传递特性的管理2013.

1、Pass Through Characteristics Pass Through Characteristics Management(Management(传递特性的管理）传递特性的管理） FoA Supplier DevelopmentFoA Supplier Development Ford Motor CompanyFord Motor Company What is Pass Through Characteristics? （什么是传递特性） Pass Through Characteristics are those internal and external supplied

2、 characteristics with potential fit or function issues that will not get 100% detected within a production assembly and test area (essentially anywhere verifiable within a plant.) Quality defects are therefore at risk of being “Passed Through” to our customers. 传递特性就是那些内部或者外部供应产品的特性的潜在的 或运行的问题在生产装配和

3、检测时（车间内部任何一个能 做验证的）没有被100%的识别，因此就存在质量缺陷被 “传递”到我们的客户那里的风险。 Pass Through Characteristic Management (传递特性的管理） Proper fit assures the mating part(s) will assemble properly when required, i.e. bores and bosses are present, located to print, with good threads, etc.配套件装配时需要 有适当的试验证明， Functionality assures

4、the component is 100% fully functional over its entire operating range, i.e. for a sensor, thermostat, or pump assembly purchased and installed in assembly. PTC SCOPE AT (PTC SCOPE AT (传递特性的定义范围）传递特性的定义范围） Analyze all T and TR final line stations for possible component, hardware, and installation fa

5、ilure modes and their current detection. Develop short and long-term corrective action plans for high-risk issues that may affect our customers.分析所有的T和TR由于可能存在的组成和 装配失败的样件以及当前的检测方式。针对可能影响到我 们的客户的高风险问题开展短期和长期的整改活动计划。 GOALGOAL（目标）（目标） Reduce T and TR warranty.减少T和TR的依据 Line Technicians 生产线上的技术人员 Proce

6、ss Engineers 工艺工程师 Controls Engineers管理工程师 Quality Engineers质量工程师 Quality Technicians质量技术员 Supplier Quality供应商的质量 Quality Manager质量经理 PROJECT TEAMPROJECT TEAM （攻关小组）（攻关小组） CONTROL PHASE SHORT TERM CORRECTIVE ACTIONS IMPROVE PHASE CONTROL PHASE LONG TERM CORRECTIVE ACTIONS IMPROVE PHASE ALLOCATE RESO

7、URCES IMPROVE PHASE PRIORITIZE FAILURE MODES ANALYZE PHASE ANALYZE FAILURE MODES MEASURE AND ANALYZE PHASES DATA ENTRY INTO EXCEL MATRIX MEASURE PHASE INDIVIDUAL STATION REVIEW MEASURE PHASE PTC PROCESS FLOWPTC PROCESS FLOW 传递特性的工艺流程传递特性的工艺流程 个别工位的评审（测量个别工位的评审（测量 阶段）阶段） 分析失效模式（测量和分析失效模式（测量和 分析阶段）分析阶

8、段） 判定失效模式的优先次判定失效模式的优先次 序（分析阶段）序（分析阶段） 分配资源（改进阶段）分配资源（改进阶段） 临时措施临时措施 （改进阶（改进阶 段）段） 永久性措施永久性措施 （改进阶段）（改进阶段） 控制阶段控制阶段 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ABC STATION: 40 Kit or Part Number / Descriptions1 Manual one-way clutch2 Wave Spring Can this component be INSTALLED IMPROPERLY? Yes NoYes No Ho

9、w? (ie.Upside Down, Backwards)Wrong HeightCocked Is there a method for DETECTING mis- assemblies? Yes No N/AYes No N/A Where or What Station? Missing is not detected at Sta.#43 or 47, wrong height is caught at #43 Sta. #40 If this component is LEFT OUT, can it be detected? Yes NoYes No Where or What

10、 Station?Sta. #43 Can a SIMILAR BUT WRONG component be installed? Yes NoYes No If so, can it be detected? Where? Can this component be installed in the WRONG MODEL? Yes NoYes No If so, can it be detected? Where? Can we install a DAMAGED component? Yes NoYes No If so, can it be detected? Where? Broke

