福特汽车-品质系统介绍.ppt

1 品質系統 天马行空官方博客 2 Agenda QualitySystem TotalQualityExcellence CompanyPolicyLetterNo 1 BriefHistoryofFLHQualityManagementQualityArrow QualityisJob 1 QS 9000 ISO14001System QualityOperatingSystemTGWReduction VRT SAQTGR KanoModel 3 1 FordTotalQualityExcellence CompanyPolicyLetterNo 1Qualityisdefinedbythecustomer thecustomerwantsproductsandservicesthat throughouttheirlife meethisorherneedsandexpectationsatacostthatrepresentsvalue 品質是由顧客所定義Qualityexcellencecanbestbeachievedbypreventingproblemsratherthanbydetectingandcorrectingthemaftertheyoccur 達成卓越的品質必須注重在問題的預防AllworkthatisdonebyCompanyemployees suppliers anddealersispartofaprocessthatcreatesaproductorserviceforacustomer Eachpersoncaninfluencesomepartofthatprocessand therefore affectthequalityofitsoutputandtheultimatecustomers satisfactionwithourproductsandservices 每個公司員工對品質及最終的顧客滿意都有貢獻 4 FordTotalQualityExcellence Sustainedqualityexcellencerequirescontinuousprocessimprovement Thismeans regardlessofhowgoodpresentperformancemaybe itcanbecomeevenbetter 維持卓越的品質必須持續作流程的改善Peopleprovidetheintelligenceandgeneratetheactionsthatarenecessarytorealizetheseimprovements 改善的智識及行動來自人Eachemployeeisacustomerforworkdonebyotheremployeesorsuppliers witharighttoexpectgoodworkfromothersandanobligationtocontributeworkofhighcalibertothosewho inturn arehisorhercustomers 後工程即是顧客 不接收不良 不傳送不良 Chairmanoftheboard 口徑 水準 程度 天马行空官方博客 5 2 福特六和品質管理之發展演進1 4 1986 Introduction Localization引入福特原廠產品開發標準如WorldwideDesignRequirement及WorldwideProductAcceptanceSpecifications 品管部門轄AP QC 裝配及製造品管 及QA 品保 對供應商推行福特Q 101全球性品質管理規範 廠內推動UPAS UniformProductAssessmentSystem 產品品質統一稽核系統 1984年起正式推動品管圈 QCC 活動 Achievement1986年正式通過加拿大法規標準 成為台灣第一個成車外銷的廠商 6 福特六和品質管理之發展演進2 4 1986 1991Self development Expansion1988年起福特六和採購部門設立專責單位 全力輔導零組件廠商提昇品質 導入先期品質規劃觀念APQP AdvancedProductQualityPlanning 及品質基礎教育如團隊導向問題解決手法 8D TeamOrientedProblemSolving8Disciplines Achievement全球福特總部品質評鑑人員評定金全壘打車系為全球同車系品質之冠 1990年引擎鑄造廠獲頒象徵福特品質最高榮譽的Q1獎1991年裝配廠獲頒象徵福特品質最高榮譽的Q1獎 天马行空官方博客 7 福特六和品質管理之發展演進3 4 1991 1996Upgrading Standardization建置QIS QualityInformationSystem 系統 在生產線上直接反應品質問題並於第一時間即時改善 1994年導入顧客導向式車輛評價系統Nova C NewOverallVehicleAssessment Customer 1996年起導入QOS品質運行系統 Achievement1994年獲得Q1再次驗證肯定 1996年成為國內首家汽車業者通過ISO 9001國際標準驗證 得到世界品質系統標準的肯定 8 福特六和品質管理之發展演進4 4 1996 nowTransformation Internationalization1996年起開始推動福特生產系統 FPS FordProductionSystem 2000年起廠內開始推動SixSigma品質改善專案活動 2002年導入新版QOS品質運作系統及FCPA消費者導向產品稽核系統 FordConsumerProductAudit Achievement1997年榮獲國際環境管理系統ISO14001驗證 1998年獲得汽車業國際品質系統QS 9000驗證肯定 2001年福特六和引擎廠新人圈榮獲福特總部CDQA CustomerDrivenQualityAward 總裁獎 2001及2002年獲得福特FPS全球評比最高層級之榮耀 2002年獲得ISO9001 QS9000及ISO14001整合系統驗證 9 3 Ford QualityisJob 1 Arrow Define Measure Analyze Improve ControlDesignfor6 SigmaCommonProblemSolvingLanguage ToolsHighQuality HighVelocityImprovementsinBusinessResults 9LeadershipPrinciplesRewardandRecognitionTrainingandFeedbackPartnershipwithUnions DealersandSuppliers VehicleQuality High LowTime In Service CustomerSatisfactionTGWWarrantyResidualValueSales ServiceSatisfactionEliminationofWaste Q1 QualityIsJob 1 QUALITYLEADERSHIPINITIATIVEEngageAllEmployees 6 SIGMADataDrivenDecisionMaking QUALITYOPERATINGSYSTEMPerformancetoStandards