按节拍生产实施细则(GP-9)(DM-SGMW05.02B.02-2009)OK.doc

上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Pur.& Supply Chain Center. management manualDM/SGMW05.02B.02-2009版本号Version#:A按节拍生产实施细则（GP-9） RunRate(GP-9)2009-12-1发布 2010-1-1实施Issued on Dec 1,2009 Implemented on Jan 1,2010上汽通用五菱汽车股份有限公司采购及供应链管理中心发布Issued by SAIC GM Wuling Automobile Co.Ltd Pur.& Supply Chain Center.上汽通用五菱汽车股份有限公司采购及供应链管理部2005-10-30发布 2005-11-08实施1 前 言Forward本文件是上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册支持性文件,目的在于证实供应商的实际制造过程能够生产同时满足以下要求的零部件：1、如生产件批准（PPAP）中指出的本公司的不断提高的质量要求；2、日常的合同规定能力；3、本公司的日产量要求（LCR/MCR）。It is a supporting document for management manual of Pur.& Supply Chain dept.，it is purpose to clarify that supplier can produce parts meeting the following requirements during real manufacture process: 1.continuous quality improvement required in PPAP; 2.capability regulated in contract; 3.SGMWs daily output requirement(LCR/MCR).本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心提出。Suggested by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心归口。Supervised by SGMW WWP& Supply Chain Center.本程序由上汽通用五菱汽车股份有限公司采购及供应链管理中心负责组织起草。Drafted by SGMW WWP& Supply Chain Center.本程序主要汇编人： 杨燕文Main drafter: YangYanwen本程序主要修改人： 钟国友 吴桐山Main redactor： Zhongguoyou Wutongshan 本程序如出现文字理解歧义，以中文为准。In the event of a conflict between the Chinese and the English language ,the Chinese language shall take precedence审核Auditing： 会签Subscribe by ： 批准Approval： 上汽通用五菱汽车股份有限公司采购及供应链管理中心管理手册SGMW Pur.& Supply Chain dept. management manual按节拍生产实施细则（GP-9） DM/SGMW05.02B.02-2009（0/A）1 编制与适用范围本文件由采购及供应链管理中心负责编制，规定了对供应商生产能力考核的方式和内容；适用于所有的供应商，规定所有新的物料及产能风险物料都要通过RunRate，除非供应商质量工程师认为可以免除并且得到SQ总监的认可。2 术语/缩写2.1 RunRate按节拍生产2.2 SQ工程师供应商质量工程师2.3 APQP产品质量先期策划和控制计划2.4 PPAP生产件批准2.5 QTC报价工装能力（件/天）2.6 LCR精益产能节拍（件/天）2.7 MCR最大产能节拍（件/天）2.8 ATC实际工装能力（件/天）3 职责3.1 SQ工程师负责确定RunRate的形式，并在APQP启动会议将此决定通知供应商；按供应商监督指定，参与节拍生产；确认QTC是精确的，并大于本公司的精益产能节拍（LCR）。提供技术支持，协助采购员推进整改措施实施。3.2 SQ经理负责对RunRate报告的审核。3.3 SQ总监负责对 RunRate 报告的审批。3.4采购员负责在与供应商签订采购意向书时明确供应商的报价工装能力（QTC）；负责根据公司发展需要提高供应商产能并跟踪进展。3.5计划员负责调查已经量产产品的产能，并向SQ、采购员提供产能风险清单。4 工作程序4.1 节拍生产流程见附件。4.2 供应商编制一个节拍生产计划并在APQP启动会议上提出。4.3 SQ工程师和供应商确认合同规定能力的精确性并将1.0 ScopeIt is constituted by PSC SQ, The document regulates assessment procedure and method for supplier production capability.The document is applicable for all suppliers, all new material must pass RunRate except approved by SQE Director2.0 Term/Abbreviation2.1 Run Rate2.2 SQSupplier quality engineer，include SQD、SQE、SQP2.3 APQPAdvanced product quality planning2.4 PPAPProduction part approval process2.5 QTCQuotation tool capability(piece/day)?2.6 LCRcapability rate(piece/day)?2.7 MCRmax capability rate(piece/day)?3.0 Responsibility3.1 Responsibility of Supplier quality engineer，confirming the way of RunRate, informing decision to supplier at APQP start-up meeting; Based on the GP9 way set in APQP start-up meeting , participate in RunRate production; confirm OTC is accurate and bigger than SGMWs LCR. provide technical support and assistant buyer to push supplier make countermeasure in good progress .3.2 SQ Director is responsible for the audit of RunRate report .3.3 SQ Dirctor is responsible for approval of GP9 result3.4 Buyer is responsible for Confirm the agreed QTC number follow the supplier capacity expand plan as SGMW demand3.5 PCL planner is responsible for check the current capacity and provide list of risk parts.4.0 Process4.1 Flow chart in appendix.4.2 Supplier makes a RunRate plan and show to PDT team at APQP star-up meeting.4.3 SQE confirm accuracy of contract regulating capability with supplier and compare this value with SGMWs planning day capacity or LCR.DM/SGMW05.02B.02-2009（0/A）这一数字与本公司的计划每日速度或基本产能率（LCR）作比较。