通用电气发动机集团对供应商控制培训材料.ppt

SupplierControlOverview BillDavisMarch1 2005 Agenda OrganizationBackground ProcurementProcessSupplierSurveillanceStrategy Systems SpecialProcessesCharacteristicAccountability FirstArticleHardwareShipments SupplierReleasePlanSupplierRatingSystemEscapesAnalysis ImprovementToolsMonitoringPerformance LynnQualityLeaderQualityProcessesandSCFarmout LeaderCustomerQualityEnginePrograms BlackBelt CoEQualityLeaders Planning Logistics Airfoils Structures ProductTest Controls RotatingParts ProductDelivery Combustion Configuration DaveCalhounCEO SupplyChainQualityOrganization LeaderRegulatoryCompliance ScottErnestVicePresidentSupplyChain LeaderQualitySystems Assessments LeaderAESCDGlobalSourcingQuality Airfoils Structures Forgings Controls International RSP Nacelles Reversers Farm Out Audits FieldOperations eQuality BobBriggs ManagerSupplyChainQuality ITSupportQualityInformationSystems FinanceSourcing QualityFinance SixSigmaSupport QualitySystems LeaderFieldOperations SupplierInitiatives LeaderAuditing Farmout AESCDGlobalSourcingQuality January 2005 SourcingQualitySupport LeaderMidwestTechnicalSupport LeaderNERegion CParts GEAEManufacturingandEngineeringSites 13internalmanufacturingfacilitieslocatedin9states4assemblylocationsinfourdifferentstates2testfacilitiesin2states 1100suppliersprovide70 oftheenginehardware Background SuppliersmustbecertifiedtoAS9100inordertoproducehardwareforGEAEAS9100isanindustry widequalitystandardbasedonISO9000CertificationperformedbyregistrarsSuppliersmustalsobecertifiedtoS1000GEAEuniquequalitysystemsrequirementsperformedbyGEAEauditorsSpecialprocesses 95processesidentifiedforcontrolbyEngineeringAS9100 SpecialprocessauditsrequireongoingsurveillanceGEAE SourcingQuality SpecialProcessTechnologyCenter NADCAP Industrymanagedauditandapproval Registrars AS9100 Auditfrequency timingNewsuppliersget2auditswithinthefirstyearTimingofsubsequentauditsbasedonperformanceandrangesfrom1 3years PrimaryStepsforHardwareProcurement AS9100 Registrar AC7004 Registrar S1000 GEAEAudit NewSupplierAuditsPriorityParts ProductValidation NadcapGEAETechnicalPlansCertifyingAgentsSupplierListing FirstArticleProductAuditsHardwareReleaseVSE VendorSubstantiation HardwareProcessAuditsSRPAudits GEAESurveillanceStrategy Hardware SpecialProcesses QualitySystems SpecialProcesses ProgramcreatedandmaintainedbyAerospaceleaderstoimprovespecialprocessesbyestablishingstringentindustryrequirementsandaccreditingonlythosesupplierswhomeetthestandards WhatisNadcap EveryPurchaseOrdercallsoutstandardremarkswhichinvokestandardrequirementsplusadditionalrequirementsbasedonthetypeofhardwareInadditiontoprice schedule etc thesedocumentsflowdownQualityrequirements Terms ConditionswhichinvokeGEAEqualityspecificationsS1000 S1002SupplierHardwareReleasePlanCharacteristicAccountabilityandFirstArticleInspectionVSE SourceSubstantiation DesignrequirementifapplicableLaboratoryCertificationRequirementsOthercomponentspecificrequirementsAllrequirementsmustbemetpriortotheshipmentofproductionhardware RequirementsFlowDown POPlacement RequirementsFlowdown QualityRequirement268Thesupplieracceptingthisorderagreespartsaremanufacturedtothesameprocesses procedurespreviouslyapprovedviatheGT7350receivedfromGeneralElectricCo Anychangestotheapprovedprocesses proceduresmusthavepriorapprovalfromtheGeneralElectricCovia RequestforaProcessChange formGT7350asdefinedinGeneralElectricspecificationP1TF17andS1001 QualityRequirement784Whenanindependentlaboratorycertificationisrequiredforproductacceptancetheoriginal notcopies mustbemaintainedonfileinaccordancewiththerecordretentionrequirementsforthepartperspecificationS 1000 Whenrequested theoriginalcertificatemustbemadeavailabletothepurchaserwithinthreeworkingdays SampleStandardRemarksre SourceSubstantiationandIndependentLabCertificationRequirements KeyGEAESourcingQuality S Specifications QualitySystems SourceSubstantiation