JBGMAPQPPresentation.ppt

JBGMAPQPPresentation,Slide112/1/2019,A.P.Q.P,AdvancedProductQualityPlanning产品质量先期策划,SupplierDevelopment/Quality供应商开发/质量,JBGMAPQPPresentation,Slide212/1/2019,ACT,PLAN,DO,STUDY,ContinualImprovement,Technology是为新的/修改的过程指导其预防,解决或监控潜在的过程问题.PFMEA是一种动态文件,当发生失效模式时需要对它进行评审和更新.,3.0过程设计和开发,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide4012/1/2019,3.0ProcessDesignandDevelopment,ProcessResponsibility,ModelYear(s)/Vehicle(s)KeyDate,CoreTeam,FMEANumberPageofPreparedByFMEADate(Orig.),ProcessFunctionRequirements,PotentialEffect(s)ofFailure,PotentialFailureMode,SEV.,Class,PotentialCause(s)ofMechanism(s)ofFailure,Occur,CurrentProcessControl,Detect,R.P.N.,RecommendedAction,Responsibility&TargetCompletionAction,ActionResults,ActionsTaken,Sev,Occ,Det,R.P.N.,ManualapplicationofwaxinsidedoorTocoverinnerdoor,lowersurfacesatminimumwaxthicknesstoretardcorrosion,Insufficientwaxcoverageoverspecifiedsurface,Deterioratedlifeofdoorleadingto:UnsatisfactoryappearanceduetothroughpaintovertimeImpairedfunctionofinteriordoorhardware,7,Manuallyinsertedsprayheadnotinsertedfarenough,Visualcheckeachhour-1/shiftforfilmthickness(depthmeter)andcoverage,Addpositivedepthstoptosprayer,MFGEngrg9X1015,Stopadded,sprayercheckedonline,ExampleofProcessFMEA过程失效模式及后果分析例表,8,5,280,72570,Automatesprayer,MFGEngrg9X1215,Rejectedduetocomplexityofdiffe-rentdoorsonsameline,Sprayheadsclogged-Viscositytoohigh-Temperaturetoolow-Pressuretoolow,5,Testspraypatternatstart-upandafteridleperiods,andpreventativemaintenanceprogramtocleanheads,Item,3.0过程设计和开发,JBGMAPQPPresentation,Slide4112/1/2019,3.0ProcessDesignandDevelopment,3.7Pre-LaunchControlPlan试生产控制计划,Tofindtheadditionalproduct/processcontroltobeimplementedafterprototypeandbeforefullproductionuntiltheprocessisvalidated.在样件研制后批量生产前,找到正式生产过程生效前要实施的附加产品/过程控制,3.0过程设计和开发,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide4212/1/2019,ProgramApproval,Prototype,Pilot,Launch,PLANNING,PRODUCTDESIGNANDDEV.,PROCESSDESIGNANDDEVELOPMENT,PRODUCTANDPROCESSVALIDATION,PLANNING,PRODUCTION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,PRODUCTQUALITYPLANNINGTIMINGCHART,ConceptInitiation/Approval,PRODUCTDESIGNANDDEVELOPMENTVERIFICATION,PROCESSDESIGNANDDEVELOPMENTVERIFICATION,PLANANDDEFINEPROGRAM,PRODUCTANDPROCESSVALIDATION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,Slide4212/1/2019,PLANNING,PRODUCTDESIGNANDDEV.,PROCESSDESIGNANDDEVELOPMENT,PRODUCTANDPROCESSVALIDATION,PLANNING,PRODUCTION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,4.0ProductandProcessValidation,Slide4212/1/2019,产品质量策划进度图表,概念提出/批准,项目批准,样件,试生产,投产,策划,生产,产品设计和开发,过程设计和开发,产品与过程确认,反馈,评定和纠正措施,计划和确定项目,产品设计和开发验证,过程设计和开发验证,产品和过程确认,反馈,评定和纠正措施,策划,4.0产品和过程确认,JBGMAPQPPresentation,Slide4312/1/2019,4.0ProductandProcessValidation,INPUTS输入,OUTPUTS输出,PackagingStandards包装标准Product/ProcessQualitySystemReview产品/过程质量体系评审ProcessFlowChart过程流程图FloorPlanLayout场地平面布置图Characteristicsmatrix特性矩阵图ProcessFMEA过程失效模式及后果分析Pre-Launch试生产ProcessInstructions过程指导书MeasurementSystemsAnalysisStudyPlan测量系统分析研究计划PackagingSpecification包装规范ManagementSupport管理者支持,ProductionTrialRun试生产MeasurementsystemEvaluation测量系统评价PreliminaryProcessCapabilityStudy初始过程能力研究ProductionPartApproval生产件审批ProductionValidationTesting生产确认试验PackagingEvaluation包装评价ProductionControlPlan生产控制计划QualityPlanningSign-offandManagementSupport质量策划认定和管理者支持,4.0产品和过程确认,JBGMAPQPPresentation,Slide4412/1/2019,4.0ProductandProcessValidation,4.1ProductionTrialRun试生产,Conductedusingproductiontooling,equipment,environment(includingproductionoperators),facilityandcycletime.采用正式生产工装,设备,环境(包括生产操作者),设施和循环时间来进行试生产.Beginningstageofvalidationofmanufacturingprocesseffectiveness开始对制造过程有效性进行验证.,4.0产品和过程确认,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide4512/1/2019,4.0ProductandProcessValidation,4.2MeasurementSystemEvaluation测量系统评价,ToassessthespecifiedmeasurementdevicesandmethodshouldbeusedtocheckthecontrolplanidentifiedKCC/KPCstoengineeringspecificationandbesubjectedtomeasurementsystemevaluationduringorpriortotheproduction.在生产当中或之前,使用规定的测量装置和方法按工程规范,检查控制计划所标识的关键控制特性(KCC)/关键产品特性(KPC),并进行测量系统的评价.,4.0产品和过程确认,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide4612/1/2019,4.0ProductandProcessValidation,4.3PreliminaryProcessCapabilityStudy初始过程能力研究,ToprovideanassessmentoftheprocessforproductiononKPC/KCCinthecontrolplan.针对控制计划所标识的关键产品特性(KPC)/关键控制特性(KCC),评价生产过程是否已准备就绪.,4.0产品和过程确认,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide4712/1/2019,4.0ProductandProcessValidation,ExampleofProcessCapabilityStudy,SPEC.,MAXIMUM,MINIMUM,92054422,DECORPANELASSEMBLY,5.40mm,5.00mm,SAMPLEQUANTITY,3DCOORDINATEM/C,UNITOFMEASURE,GAUGE,REMARK,DATE,MEASUREDBY,APPROVEDBY,21.AUG1996,J.K.KIM,C.W.KIM,100PCS,mm,GR&R:PC=29.7%,GROUPNO,SAMPLES,X1,X2,X3,X4,X5,5.235.235.255.235.245.255.255.275.245.235.225.235.255.245.265.225.235.265.225.25,5.225.245.235.275.235.235.235.245.215.245.265.265.235.275.245.275.245.275.235.24,5.245.255.255.285.235.265.285.235.235.265.235.285.245.265.225.265.245.255.235.21,5.265.235.215.265.235.235.245.235.245.275.215.255.285.285.295.285.225.265.225.27,5.225.265.245.225.255.255.225.245.265.235.245.235.255.235.305.245.245.225.235.26,26.2026.2126.1826.2626.2226.2226.2226.2126.1826.2326.1626.2726.2326.3426.2126.2726.1726.2626.1323.23,5.2405.2425.2365.2525.2445.2445.2425.2365.2465.232,0.040.030.060.040.030.030.060.040.050.040.050.050.050.080.060.020.050.010.030.06,5.232,5.252,5.246,5.268,5.242,5.252,5.234,5.252,5.226,5.246,R,CHART,CHART,R,5.271,5.244,5.217,0.097,0.046,CHART,CL=,UCL=,LUL=,RCHART,CL=R=0.064UCL=D4R=0.097=R/d2=0.00198CP=T/6=3.37CPk=(1-k)CP=2.63,=5.244,=5.271,+A2R,-A2R,=5.217,4.0产品和过程确认,过程能力研究例表,JBGMAPQPPresentation,Slide4812/1/2019,Prototype,Pre-Launch,Production,ControlPlanNumber,PartNumber/LatestChangeLevel,Supplier/Plant,PartName/Description,SupplierCode,Part/ProcessNumber,ProcessName/OperationDescription,Machine,Jig,Device,ToolsForMfg.,KeyContact/Phone,CoreTeam,Supplier/PlantApproval/Date,OtherApproval/Date(Ifreqd),Date(Orig.),Date(Orig.),CustomerEngineeringApproval/Date(Ifrequired),CustomerQualityApproval/Date(Ifrequired),OtherApproval(Ifrequired),ReactionPlan,ControlMethod,Sample,Method,Size