Key-Characteristics-Designation-System---KCDS

1、精品好资料学习推荐Key Characteristics Designation SystemTable of RevisionsJanuary 1991: 1st IssueJune 1996: 1st RevisionNovember 1998: 2nd Revision Applicable to Vehicle Groups through MY 2003Applicable to all Powertrain programs which end by Jan 2006March 2003: 3rd RevisionApplicable to Vehicle Groups for 2

2、004 MY and beyondApplicable for all Powertrain programs in production after January 2006The Key Characteristics Designation System reference manual GM 1805 QN was developed by a joint UAW-GM Quality Network TeamTable of ContentsSection1.Scope2.Purpose3.General: Benefits, Fundamental Concept for Char

3、acteristics4.Definitions5. Product Variation (includes Loss Function)6. Levels of Care7. The Three Stages of KCDS8. Selection Criteria for Parts9. Product Characteristics Pyramid10. Selection Criteria for Product Characteristics11. Tools12. Team Approach13. Objectives of the Team14. Composition of t

4、he Team15. Data Responsibility16. Documentation and Communication17. Reference SectionFigures and Tables1AGM KCDS Process2ASummary of Levels of Care vs. Cost4ACharacteristic Definition7AThree Stages of KCDS8AGM Mandated Parts & Components: Product Identification & Verification8BGeneral Application G

5、uidelines: Product Id, Traceability & Verification9AProduct Characteristic Pyramid9BRelationship between KPC/PQC and KCC10AKCDS KCC Worksheet10BKPC/PQC/KCC Fishbone Diagram12APart and Characteristic Action Steps Chart1.0 Scope1.1 This Reference Manual applies to:A. General Motors planning, product a

6、nd process designs, manufacturing and assembly processes; andB. Suppliers (internal and external) of products and processes to General Motors that are used in the design, manufacture, assembly, and distribution of GM products.1.2 The Key Characteristic Designation System (KCDS) will commonize Genera

7、l Motors approach for the identification and documentation of parts with Safety Compliance Relationships, Functional Check Requirements, Product Identification, Verification & Traceability Requirements and Component Handling Requirements (additional care) and product characteristics that are designa

8、ted as Special Characteristics (extra care).1.3 KCDS also sets forth the methods and requirements for communication of parts requiring additional care and Special Characteristics requiring extra care throughout General Motors and its supplier community1.4 The Key Characteristic Designation System Re

9、ference Manual is referenced in Quality System requirements ISO-9000, QS-9000 and the other elements of AIAG/ASQ “7-Pack”. 1.5 Additional/Extra Care in Manufacturing/Assembly is required at both the Part and Characteristic levels.A. Functional Check, Product Traceability, Safety/Compliance and Compo

10、nent Handling requirements (additional care) do not replace the need to review a part for Special Characteristics (extra care).2.0 Purpose2.1 Employees are responsible for ensuring that GM products are designed, produced, and delivered to meet the Voice of the Customer and to comply with applicable

11、government standards and regulations.A. As a means of exercising this responsibility and achieving conformance to other customer requirements, the implementation of KCDS in the organization requires that the use of Standard Care and Additional or Extra Care be designed into the Quality Systems.B. St

12、andard Care describes the usual and customary practices that are applied in the manufacturing and/or assembly environment to ensure specification and print requirements are consistently met. Usual and Customary Care encompasses all of the basic methods and systems necessary to ensure that the produc

13、t meet the Voice of the Customer based on loss function and safety/ compliance requirements with government regulations.2.2 The Key Characteristic Designation System will aid in the economical manufacture of quality products by:A. Establishing and managing a uniform system of identifying, documentin

14、g and communicating parts requiring Additional Care and Special Characteristics that require Extra Care. This is done to ensure consistency and compliance to customer requirements and government regulations within General Motors and its supplier community.B. Supporting the reduction and maintenance/

15、control of variation in the manufacturing and/or assembly process.C. Supporting the development of robust designs.2.3 Many parts require additional levels of checks and documentation. The following are part level checks and documentation that are over and above Standard Care:A. Functional Checks are

16、 controls used by manufacturing and/or assembly plants to ensure that parts, sub-systems, systems or completed vehicles comply with requirements that are subject to, or have an effect on Federal Motor Vehicle Safety Standard (FMVSS), critical performance objectives, customer satisfaction, State Stat

17、utes, various Regional Compliance procedures and/or Corporate Policies.B. Product Traceability identifies and verifies individual parts for correct usage by scanning individual major components for traceability associated with each vehicle. Other parts/components supplied in labeled containers are t

18、raced to groups of vehicles. This manual is intended to ensure that parts/ components that must be verified and traced consistently by GM and its suppliers. Traceability is a key tool in identifying parts related to vehicles involved in campaign research.C. Safety/Compliance parts may need Additiona

