夹具重复性试验转孔TOMOANAEnglish-Chinese

1、全员参与标准化作业持续改进缩短制造周期造入质量通用-全球制造系统Principle: Built In Quality 原则： 造入质量Element: 14 Manufacturing Process Validation 元素： 14个制造工艺验证GM-GMS Operating Tool 通用-全球制造系统操作工具14.5 TOMOANA仅供通用内部使用 2010年8月CopyrightNotice版权声明明 August,2000General MotorsCorporation(GM).2000年8月，通用用汽车公公司Allrights reserved.版权所有有Nopart of

2、 thismaterialmay be reproducedinany formorbyany method(photocopy,microfilm, digital, etc.) withoutthe writtenpermissionofGeneral MotorsCorporation,educationalpurposesincluded.本资料中中的任何何部分在在没有通通用汽车车公司书书面许可可证的情情况下不不得以任任何形式式或任何何方式（复印，缩微拍拍摄，数数码拍照照等等）复制，包括教教育用途途。Scope范围This operatingtool definesroles&resp

3、onsibilities forTOMOANAactivities appliedtoallGMSouthAmericaandAfricanAssemblyPlants.本操作工工具为应应用于所所有通用用南美和和非洲的的组装工工厂的TOMOANA活动定义义了角色色和责任任。Definition定义TOMOANA is amethod to ensuretheprocessrepeatability inwelding fixturesforwelded subassembliesand reducedimensionalvariationinBody-in-white buildupproce

4、ss.TOMOANA是一种确确认焊接接夹具工工艺复现现性和在在白车身身制造过过程中减减少尺寸寸变化的的方法。Purpose目的Support GM-GMSprinciple:Built-in-Quality;支持通用用-全球制造造系统原原则：制制造质量量；Support deliverable executionasrequiredinMQRR (ManufacturingQuality ReadinessReview);支持根据据MQRR（制造质质量准备备评审）要求的的交付运运行；Definethe standardizedprocess forvalidation andcontrol a

5、ndverificationofstabilityfor weldingfixture.确定验证证和控制制标准化化程序和和焊接夹夹具稳定定性验证证。Responsibility责任TheManufacturing Engineering (DimensionalEngineering) is theprocess owner forimplementationofthis processduring theLaunch. TheBody ShopManageristheprocessownerforexecution of thisprocedure in regularproduction.

6、工艺（尺尺寸工程程师）是是负责在在产品启启动过程程中实施施流程。车身车车间经理理是在量量产时运运行这个个过程的的负责人人。IntroductionTOMOANA is atoolapplied to ensurethedimensionalrepeatabilityinweldedsubassemblies anditiseffectivepreventivetool to supportthe QualityMotto;Donotaccept,buildandshipDefects.TOMOANA是适用于于焊接总总成部件件时相关关尺寸的的确认，是一种种预防性性的工具具，它是是有效来来支持质质

7、量格言言的预防工工具：绝不接接受，制制造，传传递缺陷陷。Itisa methodology appliedtoreduce dimensional variationinBodyShop andcontinuouslyimprovetheDimensionalQualityofBIWand Assemblies(Arate and6 Sigma).它是适用用于在车车身车间间减少尺尺寸变化化和持续续改进白白车身和和装配的的尺寸质质量的方方法论（等级A和6 Sigma）。DonotDefects绝不接受制造传递缺陷Enablers要素Standardparts;标准件；Weldingfixture

8、s;焊接夹具具；Measurementsystem(GaugePass-no-Pass);测量系统统（测量量及格不不及格）StandardizeWork;标准化工工作；Records( validationand daily record);记录（确确认及日日记录）TOMOANA:PDCA cycle6.Problem Solving;7.Effectiveness &Efficiency.1.TOMOANA planning;2.TOMOANA validation5.Alarm& Escalation;3.DailyControl (Productioncore)4.WeeklyMonit

9、oring( Qualitycore)PDCA周期计划验证问题解决决效力与效效率报警升级级日常管理理（生产产核心）周监督（质量核核心）1-Planning:Launch process计划：流流程启动动TheTOMOANA mustbedeveloped foralltheintheBodyShop Process. Geo-stationsmeansanysub-assembledpartsthat impactthegeometryofthe vehicleand still canbeapplicable foranysub-assembledpart thatiscausingdown