4.4 SQ工程师依据供应商的节拍生产计划、风险评估和有关零件和供应商的知识，对供应商进行RunRate的必要性进行确认，需免除 RunRate 的物料应经SQ总监的审批。如需节拍生产，SQ工程师确定GP-9方式。4.5 RunRate的形式1) 用户监督SQ工程师到现场监督整个过程，如有需要，采购员和产品工程师也可能被邀请参加。2) 供应商监督供应商自已监督整个过程，一般由其项目经理或是该项目经理指定的代表,必要时设备制造商与分包商参与。4.6 如果节拍生产是供应商监督，则供应商按节拍生产计划上显示的日期进行，对于这个日期的变更必须通知SQ工程师。4.7对于顾客监督的节拍生产，SQ工程师与供应商一起确认节拍生产日期，SQ工程师应了解可能影响节拍生产日期改变的任何工装变更。4.8 RunRate的周期在RunRate过程中所生产的物料的数量要足以表明其所具备的生产能力，并且由供应商和SQ工程师共同预先商定，诸如产品复杂程度、有效期、贮存、费用、单班运作或多班轮作等等，都是影响RunRate时间长短应考虑的因素。RunRate的默认周期是用户全速运作时每天的生产需求量。4.8.1RunRate的开始时间供应商必须在获得PPAP生产批准且准备全速生产之前八周进行RunRate。尽管一般说来越早越好，但是进行RunRate的关键考虑因素是该零件设计的稳定性，确切的日期应由SQ工程师和供应商共同确定。4.8.2供应商为RunRate所作的准备为了能有效地利用时间，在正式的RunRate进行之前，供应商应作一次演习或相应的模拟生产，完成工作表上所规定的尽可能多项目。4.4 SQE confirm whether the supplier need GP9 validation ,and only SQ director can exempt GP9 .SQ engineer confirm the method fo GP9. 4.5 RunRate manner1) Customer supervisionSQE supervise whole process at site, if necessary, buyer and PE join in the process also.2) Supplier supervisionSupplier supervises whole process, nominating a representative by project manager or by himself for supervision, if necessary, equipment manufacturer/sub-contractor join in the process. 4.6 If RunRate is supervised by supplier, RunRate should be developed on the date of plan, informing SQE if the date is changed 4.7 For user supervised RunRate, SQE/supplier decide production date, SQE should find out any tooling changed influencing production date.4.8 RunRate periodThe quantity of produced material must be able to indicate production capability during RunRate period and advanced decision by supplier/SQE, the influence elements, such as product complexity, validity, storage, charge, single shift or multi-shift and so on, should be considered.The default period of RunRate is production demand per day of user full speed operation.4.8.1 Starting time of RunRateSupplier must pass PPAP and develop RunRate before 8 weeks of full speed operation. Though normally speaking, earlier is better, key consideration element of conducting RunRate is design stability of parts, the day should be decided by SQE/Supplier.4.8.2 Suppliers preparation for RunRateIn order to use time effectively, before formal RunRate, supplier should develop a rehearse or related simulating production , completing more items to the greatest extent regulated in work list.DM/SGMW05.02B.02-2009（0/A）4.8.3装运如果物料的制造发生在主机厂需要之前，供应商应将全部零件加工完毕直到允许装运。供应商应保证有足够的生产用的装运箱和合理的成品包装以防止零部件的损坏。4.9RunRate检查内容 在RunRate过程中，检查以下一些项目：文件，制造工艺和其结果，零件质量要求和其结果，对下级供应商的要求及其RunRate的结果，还有包装和搬运。4.9.1文件在按节拍生产的同时，供应商应出具下列证明性文件以备查阅。1） PPAP包括: a)过程流程图b)过程控制示意图及相互作用示意图 c) DFMEA / PFMEA d)主要零部件清单 2）GP-12(试行)控制计划 3）加工能力信息 4）操作员/检查作业指导书 5）样件/试运行影响(PR/R) 6）分承包商控制/生产能力数据 7）分承包商材料计划及运转 8）包装/作标记示意图 9）加速生产计划 注: 所有文件必须完整和正确。 4.9.2制造工艺实际的与计划相比较1） 零件应在生产车间制造，并且使用相应的加工工具，测量，处理，材料，操作人员，环境和配套处理设备。2）实际的工艺流程应与PPAP中记载的工艺流程相吻合。3）应有操作指导书及可见的帮助并且应放在相应的4.8.3 ShipmentIf material manufacturing develops before main factorys requirement, supplier should complete all process till shipment is possible. Supplier should be sure to have enough shipping boxes and reasonable finished parts packiage in order to avoid damage. 