19、l Care to ensure the products safety and/or compliance with governmental regulations.D. Component Handling Best Practices identifies assembly and handling requirements that are necessary in addition to standard handling practices. E. Any part having a safety and/or compliance relationship must compl

20、y with governmental regulations and may require Functional Checks, Product Traceability or Component Handling.2.4 When we unnecessarily require Additional Care on parts, we add to the products cost without increasing its value.2.5 All products, and the processes that are used to make them, have char

21、acteristics (or features) that meet requirements.A. Special Characteristics (Key Product Characteristics (KPC) and Product Quality Characteristics (PQC) require Extra Care because excessive variation could result in product quality losses or affect quality in subsequent manufacturing operations. 2.6

22、 The reasons Characteristics are distinguished between Standard Care and those that require Extra Care are:A. When we give equal attention to all product characteristics, the characteristics sensitive to manufacturing variation (i.e., those that require Extra Care) may not receive sufficient attenti

23、on. By focusing on the features that are sensitive to manufacturing variation, greater improvements can be made in product quality, cost and performance, thus improving customer satisfaction with the product. B. To achieve optimum cost and quality, appropriate attention in addition to Standard Care,

24、 should be given to the “critical few” rather than the “non-critical many”.2.7 Product Characteristics designated as KPC, which have consistently demonstrated their capability over time may be reduced to that of a PQC.2.8 Product Characteristics designated as PQC, which have consistently demonstrate

25、d their capability over time may be reduced to that of Standard Characteristics.2.9 When we require Extra Care on product characteristics that have consistently demonstrated capability over time, we add to the products cost without increasing its value.Summary of the KCDS Pyramid3.0 General3.1 Benef

26、itsA. KCDS helps ensure product quality during the product design phase, process design phase, and during the ongoing manufacturing and assembly operations.B. Beliefs & Values - The Key Characteristic Designation System (KCDS) facilitates the use of the UAW-GM Quality Network Beliefs & Values. It al

27、so supports the GM global community while improving customer satisfaction, communication, efficiency, and GM products.a. KCDS facilitates response to the Voice of the Customer, utilizing teamwork to improve customer satisfaction. b. When the KCDS template is used early in the development of a produc

28、t, it helps ensure robust designs and processes that are less sensitive to variation, thus leading to increased customer satisfaction and ultimately greater job security.C. Communication - KCDS supports the concurrent (simultaneous) engineering process by use of standardized definitions, procedures,

29、 work instructions and documents. This improves communication between engineering, suppliers, production plants and other supporting activities. D. Product Design - KCDS improves product design and development methods. It identifies safety and compliance requirements early. It also reveals design ar

30、eas that may not be robust and may need additional efforts during the development process.E. Process Design - KCDS improves process design and development methods by aligning process strengths with Safety/ Compliance requirements, product traceability, functional checks, component handling, KPC, PQC

31、 and Standard Characteristics.F. Manufacturing and Assembly KCDS helps improve manufacturing and assembly operations. The focus is on Quality Improvement, Variation Reduction and Maintenance efforts on products and processes that have been identified as important to customer satisfaction and/or rela

32、ted to Safety/Compliance. G. Standardized Work Processes - KCDS supports the implementation of Standardized Work Processes through the use of Process Flow Diagrams, Process Control Plans and People Focused Practices. 3.2 Fundamental Concepts for CharacteristicsA. Basic concepts for the classificatio

33、n of characteristics are summarized in Table 4A.a. There are two kinds of characteristics:Product There are three basic categories of Product Characteristics:- Standard Product Characteristics- Product Quality Characteristics- Key Product CharacteristicsProcess - There are two basic categories of Pr

34、ocess Characteristics:- Standard Control Characteristics- Key Control Characteristicsb. Control of Process Characteristics ensures that variation of a Product Characteristic is reduced or maintained/controlled.B. The designations of “additional care” and “extra care” are based on the principle that

35、GMs minimum level of standard care is in place.C. The identification of Special Product Characteristics involves judgment and experience and is best done in the concurrent (simultaneous) engineering process, which involves all functions and a broad range of experience.4.0 Definitions4.1 Part LevelA.