11、n with parts inside detected at Sta.#47 Missing bearings and springs not. Sta. #43 Are there installation tools required? Yes NoYes No Are they used?Yes No N/AYes No N/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DE 3 Friction/Steel Plates4 Pressure Plate Yes NoYes No Steel on bottom ( upside down )Cock

12、ed/ not in grooves Yes No N/AYes No N/A No DetectionSta. #43 Yes NoYes No Sta. #43Sta. #43 Yes NoYes No Thick/Thin pressure plates have no known detection ( 4 vs. 5 plate design) Can detect thick/ thin at Sta. #43 Yes NoYes No Same as aboveSame as above Yes NoYes No Bent-Sta. #43, cracked plate-no d

13、etection Sta. #43 Yes NoYes No Yes No N/AYes No N/A INDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW 个别工位的评审个别工位的评审 INDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW 个别工位的评审个别工位的评审 DescriptionDescription Review each assembly & repair station 评审每一个装配 和返修工位 * Identify all parts installed 识别所有的安装部分

14、* Interview techs to determine what quality issues have been observed.技术部门确定已经出现 过的质量问题 * Review each station during part installation for process related quality issues.评审每一个和质量问 题有关的零部件装配工位 * Document model complexity,and review QPS sheets and visual factory for effects. * Run tests to verify assu

15、mptions运用测试手段去验 证假设 INDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW 个别工位的评审个别工位的评审 ResponsibleResponsible Core team:团队核心成员 * Quality Manager and Engineer 质量管理人员和工程师 * Manufacturing tech “expert” from area 生产技术员 * Controls Engineer操作工程师 CONTROL PHASE SHORT TERM CORRECTIVE ACTIONS IMPROVE PHASE CON

16、TROL PHASE LONG TERM CORRECTIVE ACTIONS IMPROVE PHASE ALLOCATE RESOURCES IMPROVE PHASE PRIORITIZE FAILURE MODES ANALYZE PHASE ANALYZE FAILURE MODES MEASURE AND ANALYZE PHASES DATA ENTRY INTO EXCEL MATRIX MEASURE PHASE INDIVIDUAL STATION REVIEW MEASURE PHASE PTC PROCESS FLOWPTC PROCESS FLOW 传递特性的工艺流程

17、传递特性的工艺流程 MATRIX: ASSESS RISK AND PRIORITIZEMATRIX: ASSESS RISK AND PRIORITIZE 矩阵图：矩阵图： FAILURE MODESFAILURE MODES 评估失效模式的风险和优先级评估失效模式的风险和优先级 HOW IS THIS FAILURE DETECTED? WHAT STATION? Error Proof In Process at station In Process within Team In Process After Team At Final Test or Leak Test Detectio

18、n Unknown (less than 100%)No Detection Current Controls, visual inspection, manual gage, auto gage, air test, etc. WHERE IS THIS FAILURE DETECTED? SEVERITY (S)OCCURRENCE (O)DETECTION (D) CRITICALITY (SxO) RPN (SxOxD)HISTORYCOMMENTSCORRECTIVE ACTION PLAN STATION PART NUMBER / PROCESS DESCRIPTIONPOTEN

19、TIAL FAILURE MODEPOTENTIAL FAILURE EFFECTS ARE HANDTOOLS REQUIRED?POTENTIAL CAUSE(S) Final Line station. What is this station supposed to do? Whats the part number(s)? How could this process go wrong? Examples: can the part be installed incorrectly, missing the part, damaged part, or wrong model? Wh

20、at is the impact to the customer? (next team, VO plant, end customer) This drives severity rating. Are handtools required for installation? Are they used?What could cause this to go wrong? Locate yellow pad incorrectly- shipping stap to transaxle Could result in an assembly plant returnY There are t

