福特汽车品质系统介绍ppt课件

1、品質系統李柏超品質部經理Ford Lio Ho Motor Co., Ltd.2002.12.13.Agenda Quality SystemTotal Quality Excellence Company Policy Letter No.1. Brief History of FLH Quality ManagementQuality Arrow (Quality is Job#1)QS-9000/ISO 14001 System/Quality Operating SystemTGW Reduction / VRT / SAQTGR / Kano Model.1. Ford Total

2、Quality ExcellenceCompany Policy Letter No. 1Quality is defined by the customer; the customer wants products and services that, throughout their life, meet his or her needs and expectations at a cost that represents value. 品質是由顧客所定義Quality excellence can best be achieved by preventing problems rathe

3、r than by detecting and correcting them after they occur. 達成杰出的品質必須注重在問題的預防All work that is done by Company employees, suppliers, and dealers is part of a process that creates a product or service for a customer. Each person can influence some part of that process and, therefore, affect the quality

4、of its output and the ultimate customers satisfaction with our products and services. 每個公司員工對品質及最終的顧客滿意都有貢獻.Ford Total Quality ExcellenceSustained quality excellence requires continuous process improvement. This means, regardless of how good present performance may be, it can become even better.維持杰出

5、的品質必須持續作流程的改善People provide the intelligence and generate the actions that are necessary to realize these improvements.改善的智識及行動來自人Each employee is a customer for work done by other employees or suppliers, with a right to expect good work from others and an obligation to contribute work of high calib

6、er to those who, in turn, are his or her customers.後工程即是顧客;不接纳不良,不傳送不良- Chairman of the board(口徑;水準,程度).2. 福特六和品質管理之發展演進 1/41986- Introduction/Localization引入福特原廠產品開發標準如Worldwide Design Requirement 及Worldwide Product Acceptance Specifications 。品管部門轄AP-QC (裝配及製造品管)及QA(品保) 。對供應商推行福特Q-101全球性品質管理規範。廠內推動U

7、PAS-Uniform Product Assessment System-產品品質統一稽核系統。 1984年起正式推動品管圈(QCC)活動。Achievement 1986年正式通過加拿大法規標準，成為台灣第一個成車外銷的廠商。.福特六和品質管理之發展演進2/419861991 Self-development/Expansion1988年起福特六和採購部門設立專責單位，全力輔導零組件廠商提昇品質。導入先期品質規劃觀念APQP(Advanced Product Quality Planning)及品質基礎教育如團隊導向問題解決手法-8D (Team Oriented Problem Solv

8、ing 8 Disciplines) 。Achievement全球福特總部品質評鑑人員評定金全壘打車系為全球同車系品質之冠。1990年引擎鑄造廠獲頒象徵福特品質最高榮譽的Q1獎1991年裝配廠獲頒象徵福特品質最高榮譽的Q1獎 。 .福特六和品質管理之發展演進3/419911996 Upgrading/ Standardization建置QIS(Quality Information System)系統，在生產線上直接反應品質問題並於第一時間即時改善。1994年導入顧客導向式車輛評價系統 Nova-C (New Overall Vehicle Assessment- Customer)。1996

9、年起導入QOS品質運行系統。Achievement1994年獲得Q1再次驗證一定。 1996年成為國內首家汽車業者通過 ISO-9001國際標準驗證，得到世界品質系統標準的一定。 .福特六和品質管理之發展演進4/41996now Transformation/ Internationalization1996年起開始推動福特生產系統-FPS(Ford Production System)。2000年起廠內開始推動Six Sigma品質改善專案活動。2002年導入新版QOS品質運作系統及FCPA消費者導向產品稽核系統 (Ford Consumer Product Audit)。Achieveme

10、nt1997年榮獲國際環境管理系統ISO 14001驗證 。 1998年獲得汽車業國際品質系統QS-9000驗證一定。2001年福特六和引擎廠新人圈榮獲福特總部CDQA(Customer Driven Quality Award)總裁獎。2001及2002年獲得福特FPS全球評比最高層級之榮耀。2002年獲得ISO 9001/QS 9000及ISO 14001整合系統驗證。.3. Ford Quality is Job#1 ArrowDefine, Measure, Analyze, Improve, ControlDesign for 6-SigmaCommon Problem Solvin

11、g Language & ToolsHigh Quality, High Velocity Improvements in Business Results9 Leadership PrinciplesReward and RecognitionTraining and FeedbackPartnership with Unions, Dealers and SuppliersVehicle Quality(High & Low Time-In-Service)Customer SatisfactionTGWWarrantyResidual ValueSales & Service Satis

