大宇制造质量ppt课件

1、Built-In Quality制造质量GMS不断改良员工参与规范化缩短制造周期制造质量ManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and Des

2、ignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimplePr

3、ocessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVisionShop FloorManagementManufacturingProcess Validation制造工艺认证In-ProcessControl &Verification工艺控制与确认Qualit

4、ySystemManagement质量体系管理QualityFeedback/Feed-forward质量反响/前馈ProductQualityStandards产质量量规范Built-In Quality制造质量Built-In-Quality制造质量What Is Quality? 什么是质量？Group Discussion 小组讨论Definitions 定义Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm质量是客户觉得可以接受并满足其热忱的东西Mad Cow 疯牛

5、(Diseased Meat 病牛肉)Poor Quality Means Lost Sales质量差意味着失去客户Firestone燧石(Unintended Accidents)不测事故uninstalled shift lock漏装移位锁定(Sudden Acceleration)忽然加速PP100: Not Reported Due To Insufficient Sample 样品缺乏不汇报( ) J.D. Power IQS Trend By Brand NCSI By Makers - 2002 2002 NCSI CustomerExpectationsPerceivedQua

6、lityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客户期望值感知质量感知价值客户埋怨客户忠实客户坚持力Voice of Customer 客户意见Voice of Customer客户意见 1. 停车方便 (Convenience of parking)2. 外观式样 (Exterior styling)3. 内部空间(Interior roominess)4. 节能 (Fuel economy)5. 平安(Safety)1.外观式样 (Exterior styling)2.内部空间(Interior roo

7、miness)3. 噪音与静音 (Noise and quietness)4. 节能 (Fuel economy)5. 空调性能 (Air conditioner performance)1.发动机性能 (Engine Performance)2. 发动机噪音(Engine Noise) 3.外观式样 (Exterior styling)4. 噪音与静音 (Noise and quietness)5. 坐骑 (Ride)L61. 节能(Fuel economy)2. 噪音与静音 (Noise and quietness)3. 内部空间(Interior roominess)4. 坐骑(Ride

8、)5.外观式样 (Exterior styling)1节能 (Fuel economy)2. 空调 (Air conditioner)3. 噪音 (Noise)4. 发动机噪音(Engine Noise)5. M/T转换 (M/T Shift)1. 节能(Fuel economy)2. OSRVM手工控制 (Manual OSRVM control)3. 发动机噪音(Engine noise)4. 检查发动机点火 (Check Engine light)5. 法人笼统 (Corporate Image) 1. 节能 (Fuel economy)2. 制动性能 (Brake performanc

9、e) 3. 喇叭性能 (Speaker performance)4. 内饰质量 (Interior quality)5. 喷涂质量差 (Poor paint quality)1. 3排坐椅相称 (Seats comport : 3rd line)2. 节能 (Fuel economy)3. 发动机启动(Poor engine start)4. 法人笼统 (Corporate Image) 5. 级别 (Gradablity)Built-in-Quality制造质量What is Built-In-Quality? 什么是制造质量？Group Discussion 小组讨论What is Bui

10、lt-In Quality?什么是制造质量？Definition 定义Method by which quality is built into the manufacturing process, so that defects are prevented, detected, and countermeasures are implemented to prevent reoccurrence.指质量在消费过程中产生，因此可以预防、发现缺陷，以及采取措施防止缺陷再发生的方法。Purpose 意图 Ensures defects are not passed to the customer.

11、确保不传送缺陷。Designers设计师Suppliers 供应商Production消费人员Dealers经销商Buyers采购员Sales & Marketing销售人员The Customer Chain. . . Company Perspective客户链 公司远景Built-In-Quality制造质量Assembly总装Supplier供应商Paint涂装Body车身The Customer Chain. . . Production Perspective客户链 公司远景Each Process Has at Least One “Customer and One “Suppl

12、ier每个阶段至少有一个客户和一个供应商Built-In-Quality制造质量Do not不要Accept接受Build制造Ship传送a Defect!缺陷Solve Problems Through Teamwork!团队协作处理问题！Built-In-Quality Motto制造质量口号Satisfy Your Customer满足他的客户Quality Through Teamwork Know Your Customer!What water leaks?I dont see any water leaks什么漏雨？我没发现漏雨。This car wasnt made on my

13、 shiftThe problem is Press Shop. The flange is too long.问题出自冲压，边缘过长I wont run any trial until I have an assembly method from Industrial Engineering and the manpower.The problem is that the pieces are bad from the supplier. 问题在于供应商的资料不好。It is not from my area, maybe its the sealer这辆车不是我轮班造的。在没有工业工程装配