DriveProcess DeliverResults Plan Do Check Act FordMotorCompanyQOS Product Creation Sales ServiceCertificationSystem FPDS Future Customers Current Customers Orderto Delivery Suppliers Launch CurrentModelFPS 10 QualityLeadershipInitiative 9LeadershipPrinciplesValue QualityisJobOne Itisourresponsibility ourjobsecurityandourfuture Attitude ZeroDefectMindset Don ttakeit don tmakeitanddon tpassiton Culture Arelentlessdailyfocusonquality Training Ensuringpeoplehavethenecessaryskillsandtoolstodotheirjobs Accountability Effectivemeasurementandfeedbackforcontinuousimprovement accountabilityandperformancemetrics Cooperation Helpsuppliershelpussucceed JointLeadershipCommitment EffectiveQualityLeadershipatalllevels DisciplinedExecution Changesnevercompromisequality EnterprisingApproach Thecustomerisoursharedconcern 11 4 ISO9001 QS 9000及ISO14001整合系統 ISO9001 96 QS 9000 98 內部稽核 2times yearISO14001 97 內部稽核 1times yearISO9001 96 QS 9000 98 外部稽核 1times yearISO14001 97 外部稽核 1times year2systems 2setsofprocedures 30 overlap Integration整合程序書 整併減少30 重疊 建立整合內部網站以e化管理 減少紙張及增進效率 整合內部稽核 2times year整合外部稽核 1times year不僅整合集中內部資源人力 連外部稽核費用都可降低 NextStep轉換QS 9000至TS16949ISO18000 12 QOS QualityOperatingSystem品質運行系統 由福特總部發行之一致性生產品質運行系統 涵蓋所有生產廠區 車身 塗裝 完成車 新車驗放部 之要求 以ISO9001 QS9000為基礎 連結FPS Six sigma FPDS等企業之組織系統工具 目的在推行一致性的福特組裝廠最佳品質系統 以達到監控並持續改善新車的出廠品質 共27個QOS單元要求 62個評分項目 R Y G 13 QOS QualityOperatingSystem TimeandDataManagementRequiredmeetingscheduledatdesignatedfrequenciestocommunicateandevaluatePlantQualitySystemOutput total18meetings Atoolforplantstocommunicateinformationbacktothebasedepartmentsaddressingcustomerconcerns 14 ConvoyYardReview 每日品質會議 ReviewVehicleQuality ReviewConcern Actions 15 QOS QualityOperatingSystem VariabilityReductionVRT VFGastructuredprocesstodrivequalityimprovementfocusedoncustomerexpectations Itensuresthatplantcontrollablecustomerconcernsareacteduponquicklyandpermanently ToolVerificationensureregularinspectionandcertificationofplanttestequipment tools andgagesisbeingconductedperthecorporateguidelines 16 QOS QualityOperatingSystem IncomingMaterialmeasuresplanteffectivenessinimprovingandcontrollingthequalityofmaterialenteringtheplant Aworkingrelationshipwiththeplant suppliers purchasing andotherkeyactivitiesisessentialforqualityimprovement ProcessControl Build InspectionProcessidentifyrequirementsforcontrollingspecificoperationsandinspections Thoserequirementscomefrompracticesand orproceduresthataretheinfrastructureoftheassemblyVehicleOperationsQOS CC s SC s CTQ 17 QOS QualityOperatingSystem RepairSystemaformalizedrepairprocessassuringthepreparation repair material andtooling equipmentusedareinaccordancewithestablished approvedrepairstandards QualityAcceptanceCriteriaestablishedlevelofstandardstobeusedforinspection thecriteriamustthenbecascadedthroughouttheplants toassurethateveryinspection check testisperformedtothesamestandardsthroughouttheentiresystem 18 QOS QualityOperatingSystem WeldSurveillanceInprocesschecksofweldedassemblies whencoupledwithperiodicteardownofweldedbodiesandassemblies provideapositivemethodofdeterminingweldquality ensurethatallweldproductionoperationsarebeingeffectivelyperformed