4.9 RunRate checking contentDuring the period of RunRate, checking the following items: document, manufacture engineering and its result, parts quality requirement and its result, requirement for the lower class supplier and RunRate result, package and transition.4.9.1DocuemntAt the same time of RunRate, supplier should show the following document for referring.1). PPAP includinga) Engineering flow chartb) Process control/reciprocity sketch mapc) DFMEA/PFMEAd) Key parts list2). GP-12(trial)control plan3). Process capability information4). Operator/checking rule5). Sample/trial run effect(PR/R)6). Sub-contractor control/production capability data7). Sub-contractor material plan/running8). Packing/mark sketch map9). Accelerating production planNote: all documents must be completed and accurate.4.9.2 Manufacture engineeringcompare with planned process1). Part should be manufactured at workshop, using related processing tool, measurement, material, operators, condition and equipments.2). Real engineering flow should be coherent with the recorded one in PPAP.3). There should be visible help and known by all operators, locating near station.DM/SGMW05.02B.02-2009（0/A）岗位附近。4）所有的过程中用到的文件，如流程控制图，在试运行过程中应放在相应的位置上。这个文件用来促使按照规定计划运行和保证正确的操作过程。5） 如有需要，在加工岗位上应有加工零件的边际样品。6.）应有维护计划，应有维修备用的零件，应预留有停机时间以备维护检修。4.9.3 制造能力结果1） 每次运作的净产量要与所称的生产能力相符。2）在试运行过程中，加工设备应符合规定的运作时间的要求(净产量和毛产量之比)。所有的意外的停工时间应有记录并且作相应的修理措施。3）所有的生产线的改变，应能在所称加工能力要求范围内能够实施。4）完好零件(废品去掉,任何可行的返工)的净产量应符合所称的每日生产能力。5）加速生产计划足以满足要求。4.9.4 零件质量实际与计划的对比1） 所有的生产检测设备应完备并且作一些测量系统方面的分析(即量具可重复性和可再现性)，应备有操作规则及一些可见的帮助手段。2）所有生产过程中的测量和控制设备应该完备，功能完好并且位于相应的位置。3）过程控制计划：正式的和GP-12的应与实际过程相一致。应如计划中所述的那样，有对生产零件的检查和统计监测。4）通过预防错误或控制方案来定位如PFMEA中的潜在的失效模式。5） 备有工艺控制方案反应方案以及供应商纠正性方案供审查,这些方案用于保证容量和修正。4.9.5零件质量结果1）在试运行过程中，从加工设备上生产出来的所有零部件都应满足SGMW的现行的质量要求，这在PPAP中有所表述。4). All document used during process, such as flow control chart, should be located at related station during trial run. The documents are used to regulate production and ensure production accuracy.5). If needed, there should be boundary samples at operating station.6). Maintenance plan/spare parts should be equipped, time should be reserved for maintenance.4.9.3 Manufacture capability result1). The real net output should be coherent with the theoretic one.2). During trial run, processing equipment should meet requirement of regulated run time(net output comparing gross output). All unexpected downtime should be recorded and related repairing measure should be done. 3.) All modification of production line can be implemented within the scope of processing apability.4). Net output of good parts(eliminating scrap, rework) should meet the theoretic production capability per day. 5.) Accelerating production plan can meet the requirement.4.9.4 Part quality comparison1). All checking devices should be completed and some measurement system analysis should be done(repeatability and reproducibility), operating rules and visible help method should be equipped.2). All devices of measurement and control should be completed, good function , in right position.3). Flow control plan(normal one and GP-12) should be coherent with real process, there should be parts checking and statistic monitoring as described in plan.4). For potential failure mode of PFMEA, preventivemethod or control program should be conducted for orientation.5). Engineering control program, reactive program and supplier corrective program should be equipped, these programs can ensure capacity and modification.4.9.5 Part quality result1). During trial run, all parts produced by equipment DM/SGMW05.02B.02-2009（0/A）2） 制造过程必须受控。