21、wo different locations for yellow pad depending on model- operator error Missing shipping strap YOperator Error Loose bolt that comes with shipping strap Could drop a transaxle resulting in APRYFaulty torque gun Stripped bolt , not part of shipping strap Could drop a transaxle resulting in APRYOpera

22、tor Error/Faulty torque gun Missing bolt that is not part of shipping strapCould result in dropped transaxle in-house causing scrap or repairYOperator Error 301 Auto rotate and indexIncomplete rotate and index Stop BuildNMechanical malfunction Missing kit Stop BuildNOperator Error Misoriented filter

23、 Stop BuildUnofficial toolOperator Error Damaged filter-cracked Contamination/ shift qualityUofficial toolSupplier Issue/installation problem Extra filter grommet from teardown Stop BuildUnofficial toolProcess Issue Break neck of filter Contamination/ shift qualityUnofficial toolOperator Error/or fa

24、ulty part Missing oil filter Contamination/ shift qualityUnofficial toolOperator Error Wrong model filter Unknown /no effectUnofficial toolOperator Error Broken clip on filter Unknown /no effectUnofficial toolSupplier Issue No rubber grommet on filter Stop Build wherever grommet falls outNSupplier I

25、ssue Fill tube grommet missing NOperator Issue Fill tube not seated completely Potential leakNOperator Issue Blocked end on fill tube grommet NSupplier Issue Fill tube grommet from General Motors Customer will not be impactedNSupplier Issue Mount kit on pallet and install filter and fill tube gromme

26、t ( black) 302 Install shipping strap with included bolt and loose bolt 300 MATRIX REVIEW-ASSESS CUSTOMER RISKMATRIX REVIEW-ASSESS CUSTOMER RISK DescriptionDescription Enter all data in matrix spreadsheet 将所有的资料数据输入矩阵图 * Failure modes determined from station reviews 评审工序存在的失效模式 * Potential cause of

27、failure 潜在的可能导致失效 * Categorize risk to customer (red, yellow, green) 对顾客冒的风险进行分类（红、黄、绿） * Enter all APRs NEs and other warranty 记录所有的APRs、NEs和其他的依据 * Rank risk to customer based on FMEA ranking with Severity, Occurrence and Detection * Prioritize where error proofing/controls are needed base on risk

28、 to customer (master rank) ResponsibleResponsible Core team plus: * Quality review engineer * Resident engineer * Process engineer Error Proof In Process at station In Process within Team In Process After Team At Final Test or Leak Test Detection Unknown (less than 100%)No Detection X X X X X X X X

29、X X X XX X X X X X X X X WHERE IS THIS FAILURE DETECTED? Red, Yellow, Green ChartRed, Yellow, Green Chart GreenGreenError Proofed or Caught in Sta. Caught in Team Caught in next team At Final Test or Air Test RedRedDetected Less than 100% No Detection SEVERITY (S) OCCURRE NCE (O) DETECTIO N (D) CRIT

30、ICALIT Y (SxO) RPN (SxOxD)KNOWN DEFECTHISTORYMASTER RANKCOMMENTS See Rating Sheet. 1rst priority. See Rating Sheet See Rating Sheet2nd priority.3rd priority. Defect found on APR, NE, or FQA History of NE, APRs, or FQAs associated with this failure mode? (Example: NE 11/12/00) Ranks issue 1-5 (5 most

31、 severe) based on FMEA Severity and History to determine resource allocation. 1 1 515 REAR SUN AND DRUM BUSHING WAS SEIZED TO THE FINAL DRIVE SUN GEARAPR 5/09/013 REAR SUN DRUM DIAMETER THAT MATES WITH OWC IS UNDERSIZED, OWC WILL NOT ENGAGE UNTIL HIGH RPMAPR 7/19/013 Inner race undersized. NO FORWAR

