夹具重复性试验转孔TOMOANAEnglish-Chinese课件

1、全员参与标准化作业持续改进缩短制造周期造入质量通用-全球制造系统Principle: Built In Quality 原则： 造入质量Element: 14 Manufacturing Process Validation 元素： 14个制造工艺验证GM-GMS Operating Tool 通用-全球制造系统操作工具14.5 TOMOANA仅供通用内部使用 2010年8月全员参与标准化作业持续改进缩短制造周期造入质量通用-全球制造Copyright Notice版权声明 August, 2000 General Motors Corporation (GM). 2000年8月，通用汽车公司

2、All rights reserved. 版权所有No part of this material may be reproduced in any form or by any method (photocopy, microfilm, digital, etc.) without the written permission of General Motors Corporation, educational purposes included.本资料中的任何部分在没有通用汽车公司书面许可证的情况下不得以任何形式或任何方式（复印，缩微拍摄，数码拍照等等）复制，包括教育用途。Copyrigh

3、t NoticeScope 范围This operating tool defines roles & responsibilities for TOMOANA activities applied to all GM South America and African Assembly Plants.本操作工具为应用于所有通用南美和非洲的组装工厂的TOMOANA活动定义了角色和责任。Definition 定义TOMOANA is a method to ensure the process repeatability in welding fixtures for welded subass

4、emblies and reduce dimensional variation in Body-in-white build up process.TOMOANA是一种确认焊接夹具工艺复现性和在白车身制造过程中减少尺寸变化的方法。Purpose 目的 Support GM-GMS principle : Built-in-Quality; 支持通用-全球制造系统原则：制造质量； Support deliverable execution as required in MQRR ( Manufacturing Quality Readiness Review); 支持根据MQRR（制造质量准备

5、评审）要求的交付运行； Define the standardized process for validation and control and verification ofstability for welding fixture. 确定验证和控制标准化程序和焊接夹具稳定性验证。Scope 范围Responsibility 责任The Manufacturing Engineering ( Dimensional Engineering) is the process owner for implementation of this process during the Launch.

6、 The Body Shop Manager is the process owner for execution of this procedure in regular production. 工艺（尺寸工程师）是负责在产品启动过程中实施流程。车身车间经理是在量产时运行这个过程的负责人。Introduction TOMOANA is a tool applied to ensure the dimensional repeatability in welded subassemblies and it is effective preventive tool to support the

7、Quality Motto; Do not accept, build and ship Defects.TOMOANA是适用于焊接总成部件时相关尺寸的确认，是一种预防性的工具，它是有效来支持质量格言的预防工具：绝不接受，制造，传递缺陷。It is a methodology applied to reduce dimensional variation in Body Shop and continuously improve the Dimensional Quality of BIW and Assemblies ( A rate and 6 Sigma).它是适用于在车身车间减少尺寸变

8、化和持续改进白车身和装配的尺寸质量的方法论（等级A和6 Sigma）。Do not Defects绝不接受制造传递缺陷Responsibility 责任Do not Enablers 要素Standard parts; 标准件；Welding fixtures; 焊接夹具；Measurement system ( Gauge Pass-no-Pass); 测量系统（测量及格不及格）Standardize Work; 标准化工作；Records ( validation and daily record); 记录（确认及日记录）Enablers 要素TOMOANA: PDCA cycle6. P

9、roblem Solving; 7. Effectiveness & Efficiency. 1. TOMOANA planning; 2. TOMOANA validation 5. Alarm & Escalation; 3. Daily Control ( Production core)4. Weekly Monitoring ( Quality core)PDCA 周期计划验证问题解决效力与效率报警升级日常管理（生产核心）周监督（质量核心）TOMOANA: PDCA cycle6. Problem 1- Planning: Launch process 计划：流程启动 The TOM

10、OANA must be developed for all the in the Body Shop Process. Geo-stations means any sub-assembled parts that impact the geometry of the vehicle and still can be applicable for any sub-assembled part that is causing downstream quality issues (noise, water intrusion, fits) or that is known as critical

11、. TOMOANA 必须在车身车间程序中为所有 GEO-STATIONS 发展。Geo-stations 意味着任何影响车辆几何学的初级装配零件并且仍然适用于引起质量问题（异响，水浸，匹配问题）或者是危险的初级装配零件。 During the Body Shop Readiness this tool should be initiated together with Iterative matching activities ( 53 weeks prior to SORP) and achieve 100% approved by End of MVBns. 在车身车间准备期间，此工具应该

12、和反复的匹配活动一起启动（在SORP阶段53周前）并且在MVBns结束时得到100%通过。TOMOANA Timeline 时间轴技术规格检验感觉特性设计研究生产装配文件下发100%通过第一圈1- Planning: Launch process 计1- Planning: Current process 计划：目前工艺TOMOANA is also applied in dimensional continuous improvement process for current programs. Based on the GCA, Verification Station and CMM