14、方法及人力的情况下，我不做任何实验。这不是我担任的地方，也许是粘胶担任Dont run away from the problem!不要逃避问题!Living up to the Motto. . . 符合口号. . . - What Is a Defect? 什么是缺陷？Group Discussion 小组讨论 Defect 缺陷A defect is a product that does not meet the established quality standard.缺陷是不合已定规范的产品。Measurement of a quality characteristic质量性能丈量

15、Vehicle #车辆 号Upper Specification Limit规格上限Lower Specification Limit规格下限Quality Standard质量规范Defect 缺陷Defect 缺陷xxWhy are defects undesirable?为什么缺陷不受欢迎？Defects may also result in 缺陷还能够导致 High warranty costs 过高保修本钱 Lost customer sale 失去客户Defects Require Correction = Correction is Waste 缺陷需求纠正纠正就是浪费 QUAL

16、ITY IS EVERYONES RESPONSIBILITY质量是每个人的职责Design, Engineering, Production, Quality, Support Departments and Suppliers. 设计，工程，消费，质量，相关部门及供应商OUR Best Resources:我们最好的资源: PEOPLE 员工OUR Goal :我们的目的： Everyone is a Quality Inspector 人人都是质检员 Everyone is a Problem Solver 人人都是问题处理者WHO IS RESPONSIBLE FOR QUALITY?

17、 谁对质量担任？WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?ME!我！Health andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturingProcess ValidationIn-ProcessControl & VerificationQual

18、itySystemManagementScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementValuesVision/MissionShop FloorManagementInternal Pull /DeliveryAndonConceptProblemSolvingSimpleProcessFlowProduct Quality StandardsStandardizedWorkSmall LotPackagingTemporaryMaterialStorageQualityFeedback

19、/Feed-forwardVisualManagementManagementby TAKT TimeWork-placeOrganizationEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenance Fixed Period Ordering System/ Order PartsProductQ

20、ualityStandards产质量量规范Reflect voice of the customer反映顾客的心声Simple, clear & support user简单、明晰，有利操作者Clearly Measurable at point of use在运用上可明确丈量Key Points of Good Quality Standards:质量规范的要点： In users Std. Work & posted visual在操作者的规范化任务或张贴出来Standards Must Support the Operator, too Not only the Engineer!规范不

21、仅有益于设计者，也有益于操作工人Not tighter than those applied at the previous process 不要比前道工序的更严厉Key Points of Good Quality Standards:质量规范的要点： Final Inspection Standard:Gap +/- 1mmFINAL INSPECTIONBODY SHOPBody ShopStandard:Gap +/- 2mmUse master parts and boundary samples as required to make visual规范件与边境样件需求目视化Key

22、Points of Good Quality Standards:质量规范的要点： Boundary Samples should visually indicate OK Not OK condition to help operators make quick, good decisions边境样件应该标明好或不好，以便操作人员迅速且更好地下决议。Visually “describing the defect is Not a Boundary Sample! 目视化标明缺陷不是边境样件！Crater more than this size is not acceptable不接受焊口大于

23、此尺寸Example of a Boundary Sample边境样品的范例Create a “Standards-Based Culture发明一个以规范为基点的文化气氛I wouldnt buy this!Doesnt look good to me!My opinion isThis does not meet the standard.Talk in terms of The Standard, not opinions! 以规范为基点，而非观念！ManufacturingProcess ValidationQualitySystemManagementProduct Quality

24、StandardsQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal Produ

25、ctiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam Conc

26、eptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl&VerificationManufacturingProcess Validation制造工序认证What is a process?什么是工序？Inputs投入Outputs输出A process is a set of inter-related resources and activities which transforms inputs into outputs.工序是集中相关的资源

27、进展一系列活动，把投入转换成输出！Environment环境Process 工序 Man MachinesMethod MaterialsWhere can Errors Occur?问题会出在哪？Defects缺陷Materials:资料Parts out of standard 不符规范的零件Wrong parts错误零件Poor design 设计不当 Method: 方法Poor std. Work 不好的规范任务Lack of Training 缺乏培训 Machine/Process: 机器/工序No TPM 没有TPMProcess not capable 工序不好Imprope

28、r specification 规格不当 Man:人力Not follow std. Work 不遵照规范化任务Distractions, Forgetfulness 分心、遗忘Lack of Experience 缺乏阅历Errors Result InValidate the manufacturing process prior to Start of Production! 在消费启动前认证制造工艺！Do not切勿Accept 接受Build 制造Ship 传送a Defect! 缺陷！Living Up to the Motto到达口号“Eliminate the Need for

29、 Inspection on a Mass Basis by Building Quality into the Product in the First Place - Dr. DemingPFMEAWorkstationReadiness工位预备Process ControlPlan 工艺控制方案Error-proofing Plan防错方案Error Proofing Hierarchy 防错层次Prevention 预防Detection 检测HumanJudgment人为判别None无Product / Process Design Change 产品/工艺设计改动 DFM/A &

