某汽车生产制造概论(1)

1、生產製造概論 By Ringo D. L. Lin Ford Lio Ho Motor Co., Ltd. 生產製造概論生產製造概論 品質系統品質系統 新車上市控制計畫新車上市控制計畫 環境保護環境保護 Six Sigma 物料規劃與運籌物料規劃與運籌 福特生產系統福特生產系統/工廠工程工廠工程 & 維護維護 顧客滿意顧客滿意品 質 系 統 Total Quality Excellence Company Policy Letter No.1. Brief History of FLH Quality Management Quality Arrow (Quality is Job#1

2、) QS-9000/ISO 14001 System / Quality Operating System TGW Reduction / VRT / SAQ TGR / Kano Model (to be covered by Knight in detail) Define, Measure, Analyze, Improve, Control Design for 6-Sigma Common Problem Solving Language & Tools High Quality, High Velocity Improvements in Business Results

3、9 Leadership Principles Reward and Recognition Training and Feedback Partnership with Unions, Dealers and SuppliersQualityQualityIs IsJob #1Job #1QUALITY LEADERSHIP INITIATIVE Engage All Employees6-SIGMAData Driven Decision MakingQUALITY OPERATING SYSTEMPerformance to StandardsDrive ProcessDeliver R

4、esultsPlanDoCheckActFord Motor Company QOSProductCreationSales & Service Certification SystemFPDSFutureCustomersCurrentCustomersOrder toDeliverySuppliersLaunchCurrentModelFPS3 Pillars of Ford Quality Is Job#1 StrategyFord Lio Ho Quality Resolution Flow DiagramRYGRYGRYGRYG1Time & Data Mgmt. G

5、 G G G2Variability ReductionVRT/VFG G G G G3Tool Verification G G G G4Incoming Material Y G 5Process Control /Build & InspectionProcess G G G G6Repair System Y G Y G7Quality AcceptanceCriteria G8Weld Surveillance G9Dimensional Control G10Torque Assurance Y11FCPA G12Wind Noise GQOS Area / Element

6、 R/Y/G RatingsVO QOS / QITDArea / ElementsBodyPaintFinalPDA / NOVA-CQOS 總表- 1/3RYGRYGRYGRYG13Squeak & Rattle G14Water (20 minutesoak) G15M-10 Program G16CBT (PDI or Final) 17PIC (ProductInformation Center) G18QVS Quick VIMS G19Control Pt/Tip LevelR R 20Ultra Sonic21Air Leakage Test22Joint Qualit

7、yComm./Mgmt. QualityComm.23 6-SigmaMethodologyQOS Area / Element R/Y/G RatingsVO QOS / QITDArea / ElementsBodyPaintFinalPDA / NOVA-CNew QITDArea / Elements GTBDTBDTBDQOS 總表- 2/3RYGRYGRYGRYGTime & Data Mgmt. G G G GVariability ReductionVRT/VFG GTool Verification GIncoming Material Y Process Contr

8、ol /Build & InspectionProcess G G Repair System GQuality AcceptanceCriteria G GQOS Activity / Element R/Y/G Rating24252627VO e-QOSElementAPQPMCPVTRecg / InspQOS 總表- 3/3新車上市控制計劃新車上市控制計劃課程內容課程內容1.1.製造處製造處 “ “前瞻工程部前瞻工程部” ” 新車導入職掌新車導入職掌介紹現行車輛生產流程暨製程管制介紹現行車輛生產流程暨製程管制2.2.新車上市前生產可行性評估及成本分析新車上市前生產可行性評估及

9、成本分析 ( (feasibility study & cost analysis)feasibility study & cost analysis)3.3.新車上市之製造計劃新車上市之製造計劃 ( (Manufacturing Manufacturing Launch Plan)Launch Plan)4.4.新車試作階段之流程管制新車試作階段之流程管制成功大學EMBA經營管理企業永續經營追求永續利潤由環境保護創造利基qQuality levelqWhat is Six sigma? qWhy we need Six sigma?qDevelopment and Deplo

10、yment strategyqHow Six sigma merges into our daily business? OutlineSigma Level 與合格率的關係與合格率的關係每百萬不良數每百萬不良數合格率合格率2308,53769.15%366,80793.32%46,21099.38%523399.98%63.499.99966%SigmaLevel在在1.5s s 的長期偏移量下的長期偏移量下挑戰挑戰為什麼大多數的企業在為什麼大多數的企業在 34 Sigma?3 sigma 4 sigma 5 sigma 6 sigma 大多數的企大多數的企業能力業能力障障礙礙沉醉過去的成就

11、沉醉過去的成就(不再挑戰不再挑戰)靠檢驗及檢修靠檢驗及檢修依賴嘗試錯誤法依賴嘗試錯誤法(經驗經驗)救火式的解決問題救火式的解決問題(頭痛醫頭頭痛醫頭)缺乏數據缺乏數據部門間互相的推卸部門間互相的推卸官大學問大官大學問大挑戰挑戰超越障礙超越障礙3 sigma 4 sigma 5 sigma 6 sigma 那些動力可以躍越障礙那些動力可以躍越障礙?深信我們還有進步的機會深信我們還有進步的機會相信方法論相信方法論接受挑戰現況接受挑戰現況導入新的技術導入新的技術,工具及手法工具及手法領導管理階層的態度領導管理階層的態度改變改變實事求是的行為表現實事求是的行為表現障障礙礙我們的機會我們的機會獲利減少獲

12、利減少哪一種比較有利哪一種比較有利?行政,製造,或運輸的成本利潤理論上的成本利潤*COPQ理論上的成本COPQ理論上的成本利潤COPQ*COPQ: Cost Of Poor Quality(劣質成本劣質成本)利潤售價降低目標目標 Year20012002CurrentObjProjects from S.A.Q12%83%80%Green Belts188530600Green Belt projects opened29151137Green Belt projects closed036120Projects on hands per Black belt1.23.43Black Belt

13、 projects opened218163Black Belt Projects closed443884Each Black Belt Projects closed2.92.24 Ford Production System and Vision, MP&L Mission, Role and Responsibility Model Line-Up Complexity Production Schedule and Release MP&L Exterior and Internal Logistics Common Material Management SystemIntroduction of FLH MP&L 介紹內容 福特生產系統福特生產系統內容大綱內容大綱1. 企業競爭與觀念變革企業競爭與觀念變革2. 福特生產系統之概念福特生產系統之概念3. 精實製造基本觀念精實製造基本觀念4. FPS 系統介紹與展開系統介紹與展開5. FPS小組活動小組活動6. FPS小組活動推行績效小組活動推行績效7. 結語結語工廠工程工廠工程 &