GP12初期流动管理课件

1、早期遏制-EPC-GP12-初期流动管理1 Global Purchasing and Supply Chain第1页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference GP12早期生产遏制第2页，共38页。OTSPilotPre-PilotSOPSTCAPQP 回顾现处阶段2-103-26第3页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference目标与目的期望的目标是使问题自然暴露,平稳地进入正常生产阶段。期望的目的是在早期生产阶段, 实施额外的检验控制手段，以保证在供应商现场发

2、现并解决质量问题。第4页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference1 什么是早期生产遏制？ 为什么需要早期生产遏制？ 何时使用早期生产遏制？ 如何执行早期生产遏制？第5页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference 什么是早期生产遏制？ 早期生产遏制是为了将供应商在开始生产和加速生产期间任何可能发生的质量问题，尽可能在供应商的生产现场而不是在客户处被很快地发现并解决，尽力避免在客户处或售后市场发生意外的质量事故。第6页，共38页。 为什么需要早期生产遏制？在生产初期

3、主机厂往往会遇到更多的质量问题，因为：供应商常实施不合格的APQP生产初期经验积累有限，经验欠缺如果制作一份试生产控制计划，常常缺乏认真思考及有效的验证过度自信，很难发现自身缺点有限的个人想象，有限的时间各种变化第7页，共38页。 何时适用早期生产遏制？ 在生产启动和加速阶段：适用于所有要求PPAP的供应商应用于所有要求PPAP的试生产和批量生产在原合同产能上增加能力、工装、设备、工艺过程、易地生产等过程的改变 第8页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference 实施时间段从Pilot开始至SOP后至少6个月或经SQE确认过的数量

4、 OTS装车出现过问题的 P-P生产阶段发生过质量问题的 检查项目务必经过SQE确认 派驻人员实施生产线陪伴生产第9页，共38页。 如何执行早期生产遏制？第10页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference供应商车间生产区域生产日期早期生产遏制审核区域信息板第11页，共38页。供应商的职责：制定并执行试生产控制计划：增加检测频率/抽样数量加强对分供方早期遏制附加检验/控制项目增加对标识（标签）的检查通过对已知缺陷的分析确认防错第12页，共38页。供应商的职责：明确责任人，评审小组成员须经过培训使用经确认的检查清单，对成品100%进

5、行检查（见附件）第13页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference第14页，共38页。实施100%审核以及象一级发运控制计划一样检查检查漏加工、漏装配漏孔、漏接头、漏零件、毛刺开发功能性检具检查工艺和物流上的失误磕碰伤、锈蚀、霉斑、杂物（清洁度）、混料回顾以前的PR&R和质量数据在试生产控制计划中，清晰地突出所有早期生产遏制要点，仔细记录发现的每个问题，并加以跟踪以便在正常生产中及时预防和观测同样的问题；问题零件样品。第15页，共38页。供应商的职责：在不影响正常生产的前提下，使用独立的评审区域对检查合格的零件贴绿色圆形标签 （

6、注：为了表明符合早期遏制的要求在每一发运标签上贴上一张由一指定的高级管理者代表签名的圆形绿色标贴，代表通常是指生产厂的质量经理 ）质量经理签名第16页，共38页。供应商的职责：每周对有效性进行评价，更新检查清单使用信息板明确任务、张贴作业指导书、质量数据及反应计划，对发生的所有问题，记录、分析并制定遏制措施，必要时更新作业指导书、控制计划、PFMEA第17页，共38页。第18页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch ConferencePareto Chart - Top 6 Issues0.0%0.5%1.0%1.5%2.0%2.5%3.0%P

7、roblem 1Problem 2Problem 3Problem 4Problem 5Problem 6period 1period 2period 3current period第19页，共38页。2008-4-2 荣威550 投产准备会议Roewe 550 Launch Conference第20页，共38页。 早期生产遏制退出准则：经一段时间运行后，若满足以下条件，供应商可退出早期生产遏制：没有不符合项，若已发现了不符合项客户关闭了PR&R控制计划得到验证零件数量或生产时间符合要求SQE批准第21页，共38页。第22页，共38页。早期生产遏制的好处：随着早期生产遏制的运行，生产现场发生