13、feedbacks TOMOANA can support a method to eliminate the variability existing on welded subassembly fixture after the root caused analyzed.TOMOANA也适用于目前项目的空间持续改进程序。根据GCA、检验站和CMM回馈，TOMOAMA可以在分析根本原因之后，支持消除存在于焊接部件夹具变异性的方式。偏差1- Planning: Current process TOMOANA Planning 计划 The TOMOANA must have a deploym

14、ent plan developed, which includes four key attributes (4Ms) to ensure the adequate execution level from the TOMOANA activities:TOMOANA必须发展部署计划，包括4个保证TOMOANA行为适当运行水平的关键属性：1.Man: 人员 1.1 Define team to perform the validation process; 明确小组实施验证程序； Dimensional expert should lead or support team; 空间专家应该领导

15、或支持小组； 1.2 Define by whom the Daily Control will be conducted; 明确谁来执行日常管理； 1.3 Develop training for the different levels of people involvement and deploy it; 为各阶层的参与人员开展并部署培训；2. Material: 材料 2.1 Define how standard parts will be available; 明确标准件如何可用； 2.2 Define where and how the standard parts will

16、be storage, include who is make the supports; 明确标准件应该如何存放并存放在哪里，包括谁来支持； 2.3 Define when the standard parts should be exchanged ( date); 明确何时交换标准件（日期）；3. Machine: 机器 3.1 Define which welding fixture will be implemented and when; 明确适用哪个焊接夹具，何时适用；4. Method: 方案 4.1 Deploy measurement process and pin gag

17、e must be enough for all the areas; 部署测量程序，全部地区的定位销板必须充足； 4.2 Develop Standardized Work ( STS/TIS) and apply JIT. 开展标准化工作（STS/TIS）并且应用JIT.TOMOANA Planning 计划1.Man: 人员 1. TOMOANA Planning 计划Measurement System; 测量系统Gauges in 3.0 - 3.5 and 4.0 mm are applied to measure the diameters of holes previously

18、 identified.3.0-3.5mm和4.0mm的测量仪器应用于以前确定的孔的直径。测量仪器测量系统1. TOMOANA Planning 计划Measurem验证流程：TOMOANA验证标记并打4.0mm的孔打开夹钳，移动零件，放下零件，关闭夹钳测量孔的直径并记录每10个重复项目3和4结果是依据标准的吗？分析并做调整。回到项目1阶段1阶段2打开夹钳，移动零件，放下零件，夹紧夹钳测量孔的直径并记录每5个重复项目7和8结果是依据标准的吗？打开夹钳，移动零件，放下零件，关闭夹钳测量孔的直径并记录阶段3结果是依据标准的吗？结束验证。存档文件验证流程：TOMOANA验证标记并打4.0mm的孔打开

19、夹钳，2- Validation Process;验证程序The initial validation process must be conducted in four steps as follows:最初的验证程序必须按照以下四个步骤执行：3.1 Define hole positions and make the holes; 确定孔位并打孔；3.2 Repeatability of the welding fixture clamping; 焊接夹具钳位重复定位；3.3 Repeatability with “cold” welding; 用冷焊重复定位；3.4 Study in w

20、elded substructure; 研究焊接底层结构；During the validation process is important to mention;验证程序的重点：The same subassembly parts will be used for all phase ( I, II and III); 相同组件应该应用于各个阶段（ I, II 和 III ）After runs process validation the welded subassemblies shall be disposal for scrap or if no damage was done,

21、can be used as normal production parts, as long product engineering approves. 运行验证程序之后，焊接组件应该处理废料，或者如果没有损坏，可以作为正常生产零件使用，只要产品工程批准。2- Validation Process;验证程序2- Validation Process; 验证程序3.1 Define hole positions and make the holes; 确定孔位并打孔；Its the first step for the Tomoana validation. Ensure that weldi

22、ng fixture is OK and there is not potential variation related to fixtures. Make sure that all holes defined are able to identify any variation on subassembly process and:这是Tomoana验证的第一步。确保焊接夹具没问题，并且没有涉及到夹具的潜在变化。确保所有确定的孔都能够在分部装配过程中鉴定任何变化并且： analyze all the variation to be studied ( x, y and z axles)

23、between two or more parts; 分析全部要研究的两个或多个零件之间的变化（x, y和z轴）； define a minimum of two points that guarantee this variation; 确定最小的保证这个变化的两点； define the location of the perforation considering: 确定穿孔位置时考虑到： must not coincide with welding spot position; 一定不要和焊点位置一致； must be accessible for measuring on the w