12、factionElimination of Waste Q1QualityIsJob #1QUALITY LEADERSHIP INITIATIVE Engage All Employees6-SIGMAData Driven Decision MakingQUALITY OPERATING SYSTEMPerformance to StandardsDrive ProcessDeliver ResultsPlanDoCheckActFord Motor Company QOSProductCreationSales & Service Certification SystemFPDSFutu

13、reCustomersCurrentCustomersOrder toDeliverySuppliersLaunchCurrentModelFPS.Quality Leadership Initiative9 Leadership PrinciplesValue: Quality is Job One. It is our responsibility, our job security and our future. Attitude: Zero Defect Mindset. Dont take it, dont make it and dont pass it on. Culture:

14、A relentless daily focus on quality. Training: Ensuring people have the necessary skills and tools to do their jobs. Accountability: Effective measurement and feedback for continuous improvement - accountability and performance metrics.Cooperation: Help suppliers help us succeed. Joint Leadership Co

15、mmitment: Effective Quality Leadership at all levels. Disciplined Execution: Changes never compromise quality. Enterprising Approach: The customer is our shared concern. .4. ISO 9001/QS-9000及ISO 14001整合系統ISO 9001(96)/QS-9000(98)內部稽核: 2 times/yearISO 14001(97)內部稽核: 1 times/yearISO 9001(96)/QS-9000(98

16、)外部稽核: 1 times/yearISO 14001(97)外部稽核: 1 times/year2 systems, 2 sets of procedures, 30% overlap Integration整合程序書，整併減少30%重疊。建立整合內部網站以e化管理，減少紙張及增進效率。整合內部稽核: 2 times/year整合外部稽核: 1 times/year不僅整合集中內部資源人力，連外部稽核費用都可降低! Next Step轉換QS-9000至TS 16949ISO 18000.QOS-Quality Operating System品質運行系統由福特總部發行之一致性生產品質運行

17、系統，涵蓋一切生產廠區(車身、塗裝、完成車、新車驗放部)之要求。以ISO 9001/QS 9000為基礎，連結FPS, Six-sigma, FPDS等企業之組織系統工具。目的在推行一致性的福特組裝廠最正确品質系統，以達到監控並持續改善新車的出廠品質。共27個QOS單元要求，62個評分項目。 (R/Y/G).QOS-Quality Operating SystemTime and Data ManagementRequired meeting scheduled at designated frequencies to communicate and evaluate Plant Qualit

18、y System Output, total 18 meetings. A tool for plants to communicate information back to the base departments addressing customer concerns.VOPQUG-001FLH PracticesDescriptionFrequencyParticipantsMetricsDescriptionFrequencyParticipantsMetricsNOVA-C and Quality system Performance OverviewsDailyPlant Mg

19、r.Area Mgr.Quality Mgr.Area SupervisorArea CIWG LeadersNova-cWrap reviewChips & ScratchesSqueaks / RattlesFAI/CAI review Roll TestConvoy Yard reviewDailyPlant Mgr.Area Mgr.Quality Mgr.Area SupervisorArea CIWG LeadersNova-c Wrap review Chips & ScratchesSqueaks / Rattles FAI/CAI review Road Test, Exce

20、l, PDI, FTT.Convoy Yard Review-每日品質會議Review Vehicle QualityReview Concern & Actions.QOS-Quality Operating SystemVariability Reduction VRT/VFGa structured process to drive quality improvement focused on customer expectations. It ensures that plant controllable customer concerns are acted upon quickly

21、 and permanently. Tool Verificationensure regular inspection and certification of plant test equipment, tools, and gages is being conducted per the corporate guidelines. .QOS-Quality Operating SystemIncoming Materialmeasures plant effectiveness in improving and controlling the quality of material en

22、tering the plant. A working relationship with the plant, suppliers, purchasing, and other key activities is essential for quality improvement. Process Control / Build & Inspection Process identify requirements for controlling specific operations and inspections. Those requirements come from practice

23、s and/or procedures that are the infrastructure of the assembly Vehicle Operations QOS. CCs, SCs, CTQ.QOS-Quality Operating SystemRepair Systema formalized repair process assuring the preparation, repair, material, and tooling/equipment used are in accordance with established/approved repair standar

24、ds. Quality Acceptance Criteria established level of standards to be used for inspection. the criteria must then be cascaded throughout the plants.to assure that every inspection/check/test is performed to the same standards throughout the entire system.QOS-Quality Operating SystemWeld SurveillanceI

25、n process checks of welded assemblies, when coupled with periodic tear down of welded bodies and assemblies, provide a positive method of determining weld quality.ensure that all weld production operations are being effectively performed. Dimensional Control a comprehensive body sheet metal construc