10、stream qualityissues (noise,waterintrusion,fits)orthat is known as critical.TOMOANA必须在车车身车间间程序中中为所有有GEO-STATIONS发展。Geo-stations意味着任任何影响响车辆几几何学的的初级装装配零件件并且仍仍然适用用于引起起质量问问题（异异响，水水浸，匹匹配问题题）或者者是危险险的初级级装配零零件。DuringtheBodyShop Readinessthis toolshould be initiatedtogetherwith Iterativematchingactivities (5

11、3weekspriortoSORP)and achieve100%approvedbyEndofMVBns.在车身车车间准备备期间，此工具具应该和和反复的的匹配活活动一起起启动（在SORP阶段53周前）并并且在MVBns结束时得得到100%通过。TOMOANATimeline时间轴技术规格检验感觉特性设计研究生产装配配文件下下发100%通过第一圈1-Planning:Currentprocess计划：目目前工艺艺TOMOANA is alsoappliedindimensionalcontinuous improvementprocess forcurrent programs.Basedon

12、theGCA,VerificationStationandCMMfeedbacksTOMOANAcansupporta methodtoeliminatethe variability existing onweldedsubassemblyfixture after theroot causedanalyzed.TOMOANA也适用于于目前项项目的空空间持续续改进程程序。根根据GCA、检验站和和CMM回馈，TOMOAMA可以在分分析根本本原因之之后，支支持消除除存在于于焊接部部件夹具具变异性性的方式式。偏差TOMOANA Planning计划TheTOMOANA musthavea depl

13、oymentplandeveloped, whichincludesfourkeyattributes (4Ms) to ensuretheadequateexecution level fromtheTOMOANA activities:TOMOANA必须发展展部署计计划，包包括4个保证TOMOANA行为适当当运行水水平的关关键属性性：1.Man:人员1.1Defineteamtoperform thevalidation process;明确小组组实施验验证程序序；Dimensionalexpertshould leadorsupportteam;空间专家家应该领领导或支支持小组组；1.2

14、DefinebywhomtheDailyControlwill be conducted;明确谁来来执行日日常管理理；1.3Develop training forthedifferent levelsofpeopleinvolvementanddeployit;为各阶层层的参与与人员开开展并部署培训；2.Material:材料2.1Definehow standard parts willbeavailable;明确标准准件如何何可用；2.2Definewhereand howthestandardpartswillbestorage,includewhoismake thesupports

15、;明确标准准件应该该如何存存放并存存放在哪哪里，包包括谁来来支持；2.3Definewhenthestandardpartsshould be exchanged( date);明确何时时交换标标准件（日期）；3.Machine:机器3.1Definewhichweldingfixture willbeimplementedand when;明确适用用哪个焊焊接夹具具，何时时适用；4.Method:方案4.1Deploymeasurementprocessandpin gagemustbeenoughforalltheareas;部署测量量程序，全部地地区的定定位销板板必须充充足；4.2Dev

16、elop StandardizedWork (STS/TIS)and apply JIT.开展标准准化工作作（STS/TIS）并且应应用JIT.1.TOMOANAPlanning计划MeasurementSystem;测量系统统Gaugesin3.0 -3.5 and4.0mmare appliedtomeasurethediameters ofholespreviouslyidentified.3.0-3.5mm和4.0mm的测量仪仪器应用用于以前前确定的的孔的直直径。测量仪器器测量系统统验证流程：TOMOANA验证标记并打4.0mm的孔打开夹钳，移动零件，放下零件，关闭夹钳测量孔的直径并记

17、录每10个重复项目3和4结果是依据标准的吗？分析并做调整。回到项目1阶段1阶段2打开夹钳，移动零件，放下零件，夹紧夹钳测量孔的直径并记录每5个重复项目7和8结果是依据标准的吗？打开夹钳，移动零件，放下零件，关闭夹钳测量孔的直径并记录阶段3结果是依据标准的吗？结束验证。存档文件2-Validation Process;验证程序序Theinitialvalidation processmustbeconductedinfourstepsasfollows:最初的验验证程序序必须按按照以下下四个步步骤执行行：3.1Define holepositions andmake theholes;确定孔位位