,Freq.,EvaluationMeasurementTechnique,Product/ProcessSpecification/Tolerance,SpecialChar.Class,Characteristics,No.,Product,Process,4.0ProductandProcessValidation,ExampleofProductionControlPlan,x,12345M,52321231/D,EngineerBlock,ABCCompany/Plant#2,123H,A.B.Casting813-123-4567,SeeAttachedList,9-9-92,2-20-93,3,MachineSurface“A”,Rotarymachine,Holdingfixture#4,Holdingfixture#10,51,52,53,Depthofcut,Perpendicularcut,Holdingcastinginfixtureforproperorientation,*,*,2+/-0.25,+/-,1,=,Fixturefreefromdebris,Depthgage,Gage050,Visualinspection,5,1PC,1PC,perhrperfixture,every4hrs,Aftereachcycle,X-RChart,X-MRChart,Airblow-off,Quarantineadjustandreset,Quarantineadjustandreset,Readjustairblow-off,4.0产品和过程确认,生产控制计划例表,JBGMAPQPPresentation,Slide4912/1/2019,4.0ProductandProcessValidation,4.5ProductionValidationTesting生产确认试验,Engineeringteststovalidateandverifythatproductsmadefromproductiontoolsandprocessmeetengineeringstandardsasrefertophase1to3.确认由正式生产工装和过程制造出来的产品是否满足第1至第3阶段要求的工程标准的工程试验.,4.0产品和过程确认,KeyWordsandBasicConcept关键术语和基本概念,JBGMAPQPPresentation,Slide5012/1/2019,ProgramApproval,Prototype,Pilot,Launch,PLANNING,PRODUCTDESIGNANDDEV.,PROCESSDESIGNANDDEVELOPMENT,PRODUCTANDPROCESSVALIDATION,PLANNING,PRODUCTION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,ConceptInitiation/Approval,PRODUCTDESIGNANDDEVELOPMENTVERIFICATION,PROCESSDESIGNANDDEVELOPMENTVERIFICATION,PLANANDDEFINEPROGRAM,PRODUCTANDPROCESSVALIDATION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,5.0Feedback,AssessmentandCorrectiveAction,Slide5012/1/2019,Prototype,Pilot,Launch,PLANNING,PRODUCTDESIGNANDDEV.,PROCESSDESIGNANDDEVELOPMENT,PRODUCTANDPROCESSVALIDATION,PLANNING,PRODUCTION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,PRODUCTQUALITYPLANNINGTIMINGCHART,ConceptInitiation/Approval,Slide5012/1/2019,Prototype,Pilot,Launch,PLANNING,PRODUCTDESIGNANDDEV.,PROCESSDESIGNANDDEVELOPMENT,PRODUCTANDPROCESSVALIDATION,PLANNING,PRODUCTION,FEEDBACKASSESSMENTANDCORRECTIVEACTION,Slide5012/1/2019,产品质量策划进度图表,概念提出/批准,项目批准,样件,试生产,投产,策划,生产,产品设计和开发,过程设计和开发,产品与过程确认,反馈,评定和纠正措施,计划和确定项目,产品设计和开发验证,过程设计和开发验证,产品和过程确认,反馈,评定和纠正措施,策划,5.0反馈,评定和纠正措施,JBGMAPQPPresentation,Slide5112/1/2019,INPUTS输入,OUTPUTS输出,OutputTrialRun试生产结果MeasurementsystemEvaluation测量系统评价PreliminaryProcessCapabilityStudy初始过程能力研究ProductionPartApproval生产件审批ProductionValidationTesting生产确认试验PackagingEvaluation包装评价ProductionControlPlan生产控制计划QualityPlanningSign-offandManagementSupport质量策划认定和管理者支持,ReducedVariation减少变差CustomerSatisfaction顾客满意DeliveryandService交付和服务,5.0Feedback,AssessmentandCorrectiveAction,5.0反馈,评定和纠正措施,JBGMAPQPPresentation,Slide5212/1/2019,5.1ReducedVariation减少变差,Usecontrolchartandotherstatisticaltechniqueastoolstoreducevariation使用控制图和其它统计技术来减少变差Useanalysisandcorrectiveactiontoreducevariation应用分析和纠正措施来减少变差Usecontinuousimprovementtopayattentionforspecialcauseofvariationandcommoncause.持续改进,注意产生变差的特殊原因和普通原因Usecontinuousimprovementseekingwaystoreducebothofspecialandcommoncausessourceofvariation持续改进,减少产生变差的特殊原因和普通原因,5.0Feedback,AssessmentandCorrectiveAction,5.0反馈,评定和纠正措施,JBGMAPQPPresentation,Slide531