8、的问题会越来越少，从而有更好的供货质量表现带来一系列改进PFMEA 过程失效模式分析防错对生产工艺的深入理解对过程控制的深入理解避免一级/二级发运控制成本第23页，共38页。重点重申： 确定试生产控制计划是APQP的关键部分 对待早期生产遏制要如同控制发运遏制政策一样Failure Causes CS1第24页，共38页。 GP12检验PPM趋势图 _月份日期123456789101112131415产品名称批次投入数量（单）不良品数量PPM值日期161718192021222324252627282930产品名称批次投入数量（单）不良品数量PPM值第25页，共38页。AS 63 - 8D P

9、roblem Solving ProcessCONTAINMENT(Continuation of initial Response)AS 63 8D Problem Solving Process1 Form Team 2 Problem Description 3 Containment 4 Root Cause Analysis 5 Corrective Actions 6 Evaluate Result 8 Closure 7 Prevent RecurrencePurpose:Isolate the effects of the problem from customer until

10、 permanent corrective actions are implemented. Requirement:All locations potentially holding NC parts shall be identified on a Containment Worksheet. Containment shall be: Initiated quickly to minimize effects on customers. Verified by responsible management. Supported with documentation (floor plan

11、, parts flow diagram, sorting/rework instructions, results sheets, good and bad boundary photos. marking instructions OK-NOK, training records). Validated to ensure the actions are effective (HOW? Audit, Measurement System Analysis, GR&R, Kappa Test.) Evaluated for risk (HOW? Failure Modes and Effec

12、ts Analysis (FMEA) to prevent secondary problems. Containment WorksheetAS 412 Interim Inspection Plan第26页，共38页。AS 63 - 8D Problem Solving ProcessSORT / REWORKAS 63 8D Problem Solving Process第27页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection PlanPurpose: To prevent shipment of NC produc

13、ts to customers by applying a temporary enhanced inspection, To ensure a quick response back to the manufacturing process. Ensure any quality issues that may arise are quickly detected, contained & corrected at the manufacturing location. Verify the efficiency of actions implemented to assure qualit

14、y. Support the validation of the production and/or pre-launch control plan efficiency. Scope: The IIP activity shall be implemented when risks to ship non-conforming products have been identified. Applies to all Autoliv facilities Suppliers (includes supply chain). 第28页，共38页。AS 412 Interim Inspectio

15、n PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspection Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish IIP Station 8 Monitor / Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsTraining: All involved shall be trained

16、 for Interim Inspection Activity.Need for IIP: IIP shall be applied for pre-SOP builds Early Production Containment Service parts not been produced for some time Specific inspections required by customerNote! For external suppliers the content and extent of IIP shall be determined by Autoliv. The ne

17、ed for IIP should be evaluated After corrective action implementation After tooling/programming changes After product/process changes After extended line shut downs第29页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspectio

18、n Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish IIP Station 8 Monitor / Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsIdentify and document inspection items Define which items are to be inspected if not specific customer requests All items to be inspected sha

19、ll be documented. IIP items are to be included in the Control Plans or separate enhanced Control Plan. Inspection results shall be documented in the IIP Result Sheet (Appendix A or similar) or customer specific form.Plan IIP ActivityShall include definition of extent of IIP. The extent shall be base

20、d upon risk/reliability assessments, potential failure rates, production rates, etc. IIP must be implemented for a period of time or quantity of parts as specified by the customer or until the Production Control Plan has been validated. IIP Shall be 100% unless otherwise agreed with customer. Termin

21、ation criteria is ZERO NCs for the defined inspection items. If NC found, extent of inspection shall be re-evaluated. As a minimum, the originally defined number of parts shall be inspected in sequence and verified with zero non-conformances. In case that any other non-conformances are detected (ite

22、ms not included in the IIP), extended IIP activity shall be evaluated. 第30页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspection Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish IIP Station 8 Monitor /

23、Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsIdentify and mark parts:During all steps and at any time in the inspection process, the inspection status of the parts shall be easy to identify: Parts to be inspected Parts inspected and found to be conforming Parts inspected and fou

24、nd to be non-conforming The parts of different inspection status shall be kept segregated to eliminate mixing parts Autoliv facilities shall identify all verified conforming parts by marking according to local Autoliv procedure, if no specific customer requirement. External suppliers shall identify