32、D APR 10/26/01 (4), APR 5/29/01 #169, APR 7/19/01, APR 7/19/014 1 1 1 1 1 1 1 2481 REVERSE CLUTCH SNAP RING GROOVE NOT MACHINED CORRECTLY. SNAP RING POPPED OUT. APR #16, APR 9/09/004 REVERSE CLUTCH EXTRA SET OF PLATES AND THE CUSHION SPRING WAS MISSINGAPR 8/28/003 FRONT CARRIER MISSING LUBE HOLESNE

33、2/01/20014 1 MISSING T13 NE 10/25/2000, NE 3/29/2001, NE 6/06/2001, NE 8/30/20015 Rank Risk To CustomerRank Risk To Customer FMEA Ranking Warranty Information Master Rank CONTROL PHASE SHORT TERM CORRECTIVE ACTIONS IMPROVE PHASE CONTROL PHASE LONG TERM CORRECTIVE ACTIONS IMPROVE PHASE ALLOCATE RESOU

34、RCES IMPROVE PHASE PRIORITIZE FAILURE MODES ANALYZE PHASE ANALYZE FAILURE MODES MEASURE AND ANALYZE PHASES DATA ENTRY INTO EXCEL MATRIX MEASURE PHASE INDIVIDUAL STATION REVIEW MEASURE PHASE PTC PROCESS FLOWPTC PROCESS FLOW CORRECTIVE ACTION PLANSCORRECTIVE ACTION PLANS Short Term ActionsShort Term A

35、ctions Create awareness of issue (not sustainable) * Install Pass-Thru signs at high risk stations describing the failure mode to the customer * Alert management to risk Temporary fixes/upgrades Long Term ActionsLong Term Actions Solicit ideas from manufacturing techs and engineers for error-proofin

36、g ideas In-Process Verification Stations (IPVs) CORRECTIVE ACTION PLANSCORRECTIVE ACTION PLANS Target date StatusSta Station Function ObjectivesProposalsBeforeAfter Cost To Implement (matl only) Potential Savings Master Risk(5 Highest Risk) 1/14/02Comp.109 Manual backup for Sta.# 107, which installs

37、 3 bolts into the chain cover to case and TSS model check. Eliminate missing or mistorqued bolts Comp. Used a control box with push buttons and a red/green light. The only information to the operator is O.K or not O.K to build-no info. on which bolt needs torque. No logic to prevent releasing the pa

38、llet without torque of any/all bolts or stud. Also, wrong torque may be achieved due to tray malfuction. Pallets cannot be released unless torque is achieved on any/all bolts. Installed 3 new green lights at top indicate which and how many bolts need to be torqued. Lights go out when achieved. Also

39、repaired socket to torque correlation. Included in costs for station # 13 If caught in- house results in 12 teardowns/yr or $1917.00/yr or APRs $20,400. Depends on degree of leak 2 Logged in 1/15/02 Complete and in tryout 350- 1/2 Sta. #350 Manual install chain cover plug, TSS plug, C-clip, (1) cool

40、er fitting plug and bulkhead plug Ensure Chain Cover plug is installed. Add elec. Eye after Sta. #350, just before index station to detect presence of plug Manual install of Chain Cover Plug. Plug is at back of transaxle, so is never seen visually for check of presence. Elec. Eye senses transaxle pr

41、esence first and then detects chain cover plug presence $1000. Estimate Multiple NE with estimated value of $12,500./yr 5 Low Trans. Fluid, water 12/20/01Comp.73 Backup station installs bolts for O.D. servo cover Ensure all 3 bolts installed and torqued prior to release of pallet Comp. Used a contro

42、l box with push buttons and 1 red light ( not O.K. to build) and 1 green light ( O.K. to build). A pallet could be released without achieving torque on any/all bolts. Added 3 torque lights and changed logic so that individual torques must be completed prior to pallet release Modified existing equipm

43、ent with materials in- house Inverted delta item-could result in APRs Rated 4 based on safety 8/1/01Comp.99 Install 4 accummulator springs and chain cover gasket Add detection for spring on side Comp. Spring could fall over and be detected as there, depending on orientation when on-side. Recalibrated