大宇制造质量.ppt

Built-InQuality制造质量,不断改进,员工参与,标准化,缩短制造周期,制造质量,Built-InQuality制造质量,Built-In-Quality制造质量,WhatIsQuality?什么是质量？GroupDiscussion小组讨论,Definitions定义,Qualityiswhatthecustomerperceivestobeacceptabletoachievehis/herenthusiasm质量是客户感觉能够接受并满足其热忱的东西,MadCow疯牛(DiseasedMeat病牛肉),PoorQualityMeansLostSales质量差意味着失去客户,Firestone燧石(UnintendedAccidents)意外事故,uninstalledshiftlock漏装移位锁定(SuddenAcceleration)突然加速,PP100,:NotReportedDueToInsufficientSample样品不足不汇报,(),J.D.PowerIQSTrendByBrand,NCSIByMakers-20022002NCSI,CustomerExpectations,PerceivedQuality,PerceivedValue,CustomerLoyalty,CustomerRetention,CustomerComplaints,VoiceofCustomer客户意见,VoiceofCustomer客户意见,1.停车方便(Convenienceofparking)2.外观式样(Exteriorstyling)3.内部空间(Interiorroominess)4.节能(Fueleconomy)5.安全(Safety),1.外观式样(Exteriorstyling)2.内部空间(Interiorroominess)3.噪音与静音(Noiseandquietness)4.节能(Fueleconomy)5.空调性能(Airconditionerperformance),1.发动机性能(EnginePerformance)2.发动机噪音(EngineNoise)3.外观式样(Exteriorstyling)4.噪音与静音(Noiseandquietness)5.坐骑(Ride),L6,1.节能(Fueleconomy)2.噪音与静音(Noiseandquietness)3.内部空间(Interiorroominess)4.坐骑(Ride)5.外观式样(Exteriorstyling),1节能(Fueleconomy)2.空调(Airconditioner)3.噪音(Noise)4.发动机噪音(EngineNoise)5.M/T转换(M/TShift),1.节能(Fueleconomy)2.OSRVM手工控制(ManualOSRVMcontrol)3.发动机噪音(Enginenoise)4.检查发动机点火(CheckEnginelight)5.法人形象(CorporateImage),1.节能(Fueleconomy)2.制动性能(Brakeperformance)3.喇叭性能(Speakerperformance)4.内饰品质(Interiorquality)5.喷涂质量差(Poorpaintquality),1.3排坐椅相称(Seatscomport:3rdline)2.节能(Fueleconomy)3.发动机启动(Poorenginestart)4.法人形象(CorporateImage)5.级别(Gradablity),Built-in-Quality制造质量,WhatisBuilt-In-Quality?什么是制造质量？GroupDiscussion小组讨论,WhatisBuilt-InQuality?什么是制造质量？,Definition定义Methodbywhichqualityisbuiltintothemanufacturingprocess,sothatdefectsareprevented,detected,andcountermeasuresareimplementedtopreventreoccurrence.指质量在生产过程中产生，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Ensuresdefectsarenotpassedtothecustomer.确保不传递缺陷。,Designers设计师,Suppliers供应商,Production生产人员,Dealers经销商,Buyers采购员,Sales&Marketing销售人员,TheCustomerChain.CompanyPerspective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,TheCustomerChain.ProductionPerspective客户链公司远景,EachProcessHasatLeastOne“Customer”andOne“Supplier”每个阶段至少有一个客户和一个供应商,Built-In-Quality制造质量,Donot不要,aDefect!缺陷,SolveProblemsThroughTeamwork!团队合作解决问题！,Built-In-QualityMotto制造质量口号,SatisfyYourCustomer满足你的客户,QualityThroughTeamworkKnowYourCustomer!,Whatwaterleaks?Idontseeanywaterleaks什么漏雨？我没发现漏雨。,Thiscarwasntmadeonmyshift,TheproblemisPressShop.Theflangeistoolong.问题出自冲压，边缘过长,IwontrunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower.,Theproblemisthatthepiecesarebadfromthesupplier.问题在于供应商的材料不好。,Itisnotfrommyarea,maybeitsthesealer,这辆车不是我轮班造的。,在没有工业工程装配方法及人力的情况下，我不做任何试验。,这不是我负责的地方，也许是粘胶负责,Dontrunawayfromtheproblem!不要逃避问题!,LivinguptotheMotto.符合口号.-WhatIsaDefect?什么是缺陷？GroupDiscussion小组讨论,Defect缺陷,Adefectisaproductthatdoesnotmeettheestablishedqualitystandard.