadministersthechangemanagementprocess.AnSTArepresentativeshould:AttendallchangecontrolmeetingsBepreparedtoanswerquestionsaboutPPAPissuesandsupportthelaunchteambyprovidingPSWdirectionwhenrequiredforlatedesignchangesWhenaSuppliercannotmeettherequirementstodeclarePSW,interimapprovalmaybegrantedunderanalert.,Alerts1,WrittenandapprovedbyEngineeringRequiredanytimepartsorprocessesthatvaryfromthereleaseddesignintentareusedintheassemblyofavehicleAuthorizetheplantorSuppliertofollowanalternateprocedureand/orshipanauthorizeddeviatepartNormallyspecifiedforagivennumberofpartsand/oraspecificlengthoftime,uptoamaximumof90days,Alerts2,Wheneverpossible,disposedandclosedbytheteambeforetheconclusionofthebuild:Insomecases,requireapermanentdesignchangeandmustbeclosedbyaconcernandthereleaseofanoticeTrackedbytheVOLaunchRepresentativePresentedtothelaunchteamanddiscussedattheregularchangecontrolmeetings,Issues,Issuescanberelatedto:PhysicalbuildonlineEngineeringassessmentoffitandfinishAssemblyconcerns:ErgonomicLinefeedMaterialhandling,ReviewsandEvaluations,ThefollowingreviewsandevaluationsmaygenerateadditionalAIMissues:FCPAsFreshEyesReviewsDriveevaluationsManagementreviewsG8Dsusedforresolvingissues,FCPA1,AfinishedvehicleevaluationprocessIdentifiesmanufacturingimperfections,staticanddynamicconcerns,andpotentialcustomercomplaints:FromCPtoJ1,usedtoidentifyearlybuildconcernsAfterJ1,usedtomonitorregularplantnewproductionvehicles,FCPA2,Theauditornoteseachconcern,assignsdemeritpoints,andratesitas:BlitzABCScoresforcompletedvehiclesvaryinrangefrom70to90forA,30to50forB,and10to20forC.Thetargetforfavorableunitsisnocallgreaterthan50demerits.,FCPA3,Concernsreceiving50demeritpointsorhigherareaddressedattheFCPAreviewmeeting.ConcernsarebinnedbytheteamintoQ,D,andPissues.Generally,concernsbinnedasSupplierqualityissuesrequireaG8D:ForNTEIs,STAisresponsible.Forcarryover,IQisresponsible.,FreshEyesReview1,AcritiqueofcompletedvehiclesatspecificdesignandbuildphasesbyamemberofCETTodetectpotentialrecallconcernsindesign,package,andassemblyOccuratSP,CP,FEU,andJ1,FreshEyesReview2,TeamleadercompilestheinputandshowstoappropriateProgramManager:Whenconductedattheplant,normallyGRCorotherauthorizedpersonnelareinvolved.Programmanagementisresponsibleforactingonfindings.,BuildReports,TheSTAEngineerpreparesreportstosupportthebuildphases:SupplierqualitysummarybybuildphaseformanagementreviewsHighImpact/FocusSuppliersummaryDetailedsummaryof