FirstArticle CharacteristicAccountability NPIProcessOverviewTheNewProductIntroduction NPI ProcessisGEAircraftEngines productcreationandprojectmanagementmethod TheNPIProcessconsistsofFiveElementsTeamStructureRolesandResponsibilities10TollgateFrameworkToolsandTechniquesReviewProcess NewProduct ProcessIntroduction EngineeringNPI SourcingNPIProcessPartqualificationrequirementsestablishedPre productionreviewwithsupplier DesignEngineering QualityManufacturing QualityPlanreviewFirstproductionrunFirstarticle characteristicaccountabilityandverificationComponentTestFinalapproval CharacteristicAccountability FirstArticleInspection FAI RequiredbyGEAESourcingQualitySpecificationS1002AssuresconformanceofallEngineeringcharacteristicsVerificationofcontrolstoassurecontinuedconformanceRequiredfornewsupplier partdesign specialprocess orsignificantprocesschangeStandarddocumentationsubmittedforreviewandapprovalProcessisrequiredonALLpartsmanufacturedforGEAE VSE SourceSubstantiation Process WhatisSourceSubstantiation Engineeringrequirementtoverifythatacomponentmanufacturedtoaspecificprocessanddrawingrequirementmeetsthedesignintentandthatanypartsproducedbyanalternatesource processmustbeequivalenttothepartoriginallyqualified HowDoesItAccomplishTheGoal DocumentstheprocessfornewpartsControlssignificantchangesAssurespartsunderSScontrolcontinuetobeproducedwith Samesequenceofsignificantprocesses SameoperationsforsignificantprocessesWhoisInvolvedintheProcess DesignEngineeringInternalManufacturingSourcingQualityQualitySystems VSE SourceSubstantiation Process WhathardwarerequiresVSE DisksandSpools Shafts couplingsandattachingpartssubjecttoturbinetorque Rotorthermalshields Pressurizedcompressor combustorandturbinecases Enginemounts Allengineframes Allgears Allbearings Variablevaneleverarms High speedrubbingsealelements Enginecontrolsandaccessories Allfan compressorandturbinebladesandvanes Bladeretainers AllcomponentsinthecombustionchamberandturbineexposeddirectlytocombustionandexhaustgasesPartfailure partreplacementandthenecessityforsignificantoperationsinmanufacturingalsodetermineneedforVSEWhenisVSERequired NewPart firstmakeorbuyAlternateProductionSourceSignificantProcessChange Aprocess thatifchanged couldaffectmaterialstructure mechanical chemical orelectricalproperties andcannotnormallybeevaluatedwithoutdestructivetestingandcouldaffectdesignintent PlantMovesorSub TierChange About30 ofanengine sP N srequireVSE ImplementationProcessAcceptablesupplierinfrastructureDSQRcandidatequalificationDSQRtrainingOn siteevaluationofDSQR Mgt supportContinuouseducation SupplierReleasePlan SRP Revised2003 SupplierReleasePlan SRP Qualificationforself releasebydemonstratingperformanceMaintainacceptableQualityRatingfor1year Managementbuy inDesignatedSupplierQualityRepresentative DSQR trained certifiedDSQRRequirementsMinimum1yearexperiencerelatedtoproduct Qualityresponsibility5DayTraining deliveredbyGEAE withwrittenandpracticaltestsRe certificationtrainingevery2yearsEachpartnumbermustbequalifiedtobeonselfreleaseplanApprovedfirstarticle partnumberaddedtoplandocumentation characteristicstoaudit etc MaintainingSelfReleasestatusdependsonperformance SelfReleasePrivilegesGrantedForSustainedPerformance WhatisaDSQR DesignatedSupplierQualityRepresentative TheDSQRisanemployeeofthesupplierDoesnotactasboththeDSQRandthefinalinspectorforareleaselotAnindividualappointedbytheSupplierwithGEconcurrence andtrainedbyaGEQualityRepresentative toactasthePurchasers ReleaseAgentasdefinedbytheSRPDSQRfunctionsarethoseperformedwhenactingonbehalfoftheGEQR GEQualityRepresentative forthetasksoutlinedinSRPAnalogoustotheFAA DMIRRole DSQR DesignatedSupplierQualityRepresentative AuditApproachTraingeographicallylocatedGEQualityRepresentativestoperformevaluationonpartsreadytoshipfromsuppliers MajoremphasisontheevaluationofproductcharacteristicsQualityRepresentativeTasks Spendthenecessaryamountoftimetoconductanin