质量阀程序.doc

QS/DYPT-070-0311.002005/3/13质量阀程序Quality Valve Procedure1.0 目的1.1 本程序规定了上海通用东岳动力总成有限公司(SGMDY PT)在动力总成新产品的开发，启动，升级和年型更改等过程中的质量控制及不断改进过程。质量阀在特定的时间监控和评估项目的质量就绪状态，产品和工艺已得到验证，项目启动顺利, 以保证满足客户要求。1.2 通过质量阀评审确保项目产品及过程得到适当的验证，确保生产顺利启动。1.3 确认各部门是否都有充分的计划，这些计划是否被有效地落实以降低项目风险，确保项目的可靠性。1.0 Purpose1.1 To define Shanghai General DongYue Powertrain Co. Ltd. (SGMDY PT) procedure for quality control and continuous improvement in new Powertrain product development, launch phases, upgrade and model year change etc. Quality valves monitor and evaluate the quality readiness of a program at specific times to ensure customer requirements are met, the product and process are properly validated, and the production launch is smooth.1.2 To monitor and evaluate the quality readiness of the program by quality valve review as a means to ensure the product and process are properly validated, and the production launch is smooth.1.3 To verify that all functional groups have sufficient plans and are effectively executing them to minimize risk and maximize robustness of the program.2.0 编制和适用范围本程序由质量部编制，适用于SGM所有的动力总成新产品项目启动阶段。2.0 Preparation and applicabilityThis procedure is prepared by Quality Department, and applied to all new Powertrain product development and launch in SGM. 3.0 术语质量阀-产品开发及启动过程中各阶段之间的质量控制阀。质量阀是对特定要素的强制性评审，以保证在产品项目阶段尽可能早地发现和解决质量问题。如果打开，即进入下一阶段；如果关闭，则要重新进行 前一阶段的制造及后一阶段的准备工作及评审，直至打开。 制造-相应车间按照发布的工程和工艺文件进行生产设施调试/ 改造、工艺准备和生产。 评审-对各要素进行风险评估，以决定阀是否打开，是否进入下一阶段。启动质量目标反映该阶段总体质量状况，用于判断是否可进入下一阶段生产，可包括单一问题清单中问题的关闭率，物料准备，制造工艺准备和制造质量水平等。3.0 TermsQuality Valve-Quality control valve between phases of product development and launch process. Quality Valves are a disciplined review of specific elements that drive the discovery and resolution of quality issues as early as possible in a product program. If the quality valve open, the program can go into the next phase. If close, return to the last phase of production / preparation stage for next phase and review until it open. Build -The relevant shop will make process preparation, manufacturing facility adjustment/modification and build according to released engineering and process documents.Review-Risk assessment will be executed for all the critical-to-quality deliverables. Determine whether the quality valve open and the next phase will go on.Launch Quality Target-An integrated indicator which can entirely reflect quality condition of each launch phase, it can support decision if the product launch can head to next phase. It can be included with Close rate of single issue list, Material readiness, Manufacturing process readiness and vehicle quality condition in Manufacturing and etc.4.0 责任4.1 质量部经理负责确定质量阀实施计划和组织。4.2 质量部和生产车间负责对各开发启动阶段的制造过程中的质量进行监督和改进。4.3质量部负责协调各相关部门在各阶段实施问题解决及不断改进。4.0 Responsibilities4.1 Quality Department Manager has responsibility for planning, organizing the Quality valve process.4.2 Its the responsibility for Quality Department and plant manufacture to monitor and improve quality in build in each development and launch phase.4.3 Quality Department has the responsibility for coordinating each responsible department to solve problem and execute continue improvement in each development and launch phase.5.0 规定5.1 SGM东岳动力总成新产品开发，启动，升级和年型更改等各阶段可设置以下质量阀(如必需)：Gamma 质量阀；预试生产质量阀；试生产质量阀；SOP质量阀。（见附件一） 5.2 根据各阶段的不同目的，在进入后一阶段前，前一阶段所有的质量问题都应解决或有相应的整改计划。GAMMA-采用零件供应商提供的样件，在生产线上进行样机试装，并装车进行综合认证，对产品设计进行验证的工程样机制造阶段。预试生产-在产品进入可销售阶段之前对所有零部件及各区域制造工艺进行验证。试生产-验证制造与装配的工艺能力及工艺稳定性。SOP-评审早期生产的产品质量水平。5.3 根据生产启动计划设定质量阀。每阶段质量阀由制造就绪评审和发运评审两部分组成。在每次质量阀会议上评审该阶段的所有质量问题都应解决或有具体人员负责的遏制措施。5.4 制造过程由项目执行小组负责协调相应生产车间按规定要求完成。制造中发现的质量问题在开阀应至少已得到控制，并有具体人负责的反应计划。