30、D/PFMEA Robust Designs & Capable Processes 机器设计及可行工艺 One-Way Assembly 同一装配Process Controls 工艺控制Locating Pins & Stops 固定点及停点Sensors & Process Monitors 传感器及工艺监控Electro - Mechanical Devices 电子机械仪器Color Coding 颜色信号Visual Controls 直观控制Andon Systems 暗灯系统Standardized Work 规范化任务Errors Cant Happen Small Impr

31、ovement小改良Significant Improvement 艰苦改良Introduction to Error Proofing防错引见0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:Visual Control ExampleHuman Judgment0515100396OLHM51020150151012457810115Better:ABExample: Vehicle Identification车辆认证 (Mutilation Cover Colo

32、r)(盖板颜色毁损)Human Judgment 人为判别Visual Control ExampleVertical Plate垂直板Battery Post电池接头Process Control ExampleDetection 检测XWork Piece 加工件Work Piece 加工件Fixture 夹具Fixture 夹具Process Control ExamplePrevention 预防Product Design Example (Before)REC STOP PAUSEREC STOP PAUSEOLDDESIGN老设计Can be Installed Upside D

33、own 可以反安装 Application of Labels on Cassette Decks.门板标签Prevention 预防REC STOP PAUSENEWDESIGN新设计Application of Labels on Cassette Decks.门板标签Can Only Be Installed Correctly!Product Design Example (After)PreventionLeft Hand Locator TabRight Hand Locator Tab Example - Product Error Proofing (One Way to In

34、stall Seat Belt)防错样品只需一种平安带安装方法Product Design Example 产品设计范例PreventionSimple Everyday Examples1) Error Prevention Automatic shut-off自动断电Error Proofing Exercise Think of an example at work or at home where error proofing can prevent an undesirable thing from happening 想想任务或生活中运用防错措施防止不好事情发生的例子 Discus

35、s as a team and report Take 5 minutes 小组讨论、汇报5分钟ManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)C

36、ontinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackaging

37、TemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl & Verification工序控制与认证Product Quality StandardsIn-Process Control & Verification (3

38、) Elements 工序控制与认证1. PreventionOutputs输出Inputs投入NOK2. DetectionOKNext Process下道工序Feedback 反响Do not不要Accept 接受Build 制造Ship 传送a Defect! 缺陷！Living Up to the Motto符合规范3. Containment包容1) StandardizedWork 规范化任务Follow and Continuously Improve Standardized Work!遵守及不断改良规范化任务！In-Process Control & Verification

39、 1) PREVENTIONPreventionVehicle ManifestManual 2-DoorSunroof2) Focus on Operation 集中精神消费Keep Your Concentration & Respect Standardized Work of Others!留意及尊重他人的规范化任务In-Process Control & Verification 1) PREVENTIONPrevention3) Error Proofing Prevention & Operator Aids 防错预防与操作者支持The Best Process is One T

40、hat Cannot Fail!最好工序就是不会失败的！In-Process Control & Verification 1) PREVENTIONPreventionDAEWOO4) Regular Checks of Systems & Processes定时检查系统与工艺Std. WorkChecks!检查规范化任务In-Process Control & Verification 1) PREVENTIONPreventionCHECKCHECK?CHECKProcess Control Checks!检查工序控制！TPM Checks!检查TPMSafety/5SChecks!检查

41、平安/5SSelf-Checks自检Include Quality Checksin Standardized Work!把质检作为规范化任务的一部分In-Process Control & Verification 2) DETECTIONDetectionCheck Methods:POINTTOUCHLISTENCOUNT2) Error ProofingDetection 检测防错Use Visual and Audio Signals!运用视觉、听觉信号！In-Process Control & Verification 2) DETECTIONDetectionStop the L

42、ine, or停线或Use Alarms, or运用警报或Combination of Both, depending on Criticality 根据危险程度兼用两种方法3) In-ProcessVerification 工序认证Inspectors are not there as a policeman, theysupport production byconfirming the process!检察员不充任警察角色，而是作为确定工序的消费支持者In-Process Control & Verification 2) DETECTIONDetectionVerification S

43、tations Final LineC.A.R.E.3a) Focus onCritical items 集中留意艰苦问题Frequency of checks to not allow Critical defects to leave the shop!经常检查，不让艰苦缺陷走出车间！In-Process Control & Verification 2) DETECTIONDetectionSafety Items“Walk-Home ItemsMajor Customer DissatisfierS/CF/F4) Defect Escalation缺陷逐层汇报Escalate defe

