制造业产品质量标准(ppt 69页).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 20022002 NCSI 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 QualityThroughTeamwork KnowYourCustomer Whatwaterleaks Idon tseeanywaterleaks什么漏雨 我没发现漏雨 Thiscarwasn tmadeonmyshift TheproblemisPressShop Theflangeistoolong 问题出自冲压 边缘过长 Iwon trunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower Theproblemisthatthepiecesarebadfromthesupplier 问题在于供应商的材料不好 Itisnotfrommyarea maybeit sthesealer 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 Don trunawayfromtheproblem 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 QUALITYISEVERYONE SRESPONSIBILITY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 Inuser sStd Work postedvisual在操作者的标准化工作或张贴出来 StandardsMustSupporttheOperator too NotonlytheEngineer 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 BoundarySamplesshouldvisuallyindicateOK NotOKconditiontohelpoperatorsmakequick 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 ErrorsCan tHappen 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 REC STOPPAUSE REC STOPPAUSE OLDDESIGN老设计 CanbeInstalledUpsideDown可以反安装 ApplicationofLabelsonCassetteDecks 门板标签 Prevention预防 REC STOPPAUSE 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Discussasateamandreport Take5minutes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 Verification 1 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 Verification 1 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 Verification 1 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 Verification 1 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 Verification 2 DETECTION Detection CheckMethods POINTTOUCHLISTENCOUNT 2 ErrorProofingDetection检测防错 UseVisualandAudioSignals 使用视觉 听觉信号 In ProcessControl Verification 2 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 Verification 2 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 Verification 2 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 Verification 2 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 Verification 3 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 Verification 3 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 AndonDiscussion Hoods Situation AttheBodyShopend of lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods AfterworkingthelinebackweknowthateverycarinthesystemhastheconditionallthewaytoHoodInstall Aftersortingtherawhoods itisfoundthatthereareenoughgoodhoodstokeepproducingcars howevertherearenotenoughgoodhoodstorepairthedefectivecarson line Thesupplersaysnewhoodswillarrivein6hours TheoperatorsatendoflinehavepulledtheAndonandtheescalationprocesshaspulledintheBodyShopManagerandQualityManager Considerationsare 1 ThedecouplerbetweenBodyandPaintisalmostempty 2 Hoodswithcrackedmetalwillnotaffectanyofthesubsequentprocesses and3 Hoodscanbechangedoutofstationrelativelyeasily Discussion YouarethePlantQualityManager whatisyourdecision 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 YouaretheTrimSectionLeader whatisyourdecision 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 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