缺陷是不合已定标准的产品。,Measurementofaqualitycharacteristic质量性能测量,Vehicle#车辆号,UpperSpecificationLimit规格上限,LowerSpecificationLimit规格下限,QualityStandard质量标准,Defect缺陷,Defect缺陷,x,x,Whyaredefectsundesirable?为什么缺陷不受欢迎？,Defectsmayalsoresultin缺陷还可能导致Highwarrantycosts过高保修成本Lostcustomersale失去客户,DefectsRequireCorrection=CorrectionisWaste缺陷需要纠正纠正就是浪费,QUALITYISEVERYONESRESPONSIBILITY质量是每个人的职责,Design,Engineering,Production,Quality,SupportDepartmentsandSuppliers.设计，工程，生产，质量，相关部门及供应商OURBestResources:我们最好的资源:PEOPLE员工OURGoal:我们的目标：EveryoneisaQualityInspector人人都是质检员EveryoneisaProblemSolver人人都是问题解决者,WHOISRESPONSIBLEFORQUALITY?谁对质量负责？,ME!我！,Reflectvoiceofthecustomer反映顾客的心声,Simple,clear&supportuser简单、清晰，有利操作者,ClearlyMeasurableatpointofuse在使用上可明确测量,KeyPointsofGoodQualityStandards:质量标准的要点：,InusersStd.Work&postedvisual在操作者的标准化工作或张贴出来,StandardsMustSupporttheOperator,tooNotonlytheEngineer!标准不仅有益于设计者，也有益于操作工人,Nottighterthanthoseappliedatthepreviousprocess不要比前道工序的更严格,KeyPointsofGoodQualityStandards:质量标准的要点：,Usemasterpartsandboundarysamplesasrequiredtomakevisual标准件与边界样件需要目视化,KeyPointsofGoodQualityStandards:质量标准的要点：,BoundarySamplesshouldvisuallyindicateOKNotOKconditiontohelpoperatorsmakequick,gooddecisions边界样件应该标明好或不好，以便操作人员迅速且更好地下决定。,Visually“describing”thedefectisNotaBoundarySample!目视化标明缺陷不是边界样件！,Createa“Standards-Based”Culture创造一个以标准为基点的文化氛围,TalkintermsofTheStandard,notopinions!以标准为基点，而非观点！,ProductQualityStandards,LeanDesignofFacilities,Equipment,ToolingandLayout,HealthandSafetyPriority,In-ProcessControl&Verification,Whatisaprocess?什么是工序？,Inputs投入,Outputs输出,Aprocessisasetofinter-relatedresourcesandactivitieswhichtransformsinputsintooutputs.工序是集中相关的资源进行一系列活动，把投入转换成输出！,Environment环境,Process工序ManMachinesMethodMaterials,WherecanErrorsOccur?问题会出在哪？,Defects缺陷,Materials:材料Partsoutofstandard不符标准的零件Wrongparts错误零件Poordesign设计不当,Method:方法Poorstd.Work不好的标准工作LackofTraining缺乏培训,Machine/Process:机器/工序NoTPM没有TPMProcessnotcapable工序不好Improperspecification规格不当,Man:人力Notfollowstd.Work不遵循标准化工作Distractions,Forgetfulness分心、遗忘LackofExperience缺乏经验,ErrorsResultIn,ValidatethemanufacturingprocesspriortoStartofProduction!在生产启动前认证制造工艺！,Donot切勿,aDefect!缺陷！,LivingUptotheMotto达到口号,“EliminatetheNeedforInspectiononaMassBasisbyBuildingQualityintotheProductintheFirstPlace”-Dr.Deming,PFMEA,WorkstationReadiness工位准备,ProcessControlPlan工艺控制计划,Error-proofingPlan防错计划,ErrorProofingHierarchy防错层次,Product/ProcessDesignChange产品/工艺设计改变DFM/A&D/PFMEARobustDesigns&CapableProcesses机器设计及可行工艺One-WayAssembly同一装配ProcessControls工艺控制LocatingPins&Stops固定点及停点Sensors&ProcessMonitors传感器及工艺监控Electro-MechanicalDevices电子机械仪器ColorCoding颜色信号VisualControls直观控制AndonSystems暗灯系统StandardizedWork标准化工作,ErrorsCantHappen,SmallImprovement小改进,SignificantImprovement重大改进,IntroductiontoErrorProofing防错介绍,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,Original:,Best:,VisualControlExample,HumanJudgment,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,Better:,A,B,Example:VehicleIdentification车辆认证(MutilationCoverColor)(盖板颜色毁损),HumanJudgment人为判断,VisualControlExample,VerticalPlate垂直板,BatteryPost电池接头,ProcessControlExample,Detection检测,X,WorkPiece加工件,WorkPiece加工件,Fixture夹具,Fixture夹具,ProcessControlExample,Prevention预防,ProductDesignExample(Before),RECSTOPPAUSE,RECSTOPPAUSE,OLDDESIGN老设计,CanbeInstalledUpsideDown可以反安装,ApplicationofLabelsonCassetteDecks.门板标签,Prevention预防,RECSTOPPAUSE,NEWDESIGN新设计,ApplicationofLabelsonCassetteDecks.门板标签,CanOnlyBeInstalledCorrectly!,ProductDesignExample(After),Prevention,Example-ProductErrorProofing(OneWaytoInstallSeatBelt)防错样品只有一种安全带安装方法,ProductDesignExample产品设计范例,Prevention,SimpleEverydayExamples,1)ErrorPrevention,Automaticshut-off自动断电,ErrorProofingExercise,Thinkofanexampleatworkorathomewhereerrorproofingcanpreventanundesirablethingfromhappening想想工作或生活中使用防错措施避免不好事情发生的例子DiscussasateamandreportTake5minutes小组讨论、汇报5分钟,LeanDesignofFacilities,Equipment,ToolingandLayout,HealthandSafetyPriority,ProductQualityStandards,In-ProcessControl&Verification(3)Elements工序控制与认证,1.Prevention,2.Detection,Donot不要,aDefect!缺陷！,LivingUptotheMotto符合标准,3.Containment包容,1)StandardizedWork标准化工作,FollowandContinuouslyImproveStandardizedWork!遵守及不断改进标准化工作！,In-ProcessControl&Verification1)PREVENTION,Prevention,2)FocusonOperation集中精力生产,KeepYourConcentration&RespectStandardizedWorkofOthers!注意及尊重他人的标准化工作,In-ProcessControl&Verification1)PREVENTION,Prevention,3)ErrorProofingPrevention&OperatorAids防错预防与操作者支持,TheBestProcessisOneThatCannotFail!最好工序就是不会失败的！,In-ProcessControl&Verification1)PREVENTION,Prevention,4)RegularChecksofSystems&Processes定时检查系统与工艺,Std.WorkChecks!检查标准化工作,In-ProcessControl&Verification1)PREVENTION,Prevention,CHECK,CHECK,?,CHECK,ProcessControlChecks!检查工序控制！,TPMChecks!检查TPM,Safety/5SChecks!检查安全/5S,Self-Checks自检,IncludeQualityChecksinStandardizedWork!把质检作为标准化工作的一部分,In-ProcessControl&Verification2)DETECTION,Detection,CheckMethods:POINTTOUCHLISTENCOUNT,2)ErrorProofingDetection检测防错,UseVisualandAudioSignals!使用视觉、听觉信号！,In-ProcessControl&Verification2)DETECTION,Detection,StoptheLine,or停线或UseAlarms,or使用警报或CombinationofBoth,dependingonCriticality根据危险程度兼用两种方法,3)In-ProcessVerification工序认证,Inspectorsarenotthereasapoliceman,theysupportproductionbyconfirmingtheprocess!检察员不充当警察角色，而是作为确定工序的生产支持者,In-ProcessControl&Verification2)DETECTION,Detection,VerificationStationsFinalLineC.A.R.E.,3a)FocusonCriticalitems集中注意重大问题,FrequencyofcheckstonotallowCriticaldefectstoleavetheshop!经常检查，不让重大缺陷走出车间！,In-ProcessControl&Verification2)DETECTION,Detection,SafetyItems“Walk-Home”ItemsMajorCustomerDissatisfier,S/C,F/F,4)DefectEscalation缺陷逐层汇报,Escalatedefectstoleadershipforsupportdependingonfrequencyandcriticality!根据缺陷出现频率与严重程度逐层向领导汇报以寻求支持！