3） 制造过程应表明所要求的生产能力。4）流程控制计划应能有效地满足设计记录要求(即，控制点，检查频率等等)。5）不一致性注意：生产出的所有零件数，次品零件数，返工零件数都应在总表上有所记录。a) 生产流程中的不一致由正常的PPAP控制计划来确定。如果是由GP-12控制计划或其它的控制计划来确定，则要求采取补救措施。b)由PFMEA来确定是否有潜在的失效模式。若未能做到，则PFMEA需要作更新并且采取补救措施。c)所做的返工及修复工作能有效地消除不一致性。d)所有有关的样件及试生产件,已经被修正和验证。4.9.6 分供方要求1）在供应商作按节拍生产以前，应该对子承包商是否能满足用户的质量和生产能力要求进行确认。上述核实应由供应商采用按节拍生产规程或相似的过程加以实施。2） 应采取措施阻止外来材料的流入直到它被确认。4.9.7包装及装卸1）在生产过程中最后运输时，应检查包装情况以保证零件的质量并且便于供应商的操作人员装卸零件。2）生产过程中及最后运输时所采用的包装及装卸方式应能有效地杜绝可能的差错及混装。4.10要求的补偿措施A.实际的相对于要求的。如果实际生产过程的结果不符合用户对质量和生产能力的要求，应采取补偿措施消除这些不一致的地方。B.实际制造和质量计划should meet SGMWs current quality requirement, as described in PPAP.2.) Manufacture process must be under control.3.) Manufacture process should indicate required production capability.4). Flow control plan can meet design record requirement effectively(such as control point, checking frequency and so on).5). Non-conformingNote: all produced parts, inferior parts and rework parts should be recorded in general table.a) Non-coherence is decided by PPAP control plan. If it is decided by GP-12 engineering control program or other control plan, recovery measure should be taken.b) PFMEA decides whether there is potential failure mode. If it can not be done, renewing for PFMEA and recovery measure should be done.c) Rework and repairing work should be able to eliminate non-coherence effectively.d) All related samples and trial production parts have been modified and validated.4.9.6 Sub-supplier requirement1). Before RunRate, confirmation should be done to find out whether sub-supplier can meet quality/production capability requirements or not. The above confirmation should be implemented under RunRate rules or related rules.2). Measure should be taken to avoid outer material entering into SGMW till validating.4.9.7 Parking and unloading1). When shipment, checking packing status should be done to safeguard part quality and also bring convenience to operator.2). The manners of packing and unloading during production process and shipment should be able to avoid error and mixing-loading effectively.4.10 Recovery measure requiredA. Real one to required oneIf real result can not meet requirement of quality/production capability, recovery measure should be taken to eliminate non-coherence.B. Real manufacture and quality planIf manufacture and quality plan are not coherent with real process, related changing should be done to make them coherence.DM/SGMW05.02B.02-2009（0/A）如果制造和质量计划同实际过程不相符，则应作相应的变动使两者达成一致。C.不一致性。如果按节拍生产中,发生的不符合未能被正常的PPAP控制方案识别,必须采取纠正方案计划(即预防错误或修改控制计划),并在PFMEA或工艺流程图中记录。4.11RunRate结论 按节拍生产一结束，应审查工作记录表以确保完整性，同时应作出决定：审查是否通过。可以有下述三种结果之一：通过，待定，不通过。A.通过1）定义：实际工装能力大于等于QTC且满足全部的要求。供应商证明其有足够能力满足持续的质量要求与产能要求。B.待定1） 定义：实际工装能力小于QTC但大于SGMW的精益生产节拍，或其生产过程控制有轻微不符合。2）要求的改进措施要求一个成文的纠正这些偏差的措施。至少，它应包括供应方负责人员名单，措施执行期限及考核。该计划的认定由SGMW按节拍生产及评价SQ工程师来完成，并在按节拍生产结束后两天之内完成。3）改进措施的检验检验改进措施是否顺利完成有几种不同的方法。例如，通过响应，对一批零件的检查或是参观某个工厂。通常不需要再作按节拍生产。一旦改进措施顺利地完成，SQ工程师将把按节拍生产的结果由待定改为通过。C.不通过1）定义：实际工装能力小于SGMW的精益生产节拍，或其生产过程控制有重大不符合。2）要求的改进措施要求有一个成文的改正这些偏差措施。