福特汽车-品质系统介绍

品質系統

天马行空官方博客：://；；QQ群：1755696321Agenda–QualitySystemTotalQualityExcellence–CompanyPolicyLetterNo.1.BriefHistoryofFLHQualityManagementQualityArrow(QualityisJob#1)QS-9000/ISO14001System/QualityOperatingSystemTGWReduction/VRT/SAQTGR/KanoModel21.FordTotalQualityExcellenceCompanyPolicyLetterNo.1Qualityisdefinedbythecustomer;thecustomerwantsproductsandservicesthat,throughouttheirlife,meethisorherneedsandexpectationsatacostthatrepresentsvalue.品質是由顧客所定義Qualityexcellencecanbestbeachievedbypreventingproblemsratherthanbydetectingandcorrectingthemaftertheyoccur.達成卓越的品質必須注重在問題的預防AllworkthatisdonebyCompanyemployees,suppliers,anddealersispartofaprocessthatcreatesaproductorserviceforacustomer.Eachpersoncaninfluencesomepartofthatprocessand,therefore,affectthequalityofitsoutputandtheultimatecustomers’satisfactionwithourproductsandservices.

每個公司員工對品質及最終的顧客滿意都有貢獻3FordTotalQualityExcellenceSustainedqualityexcellencerequirescontinuousprocessimprovement.Thismeans,regardlessofhowgoodpresentperformancemaybe,itcanbecomeevenbetter.

維持卓越的品質必須持續作流程的改善Peopleprovidetheintelligenceandgeneratetheactionsthatarenecessarytorealizetheseimprovements. 改善的智識及行動來自人Eachemployeeisacustomerforworkdonebyotheremployeesorsuppliers,witharighttoexpectgoodworkfromothersandanobligationtocontributeworkofhighcalibertothosewho,inturn,arehisorhercustomers.

後工程即是顧客;不接收不良,不傳送不良-Chairmanoftheboard(口徑;水準,程度)天马行空官方博客：://；；QQ群福特六和品質管理之發展演進1/4~1986-Introduction/Localization引入福特原廠產品開發標準如WorldwideDesignRequirement及WorldwideProductAcceptanceSpecifications。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UPAS-UniformProductAssessmentSystem-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。5福特六和品質管理之發展演進 2/4天马行空官方博客：://；；QQ群：1755696326福特六和品質管理之發展演進 3/41991~1996Upgrading/Standardization建置QIS(QualityInformationSystem)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(NewOverallVehicleAssessment-Customer)。1996年起導入QOS品質運行系統。Achievement1994年獲得Q1再次驗證肯定。

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肯定。

7福特六和品質管理之發展演進 4/41996~nowTransformation/Internationalization1996年起開始推動福特生產系統-FPS(FordProductionSystem)。2000年起廠內開始推動SixSigma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(FordConsumerProductAudit)。Achievement1997年榮獲國際環境管理系統ISO14001驗證。

1998年獲得汽車業國際品質系統QS-9000驗證肯定。2001年福特六和引擎廠新人圈榮獲福特總部CDQA(CustomerDrivenQualityAward)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ISO9001/QS9000及ISO14001整合系統驗證。83.Ford‘QualityisJob#1’ArrowDefine,Measure,Analyze,Improve,ControlDesignfor6-SigmaCommonProblemSolvingLanguage&ToolsHighQuality,HighVelocityImprovements inBusinessResults9LeadershipPrinciplesRewardandRecognitionTrainingandFeedbackPartnershipwithUnions,Dealersand SuppliersVehicleQuality(High&LowTime-In-Service)CustomerSatisfactionTGWWarrantyResidualValueSales&Service SatisfactionEliminationof WasteQ1QualityIsJob#1QUALITYLEADERSHIPINITIATIVEEngageAllEmployees6-SIGMADataDrivenDecisionMakingQUALITYOPERATINGSYSTEMPerformancetoStandardsDriveProcessDeliverResultsPlanDoCheckActFordMotorCompanyQOSProductCreationSales&ServiceCertificationSystemFPDSFutureCustomersCurrentCustomersOrdertoDeliverySuppliersLaunchCurrentModelFPS9QualityLeadershipInitiative9LeadershipPrinciplesValue:

QualityisJobOne.Itisourresponsibility,ourjobsecurityandourfuture.

Attitude:

ZeroDefectMindset.Don'ttakeit,don'tmakeitanddon'tpassiton.