DimensionalControlacomprehensivebodysheetmetalconstructionstrategythattakesintoaccountallkeybodysheetmetalcomponentsandtheirrelationshipstoeachotherandbodylines toidentify track andreducedimensionalvariationfromcomponenttocomponentandvehicletovehicle 19 QOS QualityOperatingSystem TorqueAssurancetoassurethatFasteningControlSystemimplementationisstandardizedandeffectiveacrossallassemblyplants FCPAtoidentifymanufacturingimperfectionsthroughaseriesofaStatic Dynamic Full combinationofstatic dynamic auditsoffinishedunits 使顧客導向所發現的問題直接回饋到生產線 以求獲得迅速對策及改善方案 20 FCPA FordConsumerProductAudit 福特消費性產品評價 是完成車的稽核流程 用以指出產品的問題及潛在可能造成顧客 消費者不滿意的地方 採用全球一致的車輛作業評價流程於所有量產車種 驅使製造精緻工藝的提昇以期在車輛交貨與初期服務時達成高度顧客滿意度 強調顧客 消費者的回饋及反應 強調會影響顧客滿意度的設計意圖及製程限制 使用顧客 消費者導向的評分系統CCRS 稽核時間約為每輛車三個小時 21 FCPA FordConsumerProductAudit 福特消費性產品評價 檢查項目包括 內外部裝配情形塗裝情形電機及各部機械功能引擎室及底盤漏水 風音及異音情形車輛動態及道路駕駛 22 CCRS CustomerConcernRatingSystem 顧客導向式評分系統 23 QOS QualityOperatingSystem WindNoiseevaluatesthenoiseacceptabilityofvehicles aswouldanaveragecustomer Duringthedriveevaluation thetrainedauditorlistenswithanunaidedearandrateswindnoiseperformance onascalefrom1to10 usingthe WindNoiseRatingCriteria formSqueak Rattletoeffectivelydetectassemblyorcomponentsqueakandrattleconcernspriortotheunitsleavingtheplant 24 Squeak RattleRoadTest Squeak RattleTestTrackUpgrade Length 100ftUniformViennaBlock 100ftSteppedViennaBlockWidth 104 40 40 24 100 UniformViennaBlock SteppedViennaBlock 25 Squeak RattleRoadTest UniformViennaBlock SteppedViennaBlock 1 StepinHeight 26 QOS QualityOperatingSystem Water 20minutesoak pre determinedcriticalwaterentryareas whichmaynotshowupduringthenormal100 productionwatertest This20 Minutetestisaverificationofprocess designactionstakentocorrectanyrepetitivewaterleakconcerns FinishVehicleEvaluationProgram M 10Program adailyevaluationofcompletedproductionlevelvehicles Theseunitsaredrivenover night overtheroadbyauthorizedplantpersonnel Itsfunctionistoidentifyissuesearlyanddevelopimmediateprocess productcontainmentandimprovementactions 27 QOS QualityOperatingSystem PIC ProductInformationCenter includesexternalandinternalqualityindicators givingtheplantsastandardizedmeansofdisplayingqualitydata description andvisualrepresentation PICallowsinformationflowtopresentqualityefforts whichfactuallydemonstrateperformanceovertime ControlPoint TipLevelutilizeseithercurrentoraddedinspectionasatooltodriveIn Station Process Control ISPC andtofacilitatecommunicationwiththeBaseOperatortodevelopcountermeasurestocontainqualityconcernswithinthezone 28 QOS QualityOperatingSystem Ultrasonicamethodtoevaluatewindnoise Theprocessisperformedbyattachinganultrasonictonegeneratortothecenterofthewindshieldandmovingadetectioninstrumentaroundthepotentialleakareas glassruns windshield dooropenings etc WindNoiseleaksaremeasuredindecibels dB andcomparedtopredeterminedlimits Predeterminedlimitsareestablishedbycorrelationofleaksandcustomerdata AirLeakageTestanevaluationofsealedpaintedvehiclebodiesandcompletedproductionvehiclesforobjectivemeasurementsofbodyairleakage 29 UltrasonicTestEquipment 30 QOS總表 1 3 31 QOS總表 2 3 32 QOS總表 3 3 33 QOSFAPAssessmentResult FLHelementlevel 2 75