26、tion strategy that takes into account all key body sheet metal components and their relationships to each other and bodylines. to identify, track, and reduce dimensional variation from component to component and vehicle to vehicle .QOS-Quality Operating SystemTorque Assuranceto assure that Fastening

27、 Control System implementation is standardized and effective across all assembly plants.FCPAto identify manufacturing imperfections through a series of a Static/Dynamic/Full (combination of static & dynamic) audits of finished units.使顧客導向所發現的問題直接回饋到生產線，以求獲得迅速對策及改善方案。 .FCPA(Ford Consumer Product Audi

28、t)福特消費性產品評價是完成車的稽核流程，用以指出產品的問題及潛在能够呵斥顧客/消費者不滿意的地方。採用全球一致的車輛作業評價流程於一切量產車種。驅使製造精緻工藝的提昇以期在車輛交貨與初期服務時達成高度顧客滿意度。強調顧客/消費者的回饋及反應。強調會影響顧客滿意度的設計意圖及製程限制。运用顧客/消費者導向的評分系統CCRS稽核時間約為每輛車三個小時。.FCPA(Ford Consumer Product Audit)福特消費性產品評價檢查項目包括：內外部裝配情形塗裝情形電機及各部機械功能引擎室及底盤漏水，風音及異音情形車輛動態及道路駕駛.CCRS(Customer Concern Rating

29、 System)顧客導向式評分系統.QOS-Quality Operating SystemWind Noiseevaluates the noise acceptability of vehicles, as would an average customer. During the drive evaluation, the trained auditor listens with an unaided ear and rates wind noise performance, on a scale from 1 to 10, using the Wind Noise Rating Cri

30、teria form Squeak & Rattleto effectively detect assembly or component squeak and rattle concerns prior to the units leaving the plant. .Squeak & Rattle Road TestSqueak & Rattle Test Track UpgradeLength:100 ft Uniform Vienna Block, 100 ft Stepped Vienna BlockWidth:104404024Track Width 66404024100Unif

31、orm Vienna BlockStepped Vienna Block.Squeak & Rattle Road TestUniform Vienna BlockStepped Vienna Block(1 Step in Height).QOS-Quality Operating SystemWater (20 minute soak)pre-determined critical water entry areas, which may not show up during the normal 100% production water test. This 20 Minute tes

32、t is a verification of process/design actions taken to correct any repetitive water leak concerns. Finish Vehicle Evaluation Program (M-10 Program) a daily evaluation of completed production level vehicles. These units are driven over-night, over the road by authorized plant personnel. Its function

33、is to identify issues early and develop immediate process/product containment and improvement actions. .QOS-Quality Operating SystemPIC (Product Information Center)includes external and internal quality indicators, giving the plants a standardized means of displaying quality data, description, and v

34、isual representation. PIC allows information flow to present quality efforts, which factually demonstrate performance over time.Control Point/Tip Level utilizes either current or added inspection as a tool to drive In-Station-Process-Control (ISPC) and to facilitate communication with the Base Opera

35、tor to develop countermeasures to contain quality concerns within the zone. .QOS-Quality Operating SystemUltrasonica method to evaluate wind noise. The process is performed by attaching an ultra sonic tone generator to the center of the windshield and moving a detection instrument around the potenti

36、al leak areas (glass runs, windshield, door openings, etc.). Wind Noise leaks are measured in decibels (dB) and compared to predetermined limits. Predetermined limits are established by correlation of leaks and customer data. Air Leakage Test an evaluation of sealed painted vehicle bodies and comple

37、ted production vehicles for objective measurements of body air leakage. .Ultrasonic Test Equipment.QOS 總表- 1/3.QOS 總表- 2/3.QOS 總表- 3/3.QOS FAP Assessment ResultFLH element level: 2.75 (Full Level: 4)U.S. VO total plant summary status for reference:The level of FLH is better than VO plants in the US.

38、Ford Lio Ho Quality Improvement Flow Diagram.5. TGW Reduction VRT / SAQTGW (Things Gone Wrong): 問題點,缺点情況VRT (Variability Reduction Team)a structured process to drive quality improvement focused on customer expectations.SAQ (Single Agenda for Quality)a systematic matrix to prioritize Customer Concern

39、s based on internal and external indicators. .VRT OrganizationMeeting DateChampionTeam LeaderSub-System /GQRS CategoryJ.D. Power CategoryTue.Ringo LinMike Chang Exterior Paint & Corrosion Vehicle exterior, (Paint issues) James Wang Body & Exterior Trim / Bumper Vehicle exterior (Exclude Wind noise, Water leaks) Steve TangInterior Trim, Water leakage, Squeaks and rattles Vehicle int