24、elding fixture; 一定在焊接夹具上能够测量； eliminate the burrs on the holes; 去除孔边的毛刺； identify the holes with numbers; 确定孔的编号；见附件A2- Validation Process; 验证程序3.1确定孔位并打孔（继续部分）例如：基准面注意孔的质量！穿孔直径：4mm确定孔位并打孔（继续部分）例如：基准面注意孔的质量！穿孔直径确定孔位和打孔；（继续部分）确保零件之间的正确匹配内部和外部部件联合区域右边左边确定零件上的部件联合区域以确保适当的穿孔确定孔位和打孔；（继续部分）确保零件之间的正确匹配内部和外

25、部2.2 Repeatability of Welding Fixtures Clamping (phase I) 焊接夹具钳位的重复性（第一阶段）Once made the holes the repeatability process on welding fixtures clamping is initiated (phase I). If the Clamping does not able to provide repeatability the welding fixture has to be adjusted or/and re-define new holes positi

26、ons. The previous step redone.一旦打孔了，焊接夹具钳位的重复性程序就启动了（第一阶段）。如果钳位不能提供重复性，必须调整焊接夹具或者重新确定孔位。然后重复前面的步骤。2.2.1 Perform Clamping Process; 执行夹紧步骤Repeat 10 times the following sequence; 重复10次以下序列；a) remove pieces and relocate them; 移动并重新安置零件；b) clamp the fixture; 夹紧夹具；c) measure the diameter of the holes and

27、register ( appendix B).测量孔的直径并记录下来（附件B）。 需要测量的孔见附件B2.2 Repeatability of Welding FFor the Validation Process is recommended to validate with every holes diameter minor than 0.5mm. Conditional accept should be avoided to not impact the next phases of the process.建议的验证程序检验每个孔的直径小于0.5mm。有条件的接受应避免影响程序的下一

28、阶段。焊接夹具钳位的重复性（第一阶段）评价夹紧步骤；验证程序的标准（一、二、三阶段）接受：直径变化：小于0.5mm有条件的接受：直径变化：0.5到1.0mm拒绝：直径变化：大于1.0mmFor the Validation Process is 2.3 Repeatability with “cold”welding; 冷焊的重复性This step will ensure whatever variation between welding fixtures and welding process ( phase II) does not occur. 这一步骤确保焊接夹具和焊接程序间是否存

29、在变化（第二阶段）。2.3.1 Apply Cold welding;应用冷焊-Repeat 5 times the following sequence:重复5次以下序列：a) remove pieces and relocate them;移动并重新安置零件；b) Apply cold welding ( with pressure and without current);应用冷焊（用压力不用电流）c) measure the diameter of the holes and register ( appendix B)测量孔的直径并记录（附件B）2.3.2 Assess Cold w

30、elding process; 评价冷焊工艺；If cold welding process is acceptable under Validation criteria move for next phase. If not, understand welding fixture variation and eliminate it. Then start the validation process again (phase I). 如果在验证标准下冷焊工艺是可接受的就进行下一阶段。如果不可接受，了解焊接夹具变化并且消除。然后再次开始验证程序（第一阶段）。焊钳冷点焊见附件B2.3 Rep

31、eatability with “cold”w2.4 Study in welded subassemblies; 研究焊接组件This is the last step of TOMOANA Validation with welded subassemblies ( phase III).这是焊接组件TOMOANA验证的最后一步。2.4.1 Welding; 焊接Repeat once the following sequence: 重复一次以下序列：remove pieces and relocate them; 移动并切重新安置零件；b) clamping the welding fi

32、xtures;夹紧焊接夹具；c) weld the parts; 焊接零件；d) measure the diameter of the holes and register ( appendix B).测量孔的直径并做记录（附件B）。 2.4.2 Assess Welding Process; If welding process is acceptable under Validation criteria the phase is over and the documents can be archived. If not, understand welding fixture vari

33、ation and eliminate it. Then start the validation process again (phase I). 如果焊接工艺在验证标准下是可以接受的，此阶段结束并且文件可以归档。如果不是，了解焊接夹具变化并消除。然后再次开始验证程序（第一阶段）。焊钳点焊见附件B2.4 Study in welded subassembl2- Validation Process;验证程序2.5- Re-Validation process;再验证程序 The TOMOANA process must be re-validated always that: TOMOANA

34、程序必须再次验证：- Change the standard parts for:改变标准件为： -Product changes;产品改变 -Welding fixture intervention/ change;焊接夹具介入/改变-Any transfer weld fixtures: 焊接夹具转移： - Movement between areas;区域之间移动 - Plant to Plant公厂之间移动When the standard parts are changed due:当更改标准件由于： -Premature abrasion of the holes;孔的前期磨损 -