44、cts to leadership for support depending on frequency and criticality!根据缺陷出现频率与严重程度逐层向指点汇报以寻求支持！In-Process Control & Verification 2) DETECTIONDetectionExample:Team LeaderSection LeaderGroup Leader2 defects/ 1 hour4 defects/ 1 hour1) Use Andon (taught morelater) 运用暗灯Make problems visual & pull in supp

45、ort!问题直观，拉线寻求协助！In-Process Control & Verification 3) CONTAINMENTAlways Remember the Priorities:一定要牢记：1) Safety平安2) Quality质量3) Responsiveness (Throughput)呼应Containment包容2) Follow Containment Process 遵照包容程序Extraordinary actionsto prevent defects frombeing passed!采取特别行动防止缺陷传送！In-Process Control & Veri

46、fication 3) CONTAINMENTSome examples:1) Stop the line停线2) 100% checks100%检查3) On-line repair 线上维修4) Reworks返工5) Sorting 整理Containment包容How Does our Quality Motto relate to Containment?Do not不要Accept 接受Build 制造Ship 传送a Defect! 缺陷！It means empowered leaders make judgments how to control quality while

47、trying to keep the line running!意味着指点有权作出决议：在尽量不停线的情况下，怎样控制好质量！Does this mean we stop the line every time we have a problem?这是不是意味着一有问题就停线呢？How Does our Quality Motto relate to Containment?Sometimes the best decision may be to let a defect pass to the next process, but有时最好的方法是让过失转到下工序，但是It is a cons

48、cious decision made by the appropriate level Action must be communicated to next “customerDefect must be clearly identified on vehicleContainment must be in place to prevent further defects Examples of Some Andon Guidelines: 暗灯运用的指点方针1) Will the problem affect the next process? 问题会不会影响下道工序？2) Can I

49、effectively repair the defect out of station? 能不能在工位外有效处理问题？3) What is the status of my decouplers? 本人的切断器是什么形状？4) Others 其他Andon Discussion Hoods Situation: At the Body Shop end-of-line Quality station it is discovered that there is a problem with cracked hoods. After working the line back we know

50、that every car in the system has the condition all the way to Hood Install. After sorting the raw hoods, it is found that there are enough good hoods to keep producing cars, however there are not enough good hoods to repair the defective cars on-line. The suppler says new hoods will arrive in 6 hour

51、s. The operators at end of line have pulled the Andon and the escalation process has pulled in the Body Shop Manager and Quality Manager. Considerations are: 1) The decoupler between Body and Paint is almost empty, 2) Hoods with cracked metal will not affect any of the subsequent processes, and 3) H

52、oods can be changed out of station relatively easily. Discussion:You are the Plant Quality Manager what is your decision?Discuss as a group! Background: In this case, the decision is is shut down the line for (6) hours and wait for parts or run the line and make a containment plan. Since the decoupl

53、er between Body and Paint is almost empty, this means all Body, Paint and GA will all eventually shut down. Potential Decision: In this case, Quality can still be achieved while maintaining our Responsiveness targets mostly because the hoods do not affect the next process. The Cost of stopping the l

54、ine will not result in better Quality or Responsiveness. Thus, a good decision would probably be to run the line and make a containment plan: All cars with bad hoods to be specially identified. Production and Quality in Paint and GA notified of the situation, know the vehicle numbers and identificat

55、ion method.100% check at Hood Install operation until process capability is assured. Paint and Final Process notified that new hoods to be painted in Paint and will be swapped in Final Process area and have time to make a plan how to accommodate that.Andon Discussion - Hoods Situation: At the Cockpi

56、t Load station in GA it is discovered that there is a problem with one of the electrical harnesses within the cockpit. The cockpits are built as a module by an outside supplier. After working the line back we know that several cockpits in the system have the condition. The operators at Cockpit Load

57、have pulled the Andon and the escalation process has pulled in the Trim Line Section Leader, who consults with the Chassis Line Section Leader. Considerations are: 1) The decoupler between Trim and Chassis about half full, 2) The electrical harness will affect the next assembly process, 3) Repairing

58、 the harnesses on-line will take approximately one hour, and 4) Repairing the Cockpit later in the process is difficult and very time consuming.Discussion:You are the Trim Section Leader what is your decision?Discuss as a group! Andon Discussion - Cockpits Background: In this case, the decision is i

59、s shut down the line for (1) hour and repair the harnesses prior to Cockpit Load or run the line and repair the cockpits out-of-station. Since the decoupler between Trim and Chassis is about half full, this means that Chassis can continue running for a short while and then eventually shut down.Poten

60、tial Decision: In this case, Quality cannot be achieved while maintaining our Responsiveness targets mostly because the bad cockpits affect the next process and are extremely difficult to repair later. The Cost of stopping the line is more desirable than the cost of repairing them later and the pote