18、并打孔孔；3.2Repeatabilityoftheweldingfixture clamping;焊接夹具具钳位重重复定位位；3.3Repeatabilitywith“cold”welding;用冷焊重重复定位位；3.4Studyinwelded substructure;研究焊接接底层结结构；Duringthevalidationprocess is importanttomention;验证程序序的重点点：Thesame subassembly parts willbeusedforall phase (I,IIand III);相同组件件应该应应用于各各个阶段段（I,II和III）Af

19、terruns processvalidationthewelded subassembliesshallbedisposalforscraporifnodamagewas done, canbeused as normalproduction parts,aslong productengineeringapproves.运行验证证程序之之后，焊焊接组件件应该处处理废料料，或者者如果没没有损坏坏，可以以作为正正常生产产零件使使用，只只要产品品工程批批准。2-Validation Process;验证程序序3.1Define holepositions andmake theholes;确定孔

20、位位并打孔孔；Itsthefirststepforthe Tomoanavalidation.Ensure thatweldingfixture is OKandthereisnotpotential variationrelated to fixtures.Make surethatallholesdefinedareabletoidentifyanyvariation on subassembly processand:这是Tomoana验证的第第一步。确保焊焊接夹具具没问题题，并且且没有涉涉及到夹夹具的潜潜在变化化。确保保所有确确定的孔孔都能够够在分部部装配过过程中鉴鉴定任何何变化并并且

21、：analyzeallthe variationtobestudied (x,yandzaxles)betweentwoormore parts;分析全部部要研究究的两个个或多个个零件之之间的变变化（x,y和z轴）；definea minimumoftwo pointsthat guaranteethis variation;确定最小小的保证证这个变变化的两两点；definethelocationofthe perforation considering:确定穿孔孔位置时时考虑到到：mustnotcoincidewithwelding spotposition;一定不要要和焊点点位置一一致；m

22、ustbeaccessible formeasuringonthe weldingfixture;一定在焊焊接夹具具上能够够测量；eliminatetheburrsonthe holes;去除孔边边的毛刺刺；identifytheholeswithnumbers;确定孔的的编号；见附件A确定孔位位并打孔孔（继续续部分）例如：基准面注意孔的的质量！穿孔直径径：4mm确定孔位位和打孔孔；（继继续部分分）确保零件件之间的的正确匹匹配内部和外外部部件联合合区域右边左边确定零件件上的部部件联合合区域以以确保适适当的穿穿孔2.2RepeatabilityofWelding Fixtures Clampin

23、g (phaseI)焊接夹具具钳位的的重复性性（第一一阶段）Once madethe holes therepeatability processonweldingfixturesclampingisinitiated(phaseI).Ifthe Clamping doesnot abletoproviderepeatability thewelding fixturehastobeadjustedor/andre-define newholespositions. Thepreviousstep redone.一旦打孔孔了，焊焊接夹具具钳位的的重复性性程序就就启动了了（第一一阶段）。如果果钳

24、位不不能提供供重复性性，必须须调整焊焊接夹具具或者重重新确定定孔位。然后重重复前面面的步骤骤。2.2.1 PerformClampingProcess;执行夹紧紧步骤Repeat10timesthe followingsequence;重复10次以下序序列；a)removepieces andrelocatethem;移动并重重新安置置零件；b)clampthefixture;夹紧夹具具；c)measure thediameteroftheholesand register (appendixB).测量孔的的直径并并记录下下来（附附件B）。需要测量量的孔见附件BForthe Validatio

25、nProcessisrecommendedtovalidatewith every holesdiameterminorthan 0.5mm.Conditionalacceptshould be avoidedtonot impactthenext phasesoftheprocess.建议的验验证程序序检验每每个孔的的直径小小于0.5mm。有条件件的接受受应避免免影响程程序的下下一阶段段。焊接夹具具钳位的的重复性性（第一一阶段）评价夹紧紧步骤；验证程序序的标准准（一、二、三三阶段）接受：直直径变化化：小于于0.5mm有条件的接接受：直直径变化化：0.5到1.0mm拒绝：直直径变化化：大于于1