depthproductevaluationCompleteathoroughDSQRactivityreviewDetailedevaluationoftypicalproductacceptancerecordsReviewofprocessingpaperwork e g router nonconformanceclearance Monthlyreviewofresults SupplierReleasePlanAudit SupplierswithdirectpurchaseordersfromGEAE 728 532onSRP 196onLotxLot SupplierReleaseData 27 ofsupplybaseonLot by Lotrelease SupplierReleasePlan 0 10 20 30 40 50 60 70 80 ofSupplyBase DSQR LotbyLot SupplierReleasePlans 1036ActiveDSQR sinNorthAmerica 170ActiveDSQR s 49ActiveDSQR s 4ActiveDSQR s DSQRLocations VastMajority over95 ofDSQR sareinNorthAmericaandEurope SupplierRatingSystem SupplierQualityRatingSystem Threesections 100pointspossibleSection1 SystemsCompliance 35pointsSuccessfullypassedSystemsAuditonscheduleSection2 DeliveredQuality 65pointsBasedonquantityofnon conformingpartsreceivedbyGESection3 QualityEngineeringAdjustment upto41pointsdeductedEvaluatesfeaturesofservice e g supplierresponsivenessregardingcorrectiveactionrequests probleminvestigations selfreleaseplans etc Ratingscalculatedmonthly usingthelastsixmonths dataRatingsbelow70requireactionfromsupplier GEAEProductQualityEngineer PQE approvesimprovementplan Ratingsbelow60stopscreationofnewpurchaseorders SupplierRatingDrivesImprovementActions SupplierRatingDistribution NoticeofDecliningRatingtoQualityLeaders PQE GEAEAIRCRAFTENGINES GEAE initially andperiodicallythereafter appraisesthequalitysystemandproductperformanceofitssuppliers Thedegreeofacceptabilityisdefinedbyoursupplierqualityrating GEAE scurrentqualityratingofyourcompanyis59whichindicatesyourcompany squalitysystemandproductperformanceisunsatisfactoryandsignificantSystemand orperformanceproblemsexist Acopyofourratingscoringsheet whichexplainsthepointreductionsonapplicableelementsinthreeratingcategories isattachedforyourinformation Asaresultofanunsatisfactoryqualityrating yourcompany sselfreleaseprivilegesarerescindedeffectiveimmediately AcomprehensivewrittencorrectiveactionprogramplanisrequiredtobesubmittedtoyourGEAEPQE NochangeintheratingwilloccuruntilthecorrectiveplanisreceivedandapprovedbyGEAE Yourcompanyistostopallshipmentseffectiveimmediately Whenpositivecontrolofmaterialsisinplace thisrestrictionmaybecancelledviawrittennoticefromtheCommoditySourcingandQualityManager PleasecontactyourPQEifyouhaveanyquestionsconcerningthismatter RatingNoticetoSupplierQualityManager SupplierEscapesAnalysis ImprovementTools EscapesAnalysis TopIssue SupplierQualityPlanning On SiteQualityPlanningEvaluationPQEs Walktheprocess reviewmanufacturing qualityplanningEvaluatecontrols inspections capabilities w standardizedtemplate 80Suppliers 475partnumbers 18 000characteristicsanalyzedProductAudits265partnumberscompleted17 214Characteristics 10withminorN C sDPMOof58111minorspecificationnon compliances processrelated On SiteReviewsFocusedonSupplierQualityPlanDetails SupplierQualityPlanning HardwareConformance DSQR EngineeringDefinition SQA Sub tierControl MaterialControl ProductAudit ProcessDrawing SupplierQualification PrimeVendorControl QualityPlanning 1stArticleInspection CharacteristicAccountability ExecutiontoS1002 GaugeSelection CapabilityData DataforChangeApproval Other Interpretation SupplierQualityImprovementInitiativeFocusedonHighLevelKeyEscapeDrivers AdditionalDrill down KeyX sandOpportunityInterpretationofReqt sExecutiontoS1002GaugeSelectionCapabilityDataDatatoSupportChanges SupplierQualityPlanningDrillDown ContinuousImprovement SupplierQuality PurchaseOrder SupplierManufacturing QualityPlanning 100 EvaluationJustification capability monitoring CharacteristicAcceptancePlan DrawingRequirements SelectMeasurementEquipment FirstArticle CharacteristicAccountability S 1000 S 1002SupplierQualityProductRequirements SupplierProductionInspection EvaluationProcesses RequirementsFlowDown SupplierPlanningProcess SupplierProductionProcess e ToolsInc CID ChangeinDesign