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1、TCF & PT Complexity Control Project1) J48 (Mazda 3)Add2) U204 & J14 (Escape & Tribute)3) C206 (Lynx/Laser)Step :#0#1#2#3#4#4Responsibility : StaffStaffStaffStaffStaffStaffSupvSupvSupvTLTLTLComplexity of ModelComplexity of PartsComplexity of OperationsAffecting MSQCDEAll Parts ListComplex
2、ity Parts ListComplexity Parts ListDetailed plan to improveTCF Responsibility : B/C & Control systemMP&L Responsibility : Sequence parts & ILVS COMPLEXITY ISSUE ANALYSIS AND IMPROVEMENT IDEAApplied FMEA Concept in identifying/prioritizing parts for improvementTCF & PT Complexity Cont
3、rol ProjectFormula for RPN (Risk Priority Number)RPN=Severity Rate x Occurrence Rate x Detection Rate=S x O x DRPN Number 1 = RPN = 1,000Complexity Parts Grouping CriteriaGroup A=201 = RPN = 1,000 ( First priority for improvement)Group B=101 = RPN = 200 ( Second priority for improvement)Group C=1 =
4、RPN = 100 ( Third priority for improvement)Failure Mode and Effect Analysis (FMEA) Evaluation CriteriaTCF & PT Complexity Control Project1) Severity Rate Evaluation CriteriaHazardous w/o warningHazardous w/ warningHighModerateLowNormalEffected to CustomerRating ScoreEffect* Safety or Government
5、regulation issue* Safety issue by w/o warningExternal CustomerInternal Customer by w/o warning* Safety or Government regulation issue * Safety issue by w/ warning by w/ warning* Function inoperable and Customer very* Can not drive or can not produce or dissatisfy stop line* Function of comfortable o
6、r convenience * Off line reprocess or more reprocess time items inoperable and Customer dissatisfy* Poor appearance or squeak & rattle* In line reprocess or noise issue8105731* No discernible effect* No effectTCF & PT Complexity Control Project2) Occurrence Rate Evaluation CriteriaVery highH
7、ighModerateLowVery lowMore than 10 itemsMore than or equal 1% : (10 / 1,000)105 - 10 0.5% : (5 / 1,000)840.1% : (1 / 1,000)63 0.05% : (0.5 / 1,000)320.01% : (0.1 / 1,000)1Likely failure rateProbabilityCriteriaRating ScoreNo. of Complexity parts (Kind of parts)TCF & PT Complexity Control Project3
8、) Detection Rate Evaluation CriteriaVery highHighModerateLowVery lowDetectionInspectionRating ScoreType or MethodDescriptionA : Error Proofed* Defect can not pass1B : Check by Measurement tools * Using GO / NO GO gauge or can detect by next3 processC : Check by Measurement tools* Using variable gaug
9、e6D : Check by Manual* Using visual check by eyes, hands and ears8E : No checking* No item to check10TCF & PT Complexity Control ProjectSAMPLE SHEET FOR SELECTION PROCESS:CRITERIA:GROUP A: 201 RPN 1000GROUP B: 101 RPN 200GROUP C: 0 RPN 100IMPROVEMENT IDEAS:Broadcast System, Sequential Delivery,
10、Marshalling ConceptTCF & PT Complexity Control ProjectTCF COMPLEXITY MANAGEMENT PROJECT:ModelStationTotal PartsParts w/ CompleLess: Parts alreadQty for ImprovementPriority ItemsPriority Items*Group AGroup BGroup CMP&LGroup AGroup BGroup CTCFGroup AGroup BGroup CU204/J143251159321813757064661
11、3713819120911557372572281154Trim 1&2285285100646421694505523716Trim 3&431924295146964727226642222305520Trim 5&623342297730014168080220616HL165181478447172282717010200218ED1608152108604091160409110000Final43116426719116927449839121314130153184J482346868109759273239266614711820356312163184
12、Trim 1&213113140423122739012273300Trim 3&417813165393901623240168150015Trim 5&6213213371734100000173410HL444401111001130038008ED8768142422031942203190000Final215861291048803157100467802751C2067980002731144126413160863142232198Trim 1&2136293112910000290227Trim 3&41997011047597646Trim 5&6141262020006402HL732904282904250000ED1075336017533
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