Culture:

Arelentlessdailyfocusonquality.

Training:

Ensuringpeoplehavethenecessaryskillsandtoolstodotheirjobs.

Accountability:

Effectivemeasurementandfeedbackforcontinuousimprovement-accountabilityandperformancemetrics.Cooperation:

Helpsuppliershelpussucceed.

JointLeadershipCommitment:

EffectiveQualityLeadershipatalllevels.

DisciplinedExecution:

Changesnevercompromisequality.

EnterprisingApproach:

Thecustomerisoursharedconcern.

104.ISO9001/QS-9000及ISO14001整合系統ISO9001(’96)/QS-9000(’98)內部稽核:2times/yearISO14001(’97)內部稽核:1times/yearISO9001(’96)/QS-9000(’98)外部稽核:1times/yearISO14001(’97)外部稽核:1times/year2systems,2setsofprocedures,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:2times/year整合外部稽核:1times/year不僅整合集中內部資源人力，連外部稽核費用都可降低!

NextStep轉換QS-9000至TS16949ISO1800011QOS-QualityOperatingSystem品質運行系統12QOS-QualityOperatingSystemTimeandDataManagementRequiredmeetingscheduledatdesignatedfrequenciestocommunicateandevaluatePlantQualitySystemOutput,total18meetings.

Atoolforplantstocommunicateinformationbacktothebasedepartmentsaddressingcustomerconcerns.VOPQUG-001FLHPracticesDescriptionFrequencyParticipantsMetricsDescriptionFrequencyParticipantsMetricsNOVA-CandQualitysystemPerformanceOverviewsDailyPlantMgr.AreaMgr.QualityMgr.AreaSupervisorAreaCIWGLeaders…Nova-cWrapreviewChips&ScratchesSqueaks/RattlesFAI/CAIreviewRollTest…ConvoyYardreviewDailyPlantMgr.AreaMgr.QualityMgr.AreaSupervisorAreaCIWGLeaders…Nova-cWrapreviewChips&ScratchesSqueaks/RattlesFAI/CAIreviewRoadTest,Excel,PDI,FTT…

13ConvoyYardReview-每日品質會議ReviewVehicleQualityReviewConcern&Actions14QOS-QualityOperatingSystemVariabilityReductionVRT/VFGastructuredprocesstodrivequalityimprovementfocusedoncustomerexpectations.Itensuresthatplantcontrollablecustomerconcernsareacteduponquicklyandpermanently.ToolVerificationensureregularinspectionandcertificationofplanttestequipment,tools,andgagesisbeingconductedperthecorporateguidelines.

15QOS-QualityOperatingSystemIncomingMaterialmeasuresplanteffectivenessinimprovingandcontrollingthequalityofmaterialenteringtheplant.Aworkingrelationshipwiththeplant,suppliers,purchasing,andotherkeyactivitiesisessentialforqualityimprovement.

ProcessControl/Build&InspectionProcess

identifyrequirementsforcontrollingspecificoperationsandinspections.Thoserequirementscomefrompracticesand/orproceduresthataretheinfrastructureoftheassemblyVehicleOperationsQOS.

CC’s,SC’s,CTQ…16QOS-QualityOperatingSystemRepairSystemaformalizedrepairprocessassuringthepreparation,repair,material,andtooling/equipmentusedareinaccordancewithestablished/approvedrepairstandards.

QualityAcceptanceCriteria

establishedlevelofstandardstobeusedforinspection.

thecriteriamustthenbecascadedthroughouttheplants.toassurethateveryinspection/check/testisperformedtothesamestandardsthroughouttheentiresystem.17QOS-QualityOperatingSystemWeldSurveillanceInprocesschecksofweldedassemblies,whencoupledwithperiodicteardownofweldedbodiesandassemblies,provideapositivemethodofdeterminingweldquality.ensurethatallweldproductionoperationsarebeingeffectivelyperformed.