5.0 Provisions5.1 In each phases of SGMDY Powertrain new product development, launch, upgrade and model year change, different valves are set as follows (if necessary): Gamma valve, Pre-pilot valve, Pilot valve, Start of production valve. (See Attachment 1)5.2 Based on the purpose of each phase all the quality problems of previous phase should be solved or relevant corrective actions are taken prior to the next phase.GAMMAPrototype is to validate the design using components made on production intent processes and production processes whenever possible. Pre-pilot -Takes the opportunity to validate all parts and assemble process before the products to be salable. Pilot -Validates build & assembly process and stability .Regular production -Review the quality level of product in early production.5.3 Quality valve is set up according to production launch plan. The quality valve meeting consist of two parts, readiness review and shipping review. All quality problems should be solved or have containment in place with action plans and assigned owners.5.4 Build and assembly process will be coordinated by PET to ensure that the relevant workshops meet specified requirements. Quality issues identified during manufacturing should have at least containment in place and action plans with owners prior to opening the quality valve.5.5质量阀评审会议由质量经理组织实施，由项目经理和各相关负责人员向总经理或其授权人等汇报本阶段的产品/样机质量状况及生产准备情况，由质量阀评审小组决定是否可以开启质量阀进入后一阶段。5.6 在正式的质量阀评审中，各区域负责人需要汇报相应的质量阀报告文档，解释其当前状况。对于质量阀先期评审中状态为绿色的要素，若无疑问，则无需详细的解释（所有的要素汇报文档都必须完成并存档）。初评为黄色或红色的要素必须有详细的说明及解决方案。经过评审，质量阀决策人将确定是否有必要更新初评的结果，由项目质量工程师记录所做的决定。5.7 与所有的动力总成项目评审定义相同，质量阀要素评审结果定义如下：- 确信会达到目标- 有风险，但有相应对策以确保达到目标- 高风险，无相应措施以确保达到目标 NA - PET已经决定此项目不适用确定质量阀要素的评审结果时应考虑相应的风险程度及下列问题：计划状态，工作是否达到要求，后备计划是否充分，对制造及项目时间进度的影响，要求跟踪的程度，需要那些额外的资源。5.5 Review Meeting of quality valve will be organized and held by Quality Manager. Responsible person of relative manufacturing line for new product and PLE report quality status and build preparation to general manager his vicegerent etc. The whole Quality Valve review team shall discuss and make decision whether quality valve is open and the product proceed to the next phase or not. 5.6 During the formal Quality Valve meeting, each champion should begin his element review by showing the respective Presentation Lead Sheet. For elements initially coded GREEN, no further detail information need be shown unless requested during the review (however, all deliverables must be submitted for documentation purposes). For elements pre-assessed as YELLOW or RED, a detailed review of the deliverables and recovery plan is expected. After the element is reviewed, the valve decision-makers will confirm the pre-assessment rating or revise it as appropriate, with the PQM capturing the decision on the check sheet.5.7 To be consistent with common Powertrain program assessment definitions, valve elements should be coded as follows:- Confident: Targets will be met.- Concerned: Action plan / countermeasures in place to meet Targets.- Not Confident: No action plan in place to meet Targets.NA - PET has determined the element to be “non-applicable”In determining the appropriate code to assign, the level of risk must be taken into account and the following issues should be considered: status to plan, compliance to requirements, sufficiency/support of required recovery plans, impact on build/program timing, degree of follow-up required, and amount of additional resources necessary.5.8 每次质量阀活动的最终评价结果为三类(参见 附件二)： 开启/通过 开启/存在风险 关闭/失败各质量阀要素审核应基于附件三。5.9 质量阀评审过程中，项目质量经理/质量系统经理应记录所有问题以进行跟踪。项目质量经理/质量系统经理应在质量阀评审后发布正式的评审结果。5.8 Final result of each quality valve activity will be divided into three levels.(See Attachment 2) Open/Pass Open/With Risk Close/FailIndividual quality valve elements should be rated based on Attachment 3.5.9 During the valve, the PQM/QSM should capt