35、Damaged;损坏 - Corrosion points;锈蚀点There is no need to re-validated the TOMOANA, only change the parts.没有必要再验证TOMOANA，只是改变零件即可。2- Validation Process;验证程序3- Daily control:日常管理 Production team is accountable for execute the TOMOANA daily control and maintain Standard Part in capable condition. 生产小组在允许条件

36、下负责允许TOMOANA日常管理并威胁标准件。3.1. Standard Part;标准件 After TOMOANA process approved a new subassembly part shall be created and available as Standard Part. 在TOMOANA程序通过后，应造新的组件并且可以作为标准件使用。 Standard Part has to follow the characteristics below: 标准件必须符合以下特点： keep the same figure as the holes and positions th

37、at used during the validation process ( step 2 of flow); 保证在验证程序中使用的孔和位置一致（步骤2的流程）； Recommended to submit in Elpo Process; If the decision is submit in Elpo the parts have to be processed prior to holes perforated. If the decision is not Elpo process the parts have to be applied with protective oil

38、in order to avoid premature corrosion; 建议在电泳工艺中提交；如果在电泳过程中提交决定，在打孔之前必须加工零件。如果不在电泳过程中做决定，在零件上必须涂上防护油以避免前期锈蚀。3- Daily control:日常管理3.1. Standard Part; ( continuation) 标准件（继续部分）All the measurable points identified; 确定所有测量点Part identification; 确认零件allocate in properly area; 在适当区域分配validate date & exchang

39、e part definition ( without: damages, corrosion points, premature abrasion of the holes). 检验日期& 交换零件明确（没有：损坏、锈蚀点、孔的前期磨损）见附件E3.1. Standard Part; ( continua3- Daily control: 日常管理3.2 Execution; 执行 The TOMOANA must be execute in beginning of the each shift. TOMOANA必须在每轮开始执行。 To initiate the TOMOANA the

40、standard parts must be according, with no damages and the holes must not be wider or closed. Otherwise call the Team Leader and wait for his decision. 启动TOMOANA时，标准件必须符合要求，没有损坏，孔不能过大或者关闭。否则通知小组领导等待他的决定。 The Tomoana daily control consist in allocate the standard parts in the welding fixture and close

41、 the clamps and then measure the holes specified. (phase I of validation process) TOMOANA日常管理包括在焊接夹具中分配标准件，关闭夹钳然后测量具体的孔（验证程序的第一阶段）。 The welding fixture will be evaluate under criteria below to be release for production 焊接夹具将按照下面生产中发放的标准来评估。 If the result is OK, record it on TOMOANA register and rele

42、ase the production. On the other hand if the result is NOK, record it and initiate the reaction plan according to Alarm & Escalation process. 如果结果是合格的，将它记录在TOMOANA登记簿上并且发放生产。另一方面如果结果是不合格的，将它记录下来并且根据警报和升级程序启动反应计划。见附件C开始标准件合格吗？为焊接夹具分配标准件打电话给小组组长，等待他的授权来开始生产关闭焊接夹具夹钳测量并登记每个指定的孔结果合格吗？根据警告 & 升级流程启动反应计划准备生

43、产开始3- Daily control: 日常管理 If 4- Weekly Monitoring: Quality team is accountable for TOMOANA monitoring. It means perform weekly the following requirements; 质量小组负责TOMOANA监督。这意味着每周按照以下要求执行：1- must ensure documentation is in place ( STS/TIS); 必须确保文件到位（STS/TIS）；2- must verify the Standard Part integrity:

44、 quality, identification; 必须检验标准件的完整性：质量、确认；3- must verify the gauge, pin; 必须检验标准尺寸、识别码；4- must confirm the Daily control execution: frequency and criteria; 必须确认日常管理执行：频率和标准；5- must ensure any process variation related to measurements have a reaction plan; 必须确保任何与测量有关的程序变化有反应计划；6- must request weldi

45、ng fixture adjustment when necessary; 必须在必要时要求焊接夹具调整； There are others requirements that are recommended as: 还建议以下其他要求：7- could verify the TOMOANA area and allocation; clean up, organized and safety; 可以检验TOMOANA区域和分配；清洁；组织和安全；8- could check the TOMOANA board if all documentation proposed is availabl

46、e; 如果所有提交的文件都是可用的，可以检查TOMOANA看板；见附件D4- Weekly Monitoring:见附件D5- Alarm & Escalation Process: 警告与升级程序 The reaction plan must be initiated based on Alarm & Escalation process defined when non-standard condition occurs. 反应计划必须根据在不标准条件发生是确认的警告和升级程序启动。The subassembly production must stop on first NOK hole and corrective action done. 组件生产必须在第一个不合格的孔时就停止，做校正工作。If remain 3 consecutive days in Alarm 1, the production should stop and corrective