至少，它应包括供应方负责人名单，措施执行期限及核实。该计划的认定由SGMW-SQE来完成，并在试运行结束后两天内完成。C. Non-coherence. If occurring of non-coherence can not be recognized by normal PPAP control program during RunRate, corrective program plan should be taken(preventing error or modifying control plan), recording in PFMEA or engineering flow chart.4.11RunRate resultAfter RunRate finished, checking record, at the same time to decide: pass or not. There are three results: pass, under-decided, no pass.A. PassDefinition: real tooling capability is above or equivalent with OTC and meets all requirements. Supplier proves that there is enough capability to meet continuous quality/production capability requirements. B. Pending1)Definition: real tooling capability is less QTC but above SGMWs LCR, or there is little non-coherent item.2). Improvement measure requiredRequiring a corrective measure document, at least, including supplier responsible person list, implementing time and assessment. The confirmation of this plan is done by SQE, finished within two days after RunRate completed.3). Checking of improvement measureThere are different methods to check improvement measure. Such as, through response to check parts or visit a factory. Normal RunRate does not need. Once improvement measure is completed successfully, SQE will change the result from under-decided to pass.C. No pass1). Definition: real tooling capability is less SGMWs LCR, or there is big non-coherence during production process control.2). Improvement measure requiredRequiring a corrective measure document, at least, including supplier responsible persons list, implementing time and assessment. The confirmation of this plan is done by SQE, finished within two days after RunRate completed.DM/SGMW05.02B.02-2009（0/A）3）改进措施的检验改进措施完成以后，供应商质量工程师将按照新的按节拍生产的要求来检验改进措施是否顺利地完成。4.12 供应商监督下的RunRate的附加要求4.12.1由供应商监督的RunRate日期安排应得到SQ工程师的认可。4.12.2由于SQ工程师不参加RunRate，因此供应商应该完成以下工作。1) 在完成RunRate以后24小时内，供应商应写出RunRate总结及工作表，将其交给SQ工程师，并对RunRate的结果提出某些建议。2)另外，如果发现有不一致的地方，供应商应制定并实施改进计划，并在完成RunRate两天内，将该信息通知SQ工程师。3) 根据供应商提供的信息，SQ工程师要做如下几项工作：a) 确定运行结果是通过，待定还是不通过b) 审批改进措施计划c) 确定是否需要再作RunRate d) 将上述审查结果与供应商交流讨论如果由供应商监督的按节拍生产结果不通过，则下一次的按节拍生产将由SQ工程师来监督完成。413 RunRate报告的发布与归档 SQE在实施RunRate审核后一周内将相关资料归档，并将按报价节拍生产报告向采购员与计划员发布。 414 产能调查 当公司需要提高产品产量，或供应商供货存在风险时，计划员负责调查已经量产产品的产能，并向SQ、采购员提供产能风险清单。415 产能提升 经过产能评估，供应商产能不能满足公司生产时，采购员负责采取措施提高供应商产能并跟踪进展。3). Checking of improvement measureAfter improvement measure finished, SQE will checking whether improvement measure completes or not successfully according to new RunRate requirement.4.12 Additional requirements of RunRate under supplier supervision4.12.1The date of RunRate should get SQE approval.4.12.2 For SQE absence of RunRate, supplier should complete the following works.1) After finished RunRate , within 24 hours, supplier should make RunRate summarization and work list, submitting it to SQD/SQE, giving some suggestions for RunRate result.2) Moreover, if non-coherence is founded, supplier should make and implement improvement plan, informing related information to SQE within 2 days after RunRate finished.3) Based on suppliers information, SQE should do the following works:a) Confirming the result, pass, under-decided or no pass.。b) Assessing improvement measure plan。c) Deciding whether it is necessary to do RunRate again or not.。d)Discussing the above result wi