26、.0mm2.3Repeatabilitywith “cold”welding;冷焊的重重复性This stepwillensurewhatevervariation betweenweldingfixturesandweldingprocess (phaseII) doesnot occur.这一步骤骤确保焊焊接夹具具和焊接接程序间间是否存存在变化化（第二二阶段）。2.3.1ApplyCold welding;应用冷焊焊-Repeat 5timesthe followingsequence:重复5次以下序序列：a)removepieces andrelocatethem;移动并重重新安置置零件

27、；b)Applycold welding(with pressure andwithout current);应用冷焊焊（用压压力不用用电流）c)measure thediameteroftheholesand register (appendixB)测量孔的的直径并并记录（附件B）2.3.2AssessColdwelding process;评价冷焊焊工艺；Ifcold weldingprocessisacceptable under Validationcriteriamovefornextphase.Ifnot,understand weldingfixturevariationand

28、eliminateit.Thenstartthevalidationprocess again (phaseI).如果在验验证标准准下冷焊焊工艺是是可接受受的就进进行下一一阶段。如果不不可接受受，了解解焊接夹夹具变化化并且消消除。然然后再次次开始验验证程序序（第一一阶段）。焊钳冷点焊见附件B2.4Studyinwelded subassemblies;研究焊接接组件This is thelast stepofTOMOANAValidation withwelded subassemblies(phaseIII).这是焊接组组件TOMOANA验证的最最后一步步。2.4.1Welding;焊接Re

29、peatoncethefollowing sequence:重复一次次以下序序列：removepiecesand relocate them;移动并切切重新安安置零件件；b) clamping thewelding fixtures;夹紧焊接接夹具；c) weldthe parts;焊接零件件；d) measurethe diameter of theholesandregister(appendixB).测量孔的的直径并并做记录录（附件件B）。2.4.2AssessWeldingProcess;Ifwelding processisacceptableunderValidation crit

30、eria thephaseisover andthedocuments canbearchived.Ifnot,understand weldingfixturevariationand eliminateit.Thenstartthevalidationprocess again (phaseI).如果焊接接工艺在在验证标标准下是是可以接接受的，此阶段段结束并并且文件件可以归归档。如如果不是是，了解解焊接夹夹具变化化并消除除。然后后再次开开始验证证程序（第一阶阶段）。焊钳点焊见附件B2-Validation Process;验证程序序2.5- Re-Validationprocess;再验证

31、程程序TheTOMOANA processmustbere-validatedalways that:TOMOANA程序必须须再次验验证：- Changethestandardpartsfor:改变标准准件为：-Product changes;产品改变变-Welding fixtureintervention/change;焊接夹具具介入/改变-Any transfer weldfixtures:焊接夹具具转移：-Movementbetween areas;区域之间间移动-PlanttoPlant公厂之间间移动Whenthestandardpartsare changeddue:当更改标标准件

32、由由于：-Prematureabrasionofthe holes;孔的前期期磨损-Damaged;损坏-Corrosionpoints;锈蚀点Thereisnoneed to re-validatedtheTOMOANA,onlychangethe parts.没有必要要再验证证TOMOANA，只是改改变零件件即可。3-Dailycontrol:日常管理理Productionteam is accountable forexecute theTOMOANA daily controlandmaintainStandardPart in capablecondition.生产小组组在允许许条件

33、下下负责允允许TOMOANA日常管理理并威胁胁标准件件。3.1. Standard Part;标准件AfterTOMOANA processapprovedanewsubassemblypartshallbecreated andavailableasStandardPart.在TOMOANA程序通过过后，应应造新的的组件并并且可以以作为标标准件使使用。StandardPart hastofollowthe characteristicsbelow:标准件必必须符合合以下特特点：keep thesame figureastheholesand positionsthat usedduring