,In-ProcessControl&Verification2)DETECTION,Detection,Example:,TeamLeader,SectionLeader,GroupLeader,2defects/1hour,4defects/1hour,1)UseAndon(taughtmorelater)使用暗灯,Makeproblemsvisual&pullinsupport!问题直观，拉线寻求帮助！,In-ProcessControl&Verification3)CONTAINMENT,AlwaysRememberthePriorities:一定要牢记：1)Safety安全2)Quality质量3)Responsiveness(Throughput)响应,Containment包容,2)FollowContainmentProcess遵循包容程序,Extraordinaryactionstopreventdefectsfrombeingpassed!采取特别行动防止缺陷传递！,In-ProcessControl&Verification3)CONTAINMENT,Someexamples:1)Stoptheline停线2)100%checks100%检查3)On-linerepair线上维修4)Reworks返工5)Sorting整理,Containment包容,HowDoesourQualityMottorelatetoContainment?,Donot不要,aDefect!缺陷！,Itmeansempoweredleadersmakejudgmentshowtocontrolqualitywhiletryingtokeepthelinerunning!意味着领导有权作出决定：在尽量不停线的情况下，怎样控制好质量！,Doesthismeanwestopthelineeverytimewehaveaproblem?这是不是意味着一有问题就停线呢？,HowDoesourQualityMottorelatetoContainment?,Sometimesthebestdecisionmaybetoletadefectpasstothenextprocess,but有时最好的办法是让差错转到下工序，但是ItisaconsciousdecisionmadebytheappropriatelevelActionmustbecommunicatedtonext“customer”DefectmustbeclearlyidentifiedonvehicleContainmentmustbeinplacetopreventfurtherdefects,ExamplesofSomeAndonGuidelines:暗灯使用的指导方针1)Willtheproblemaffectthenextprocess?问题会不会影响下道工序？2)CanIeffectivelyrepairthedefectoutofstation?能不能在工位外有效解决问题？3)Whatisthestatusofmydecouplers?自己的切断器是什么状态？4)Others其他,AndonDiscussionHoods,Situation:AttheBodyShopend-of-lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods.AfterworkingthelinebackweknowthateverycarinthesystemhastheconditionallthewaytoHoodInstall.Aftersortingtherawhoods,itisfoundthatthereareenoughgoodhoodstokeepproducingcars,howevertherearenotenoughgoodhoodstorepairthedefectivecarson-line.Thesupplersaysnewhoodswillarrivein6hours.TheoperatorsatendoflinehavepulledtheAndonandtheescalationprocesshaspulledintheBodyShopManagerandQualityManager.Considerationsare:1)ThedecouplerbetweenBodyandPaintisalmostempty,2)Hoodswithcrackedmetalwillnotaffectanyofthesubsequentprocesses,and3)Hoodscanbechangedoutofstationrelativelyeasily.,Discussion:YouarethePlantQualityManagerwhatisyourdecision?Discussasagroup!,Background:Inthiscase,thedecisionisisshutdownthelinefor(6)hoursandwaitforpartsorrunthelineandmakeacontainmentplan.SincethedecouplerbetweenBodyandPaintisalmostempty,thismeansallBody,PaintandGAwillalleventuallyshutdown.,PotentialDecision:Inthiscase,QualitycanstillbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethehoodsdonotaffectthenextprocess.TheCostofstoppingthelinewillnotresultinbetterQualityorResponsiveness.Thus,agooddecisionwouldprobablybetorunthelineandmakeacontainmentplan:Allcarswithbadhoodstobespeciallyidentified.ProductionandQualityinPaintandGAnotifiedofthesituation,knowthevehiclenumbersandidentificationmethod.100%checkatHoodInstalloperationuntilprocesscapabilityisassured.PaintandFinalProcessnotifiedthatnewhoodstobepaintedinPaintandwillbeswappedinFinalProcessareaandhavetimetomakeaplanhowtoaccommodatethat.,AndonDiscussion-Hoods,Situation:AttheCockpitLoadstationinGAitisdiscoveredthatthereisaproblemwithoneoftheelectricalharnesseswithinthecockpit.Thecockpitsarebuiltasamodulebyanoutsidesupplier.Afterworkingthelinebackweknowthatseveralcockpitsinthesystemhavethecondition.TheoperatorsatCockpitLoadhavepulledtheAndonandtheescalationprocesshaspulledintheTrimLineSectionLeader,whoconsultswiththeChassisLineSectionLeader.Considerationsare:1)ThedecouplerbetweenTrimandChassisabouthalffull,2)Theelectricalharnesswillaffectthenextassemblyprocess,3)Repairingtheharnesseson-linewilltakeapproximatelyonehour,and4)RepairingtheCockpitlaterintheprocessisdifficultandverytimeconsuming.,Discussion:YouaretheTrimSectionLeaderwhatisyourdecision?Discussasagroup!,AndonDiscussion-Cockpits,Background:Inthiscase,thedecisionisisshutdownthelinefor(1)hourandrepairtheharnessespriortoCockpitLoadorrunthelineandrepairthecockpitsout-of-station.SincethedecouplerbetweenTrimandChassisisabouthalffull,thismeansthatChassiscancontinuerunningforashortwhileandtheneventuallyshutdown.,PotentialDecision:Inthiscase,QualitycannotbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethebadcockpitsaffectthenextprocessandareextremelydifficulttorepairlater.TheCostofstoppingthelineismoredesirablethanthecostofrepairingthemlaterandthepotentialtocreatemoredefects.Inthiscase,thedecouplerstatusdoesnotreallyimpactthefinaldecisiontoomuch.Thus,agooddecisionwouldprobablybetostopthelineandfixtheharnessespriortoCockpitInstall.TheTrimLineSectionLeaderwillinformtheGAAreaManagerofthisdecisionandtheimpactonourResponsivenesstarget.,AndonDiscussion-Cockpits,LeanDesignofFacilities,Equipment,ToolingandLayout,HealthandSafetyPriority,ProductQualityStandards,In-ProcessControl&Verification,“Customer”客户,QualityInformationFeedback/Feedforward质量反馈与前馈,“Suppliers”供应商,You你,ProcessAProcessBProcessC,back,DefectflowingfromAtoB缺陷从A流到BStatusonProblemResolution问题解决状态,forward,EscapeddefectflowingtoProcessC避免缺陷流到CTemporaryprocessbeingusedinProcessB过程B的暂时方案Process/productchangewithtime工艺/产品随时间改变StatusonProblemResolution问题解决状态,MotivationforTimelyFeedback及时反馈的动机,Immediate1Day1YearHighMediumLow1s100s1000s,TimetoDiscoverDefect发现缺陷的时间,AbilitytoDiscoverRootCause发现根源的能力,NumberofDefectiveVehiclesBuilt已经生产的缺陷产品,Example-DailyReportingMetrics(DirectRun)每天汇报制度,DefinitionPercentageofvehiclesthatmadeitthroughtotheEnd-of-Lineinspectionprocesseswithnodefects.Thisisacommon,globalmetricthatiscomputeddailybyallAssemblyPlants.下线检查合格的车辆百分比，这是全球统一在所有总装厂每天用电脑记录的制度。,FinalInspection(End-of-Line)下线检测,DynamicVehicleTestorequivalent动态测试,Other100%Inspections*其他10%检测(i.e.U/BCheck),TotalDirectRun=(92%*98%*96%*99%)=86%vehicleswithnodefect,Repair,CARELine,#offirsttimevehicleswithatleastonedefect至少有一个缺陷的第一次认证,80,20,40,10,%FirstTimeQuality一次质量认证百分比,92%,98%,96%,99%,Totalfirsttimevehiclesth