eCAVerrorproofingeNPIQualityPlanningToolGaugeSelectionwizardSoftwareQualityTrainingModule PartInspectionsHardwareProcessPriorityPartsMaterialReleaseProductAudits SupplierCommunication SCWCeCIDQualityAlertsDSQRNewsletter QualityAlertsS1002Re WriteClarify simplify provideexamplesTrainingS1000Re Write SurveillanceofQuality ManufacturingChanges GEApproval SupplierProductAudits PROCESS Tools GEPROPRIETARYINFORMATIONSubjecttorestrictionsonthecoverorfirstpage SupplierAccesstoGEAE e tools DocumentationandSystemsviatheInternet Inc CID INITIATION DetailedCheckliststoDevelopComprehensiveQualityPlan QualityPlanningNPIProcess e CAV GageSelectionWizard Newe Tools MonitoringPerformance SupplierScorecards Dimensional Functional IImprovedNPI ErrorProofFixture Gages FunctioninToolingDesign MRBReviewCharacteristicTaggingProductValidationReview PVR ProcessCapabilityAnalysisPart Print ProcessAuditMRBMemo Sub tiervisibilitySeparationofNPI LegacyProjectID d TrackedKC CTQ s ProjectID d TrackedDrivealltoSixSigmaMarking DrivetoRobusteControlledDotPeen Measure ControlviaScorecardsReviews ContinuousImprovementviaScorecards 1 2 3 2004BusinessInitiativesCaptured Re Measure AnalyzeSemi Annually QuarterlyReviewofTop80 Volume Escapes DrivingImprovement 2004QualityInitiatives GEAELeadershipReviewsofSupplierPerformance Level1 SourcingCommodity ScorecardReviewsQuarterlyreview SourcingCommoditypersonnel QualityperformancereviewandimprovementplansTop85 volume escapesuppliers 160 Level2 SourcingDepartment SupplierEscapesReviewBi Weeklyreview Sourcing Qualityleadership Escapesforallsuppliers bycommodityScorecardreviewswithselectedsuppliers SuppliermanagementLevel3 SupplyChainQualityReviewBi Weeklyreview V P Sourcing CoE andQualityLeaders ReviewofhighimpactissuesandcorrectiveactionLevel4 SupplyChainManufacturing EngineeringCommodityReviewsQuarterlyreview focusonmanufacturing designqualityimprovementactions MRBreduction processcapability internalaudits etc SummaryofSupplierQualityImprovementInitiatives Tools Inc CIDforchangecontrole FirstArticle errorproofingtheprocessNPIQualityPlanning Incorporatingbestpractices lessonslearnedGageSelectionWizard Incorporatingbestpractices errorproofingtheprocessSoftwareQualityAssurance Morerigorousprocess mandatorytrainingImprovedsystemsindevelopment Audits Ratings ScorecardsAssuringSupplierEngagementQualityPerformanceLetterstoCEOsWeeklyescapecommunicationtosupplierleadershipSupplierleadershippresentQualityImprovementplanstoGEAEleadership ComprehensiveApproachtoSupplierControlUtilizingSupplierPerformanceDataFromAllSourcesDevelopingImprovementToolsBasedonSupplierQualityPerformanceDataLeadershipTeamsFullyEngaged Summary AdditionalData e ToolsInc CIDeCAVQualityPlanningGageSelectionWizard SupplierAccesstoGEAE e tools documentationandsystemsprovidedviatheinternet Improve SupplierAccesstoe Tools CIDTrackingAllManualNoVisibilityofPlannedDatesStandaloneDataBases SystemIntegratedTrackingAutomatedMetricsAutomated1DBforBusinessAutoP NBreakdown Old New THISDOCUMENTCONTAINSTRADESECRETSANDCONFIDENTIALCOMMERCIALORFINANCIALINFORMATIONEXEMPTFROMDISCLOSUREUNDERTHEFREEDOMOFINFORMATIONACT 5USCSECTION552 b 4 ITISSUBMITTEDVOLUNTARILYFORTHESOLEPURPOSEOFALLOWINGEVALUATIONBYTHEU S GOVERNMENT Improve Inc CID MyCID s Newly issuedCID sareontopColorcodedtoidentifystatus age THISDOCUMENTCONTAINSTRADESECRETSANDCONFIDENTIALCOMMERCIALORFINANCIALINFORMATIONEXEMPTFROMDISCLOSUREUNDERTHEFREEDOMOFINFORMATIONACT 5USCSECTION552 b 4 ITISSUBMITTEDVOLUNTARILYFORTHESOLEPURPOSEOFALLOWINGEVALUATIONBYTHEU S GOVERNMENT Improve Inc CID AMasterSpecificationforapartcontainsalldrawingrequirementsthatneedtobefloweddowntotheinternalsourceorsupplier Allspecificationsreferencedonthedrawing AlldimensionalcharacteristicsAlldrawingnoterequirements Singleelectronicdocumentcontainsallrequirements MasterSpecification Improve e CAV Web basedApplication StandardizesFirstArticleDataEntryEasyAccesstoData