34、thevalidation process( step2offlow);保证在验验证程序序中使用用的孔和和位置一一致（步步骤2的流程）；RecommendedtosubmitinElpoProcess;Ifthedecisionissubmit in Elpothepartshave to be processedpriortoholesperforated.IfthedecisionisnotElpoprocessthepartshavetobeapplied withprotectiveoilinordertoavoidprematurecorrosion;建议在电电泳工艺艺中提交交；如果

35、果在电泳泳过程中中提交决决定，在在打孔之之前必须须加工零零件。如如果不在在电泳过过程中做做决定，在零件件上必须须涂上防防护油以以避免前前期锈蚀蚀。3.1. Standard Part; (continuation)标准件（继续部部分）Allthemeasurablepointsidentified;确定所有有测量点点Partidentification;确认零件件allocateinproperlyarea;在适当区区域分配配validatedate &exchangepartdefinition (without:damages,corrosion points,premature abra

36、sion of theholes).检验日期期&交换零件件明确（没有：损坏、锈蚀点点、孔的的前期磨磨损）见附件E3- Daily control: 日常管理3.2 Execution; 执行 The TOMOANA must be execute in beginning of the each shift. TOMOANA必须在每轮开始执行。 To initiate the TOMOANA the standard parts must be according, with no damages and the holes must not be wider or closed. Other

37、wise call the Team Leader and wait for his decision. 启动TOMOANA时，标准件必须符合要求，没有损坏，孔不能过大或者关闭。否则通知小组领导等待他的决定。 The Tomoana daily control consist in allocate the standard parts in the welding fixture and close the clamps and then measure the holes specified. (phase I of validation process) TOMOANA日常管理包括在焊接

38、夹具中分配标准件，关闭夹钳然后测量具体的孔（验证程序的第一阶段）。 The welding fixture will be evaluate under criteria below to be release for production 焊接夹具将按照下面生产中发放的标准来评估。 If the result is OK, record it on TOMOANA register and release the production. On the other hand if the result is NOK, record it and initiate the reaction pl

39、an according to Alarm & Escalation process. 如果结果是合格的，将它记录在TOMOANA登记簿上并且发放生产。另一方面如果结果是不合格的，将它记录下来并且根据警报和升级程序启动反应计划。见附件C开始标准件合格吗？为焊接夹具分配标准件打电话给小组组长，等待他的授权来开始生产关闭焊接夹具夹钳测量并登记每个指定的孔结果合格吗？根据警告 & 升级流程启动反应计划准备生产开始4-WeeklyMonitoring:Qualityteam is accountable forTOMOANA monitoring. Itmeansperformweeklythefol

40、lowing requirements;质量小组组负责TOMOANA监督。这这意味着着每周按按照以下下要求执执行：1-must ensuredocumentation is in place (STS/TIS);必须确保保文件到到位（STS/TIS）；2-must verifytheStandardPartintegrity: quality, identification;必须检验验标准件件的完整整性：质质量、确确认；3-must verifythegauge, pin;必须检验验标准尺尺寸、识识别码；4-must confirmthe Daily controlexecution:freq

41、uencyand criteria;必须确认认日常管管理执行行：频率率和标准准；5-must ensureanyprocessvariationrelatedtomeasurementshavea reaction plan;必须确保保任何与与测量有有关的程程序变化化有反应应计划；6-must requestweldingfixture adjustmentwhennecessary;必须在必必要时要要求焊接接夹具调调整；Thereareothers requirementsthat arerecommendedas:还建议以以下其他他要求：7-couldverifythe TOMOANAar

42、eaandallocation;cleanup, organizedandsafety;可以检验验TOMOANA区域和分分配；清清洁；组组织和安安全；8-couldchecktheTOMOANAboardifalldocumentationproposedisavailable;如果所有有提交的的文件都都是可用用的，可可以检查查TOMOANA看板；见附件D5-Alarm& EscalationProcess:警告与升升级程序序Thereactionplan mustbeinitiated based on Alarm &Escalationprocess definedwhen non-standardconditionoccurs.反应计划划必须根根据在不不标准条条件发生生是确认认的警告告和升级级程序启启动。Thesubassemblyproduction muststoponfirstNOKhole