36、 Safety/Compliance Regulatory or corporate requirements on a part, sub-system or system that can affect compliance with government regulations or vehicle/product safety performance to said regulations.B. Functional Checks - Checks performed by manufacturing and/or assembly plant personnel to observe

37、, verify and help ensure that the operations of a part, sub-system, system or completed vehicle comply to requirements that are subject to or have an effect on FMVSS, critical performance objectives, customer satisfaction or State Statutes.C. Product Verification and Traceability A tracking method u

38、sed in the GM manufacturing process to track and document parts and components from the point and time of manufacture to a specific vehicle/vehicle identification number (VIN).D. Component Handling Best Practices - Identifies assembly and handling requirements that are necessary in addition to stand

39、ard practices. These best practices are intended to provide direction to the assembly plants regarding critical components.4.2 Characteristic LevelA. A Product Characteristic is a feature of a part, sub-system or system (such as dimension, property, function, chemistry, appearance, or finish) on eng

40、ineering documentation. The characteristic is classified as Special or Standard and can be measured. B. A Key Product Characteristic (KPC) is a special characteristic where the loss function shows that reasonably anticipated variation within specification could significantly affect customer satisfac

41、tion with a product. a. Maintaining/controlling the process within the target zone can optimize customer satisfaction.b. For organizations that use symbols to designate special characteristics, use the symbols in Table 4A. C. A Product Quality Characteristic (PQC) is a special characteristic in whic

42、hthe customer is equally satisfied across the entire specification, butthe loss function is steep just outside of the specification limits.a. Variation within the tolerance does not significantly affect customer satisfaction, whereas variation outside the tolerance may significantly impact customer

43、satisfaction.b. For organizations that use symbols to designate special characteristics, use the symbols in Table 4A. D. A Standard Product Characteristic is a characteristic where the loss function shows no incremental economic or customer satisfaction loss inside the tolerance. The customer is equ

44、ally satisfied across the tolerance. a. Variation within the tolerance does not significantly affect customer satisfaction.E. Special Product Characteristics must be identified on engineering documents such as: drawings, Global Product Description System (GPDS), specifications, Product Assembly Docu

45、ments (PADS), layouts, process flow diagrams, process control plans and/or other primary engineering documents per local Engineering requirements.The above definitions are based on the principle that Standard Care is followed during manufacturing and assembly. This principle applies to characteristi

46、cs measured by attribute or variable data.4.3 Target Zone - the area within specifications that satisfies the customer. This may or may not be the nominal value.4.4 Variable data data that is continuous and measurable relative to the specifications on a continuous scale such as millimeters, kilogram

47、s, etc. 4.5 Attribute data data for characteristics measured with and resulting from correct part or incorrect part, present or not present, etc., and is generally synonymous with conformance or nonconformance and when designated as a special product characteristic an attribute control method shall

48、be used. 4.6 Process Characteristics related to Special Product Characteristics must be documented on process control plans, process flow diagrams or manufacturing and/or assembly work instructions.A. A Process Characteristic is a Process Parameter for which variation must be reduced or maintained/c

49、ontrolled around a target value to ensure that customer requirements are met.a. Process Characteristics are further classified asKey Control Characteristics or Standard Control Characteristics.b. A Key Control Characteristic (KCC) is a process parameter (such as temperature, speed, pressure, viscosi

50、ty, etc.) that has a strong causal relationship to a Key Product Characteristic or Product Quality Characteristic. Variation must be reduced around some target value to ensure that variation in a Key Product Characteristic is reduced around its target value. Variation must be maintained/controlled a

51、round some target value to ensure that variation in a PQC is maintained/controlled around its target value.c. A Standard Control Characteristic is a process parameter that controls or affects one or more product characteristics.d. When Process Characteristics are controlled to requirements, product

52、quality levels are predictable.5.0 Product Variation5.1 The designation of Special Characteristics - Key Product Characteristics (KPC) and Product Quality Characteristics (PQC) - provides additional information to product and process design, pre-production, production and monitoring/inspection organ

53、izations that can be used to direct “extra care” on characteristics according to the consequences of the Loss Function. A. Loss Function is “The incremental economic / customer satisfaction loss for any deviation from a customer specified target zone. The target zone is the tolerance zone that will

54、lead a customer to praise the product.” (Ref. The Deming Route by William W. Scherhenback )5.2 Variation is inherent in any manufacturing and/or assembly process. Knowledge of the magnitude and consequences of this variation will help Engineers design appropriate products and processes within approp

55、riate parameters that meet or exceed customer requirements. Manufacturing and/or assembly can then control the processes accordingly.A. The concept of “reasonably anticipated” variation stresses the importance of anticipated variation and likelihood of occurrence in determining the classification.a.

56、 Reasonably anticipated variation within the KCDS process is interpreted to mean the expected variation from a given process. b. To develop robust designs, engineers must have knowledge of the magnitude of the inherent variation in the manufacturing and or assembly process as early as possible in th

57、e design process. B. It is necessary to anticipate, through the use of historical data and other engineering tools, the magnitude and consequence of the variation that could reasonably be expected to occur during manufacturing and/or assembly, if Standard Care were to be used.6.0 Levels of Care are

58、intended to define the requirements in the manufacturing and assembly environment needed to ensure economical manufacture of quality products. These requirements must be described in local quality procedures, business unit procedures and other quality procedures. The relationship between part and characteristic levels of care is described below:Level of CareAll