25、all verified conforming parts by marking according to agreement with Autoliv using facilities. 第31页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspection Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish

26、IIP Station 8 Monitor / Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsEstablish IIP Station:IIP station should be off-line, separate and independent from the normal production process and located at the end of the process (after the last step). When off-line IIP is not practicabl

27、e, in-process containment stations could be approved by customer SQE (valid for suppliers to Autoliv) and documented. Inspection process is to be clearly identified with a well-defined containment box for nonconforming parts. The following locations need to be clearly marked: Parts to be inspected I

28、nspection area Parts inspected All IIP parts shall be provided FIFO to the inspection station 第32页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspection Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish I

29、IP Station 8 Monitor / Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsPerform Corrective Actions: IIP is not sorting but immediate detection of non-conformances. Detected non-conformances shall be reported immediately by the IIP Inspector. A reaction plan shall be documented in “8

30、D format” and include chain of responsibilities. Responsibility and timing for corrective action shall be noted in the IIP Result Sheet, Use Appendix A (or similar) Use customer specific form if specified For each corrective action “Lessons Learned” should be considered. The Project and/or Productio

31、n Management is responsible to monitor and evaluate the IIP result on a regular basis. 第33页，共38页。AS 412 Interim Inspection PlanAS 412Interim Inspection Plan1 Training 2 Determine need for IIP 3 Identify & Document Inspection Items 4 Plan Closure Criteria 5 Identify and mark parts6 Establish IIP Stat

32、ion 8 Monitor / Close IIP Initiate LL 7 Perform corrective Actions on IIP findingsMonitor Activity, IIP Closure, Lessons Learnt:IIP is a temporary activity. IIP activity shall not be terminated before the criteria have been fulfilled (defined number of parts inspected with 0 defects). IIP activity r

33、equired by Autoliv at external suppliers shall not be closed before a written approval from Autoliv has been received. IIP results and experiences shall be used as input to Lessons Learned and/or to review and update existing Work Instructions, Control Plans, FMEAs and other relevant documents. 第34页

34、，共38页。The Journey MapProblem DescriptionD2Form the TeamD1D3Root Cause AnalysisD4Evaluate resultsD6Corrective ActionsD5Official ClosureD8Preventive ActionsD7Problem Solving ProcessIntroductionPurposeScope8D FormInitial ResponseAS62 Category A Problem Management AS63IS/ISNOTAS412 Interim Inspection Pl

35、anContainment DifferencesChnagesTheoriesDrill WideDrill DeepAS65 Lessons LearntError Proofing VerificationAS 53 Quality AlertData AnalysisAS105 PFMEA Team Feasability Study & Contract ReviewAS52 Product Characteristics Classification 8D ProcessProblem StatementContainment SheetCC/SC ListJourney Map第

36、35页，共38页。AS 63 - 8D Problem Solving ProcessROOT CAUSE ANALYSISAS 63 8D Problem Solving Process1 Form Team 2 Problem Description 3 Containment 4 Root Cause Analysis 5 Corrective Actions 6 Evaluate Result 8 Closure 7 Prevent RecurrencePurpose: Determine the technical and systemic cause(s) for the prob

37、lem occurring and Why did it escape (not detected). Requirement:Analyze from the following perspectives: Technical: Causes directly related to the technical aspects of the problem and not detected (may include physical, chemical, electrical, mechanical, or optical properties). Technical root cause a

38、nalysis starts with the problem statement and ends with defining an identifiable cause(s) for: Why the problem occurred Why the problem was not detected (escaped) Systemic: Causes linked to the business or management process that allowed the technical cause(s) to exist - addressed in Step 7 Preventi

39、on). Also referred to as Drill Deep. AS52 Product Characteristics Classification第36页，共38页。NCM Containment Check List1.What is the problem description? a.Do we have the non-conforming part? b.Do we have a picture? c.Can we confirm the problem?2.What parts and which lots are suspect? a.Stop production

40、 until improved inspecion method is in place. b.Find and contain all suspect parts and lots. c.What will be done with parts at customer? (return or inspect at customer) d.What will be done with parts in transit?3.Define improved inspection method and/or rate.4.Verify inspection method can identify good and bad parts.