DimensionalControl

acomprehensivebodysheetmetalconstructionstrategythattakesintoaccountallkeybodysheetmetalcomponentsandtheirrelationshipstoeachotherandbodylines.toidentify,track,andreducedimensionalvariationfromcomponenttocomponentandvehicletovehicle18QOS-QualityOperatingSystemTorqueAssurancetoassurethatFasteningControlSystemimplementationisstandardizedandeffectiveacrossallassemblyplants.FCPAtoidentifymanufacturingimperfectionsthroughaseriesofaStatic/Dynamic/Full(combinationofstatic&dynamic)auditsoffinishedunits.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。

19FCPA(FordConsumerProductAudit)

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可能造成顧客/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所有量產車種。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。使用顧客/消費者導向的評分系統CCRS〔稽核時間約為每輛車三個小時〕。20FCPA(FordConsumerProductAudit)

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21CCRS(CustomerConcernRatingSystem)

顧客導向式評分系統22QOS-QualityOperatingSystemWindNoiseevaluatesthenoiseacceptabilityofvehicles,aswouldanaveragecustomer.Duringthedriveevaluation,thetrainedauditorlistenswithanunaidedearandrateswindnoiseperformance,onascalefrom1to10,usingthe"WindNoiseRatingCriteria"formSqueak&Rattletoeffectivelydetectassemblyorcomponentsqueakandrattleconcernspriortotheunitsleavingtheplant.23Squeak&RattleRoadTestSqueak&RattleTestTrackUpgradeLength: 100ftUniformViennaBlock,100ftSteppedViennaBlockWidth: 104〞40”40”24”TrackWidth~66”40〞40〞24〞100’UniformViennaBlockSteppedViennaBlock24Squeak&RattleRoadTestUniformViennaBlockSteppedViennaBlock(~1〞StepinHeight)25QOS-QualityOperatingSystemWater(20minutesoak)pre-determinedcriticalwaterentryareas,whichmaynotshowupduringthenormal100%productionwatertest.This20–Minutetestisaverificationofprocess/designactionstakentocorrectanyrepetitivewaterleakconcerns.FinishVehicleEvaluationProgram(M-10Program)

adailyevaluationofcompletedproductionlevelvehicles.Theseunitsaredrivenover-night,overtheroadbyauthorizedplantpersonnel.Itsfunctionistoidentifyissuesearlyanddevelopimmediateprocess/productcontainmentandimprovementactions.26QOS-QualityOperatingSystemPIC(ProductInformationCenter)includesexternalandinternalqualityindicators,givingtheplantsastandardizedmeansofdisplayingqualitydata,description,andvisualrepresentation.PICallowsinformationflowtopresentqualityefforts,whichfactuallydemonstrateperformanceovertime.ControlPoint/TipLevel

utilizeseithercurrentoraddedinspectionasatooltodriveIn-Station-Process-Control(ISPC)andtofacilitatecommunicationwiththeBaseOperatortodevelopcountermeasurestocontainqualityconcernswithinthezone.27QOS-QualityOperatingSystemUltrasonicamethodtoevaluatewindnoise.Theprocessisperformedbyattachinganultrasonictonegeneratortothecenterofthewindshieldandmovingadetectioninstrumentaroundthepotentialleakareas(glassruns,windshield,dooropenings,etc.).WindNoiseleaksaremeasuredindecibels(dB)andcomparedtopredeterminedlimits.Predeterminedlimitsareestablishedbycorrelationofleaksandcustomerdata.AirLeakageTest

anevaluationofsealedpaintedvehiclebodiesandcompletedproductionvehiclesforobjectivemeasurementsofbodyairleakage.28UltrasonicTestEquipment29QOS

總表-1/330QOS

總表-2/331QOS

總表-3/332QOSFAPAssessmentResultFLHelementlevel:2.75(FullLevel:4)U.S.VOtotalplantsummarystatusforreference:ThelevelofFLHisbetterthanVOplantsintheUS.33FordLioHoQualityImprovementFlowDiagram345.TGWReduction–VRT/SAQTGW(ThingsGoneWrong):問題點,故障情況VRT(VariabilityReductionTeam)astructuredprocesstodrivequalityimprovementfocusedoncustomerexpectations.SAQ(SingleAgendaforQuality)asystematicmatrixtoprioritizeCustomerConcernsbasedoninternalandexternalindicators.35VRTOrganizationMeetingDateChampionTeamLeaderSub-System/GQRSCategoryJ.D.PowerCategoryTue.RingoLinMikeChang

ExteriorPaint&Corrosion

Vehicleexterior,(Paintissues)

JamesWang

Body&ExteriorTrim/Bumper

Vehicleexterior(ExcludeWindnoise,Waterleaks)

SteveTangInteriorTrim,Waterleakage,Squeaksandrattles

VehicleinteriorWaterleaksSqk&Rat

Wed.RichardChenS.M.Lee

Mirror,Seating&Restraints

Mirror