通用大宇制造质量课件

Built-InQuality

制造质量GMS不断改进员工参与标准化缩短制造周期制造质量Built-InQuality

制造质量GMS不断改进员工Manufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementIn-Process

Control&VerificationQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementManufacturing

Process

Validation制造工艺认证In-ProcessControl&Verification工艺控制与确认Quality

System

Management质量体系管理Quality

Feedback/

Feed-forward质量反馈/前馈ProductQualityStandards产品质量标准Built-InQuality制造质量Manufacturing

Process

ValidatBuilt-In-Quality

制造质量WhatIsQuality?

什么是质量？GroupDiscussion小组讨论Built-In-Quality

制造质量WhatIsQDefinitions定义Qualityiswhatthecustomerperceivestobeacceptabletoachievehis/herenthusiasm质量是客户感觉能够接受并满足其热忱的东西Definitions定义QualityiswhatMadCow疯牛(DiseasedMeat病牛肉)PoorQualityMeansLostSales质量差意味着失去客户Firestone燧石(UnintendedAccidents)意外事故uninstalledshiftlock漏装移位锁定(SuddenAcceleration)突然加速MadCow疯牛PoorQualityMeansPP100:NotReportedDueToInsufficientSample样品不足不汇报()J.D.PowerIQSTrendByBrand

PP100:NotReportedDueToIns

NCSIByMakers-2002

2002제작사별NCSICustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客户期望值感知质量感知价值客户埋怨客户忠诚客户保持力NCSIByMakers-2002Custo通用大宇制造质量课件VoiceofCustomer

客户意见VoiceofCustomer客户意见VoiceofCustomer客户意见차종만족사항불만족사항마티즈1.停车方便(Convenienceofparking)2.外观式样(Exteriorstyling)3.内部空间(Interiorroominess)4.节能(Fueleconomy)5.安全(Safety)1.外观式样

(Exteriorstyling)2.内部空间(Interiorroominess)3.噪音与静音(Noiseandquietness)4.节能(Fueleconomy)5.空调性能(Airconditionerperformance)칼로스1.发动机性能(EnginePerformance)2.发动机噪音(EngineNoise)3.外观式样

(Exteriorstyling)4.噪音与静音(Noiseandquietness)5.坐骑(Ride)L6매그너스1.节能(Fueleconomy)2.噪音与静音(Noiseandquietness)3.内部空间(Interiorroominess)4.坐骑(Ride)5.外观式样

(Exteriorstyling)레조1节能(Fueleconomy)2.空调(Airconditioner)3.噪音(Noise)4.发动机噪音(EngineNoise)5.M/T转换

(M/TShift)1.节能(Fueleconomy)2.OSRVM手工控制(ManualOSRVM

control)3.发动机噪音(Enginenoise)4.检查发动机点火(CheckEnginelight)5.法人形象(CorporateImage)1.节能(Fueleconomy)2.制动性能(Brakeperformance)3.喇叭性能(Speakerperformance)4.内饰品质(Interiorquality)5.喷涂质量差(Poorpaintquality)1.3排坐椅相称(Seatscomport:3rdline)2.节能(Fueleconomy)3.发动机启动(Poorenginestart)4.法人形象(CorporateImage)5.级别(Gradablity)VoiceofCustomer客户意见차종만족Built-in-Quality

制造质量WhatisBuilt-In-Quality?

什么是制造质量？GroupDiscussion

小组讨论Built-in-Quality

制造质量WhatisBWhatisBuilt-InQuality?什么是制造质量？Definition定义Methodbywhichqualityisbuiltintothemanufacturingprocess,sothatdefectsareprevented,detected,andcountermeasuresareimplementedtopreventreoccurrence.指质量在生产过程中产生，因此可以预防、发现缺陷，以及采取措施防止缺陷再发生的方法。Purpose意图

Ensuresdefectsarenotpassedtothecustomer.确保不传递缺陷。WhatisBuilt-InQuality?DefinDesigners设计师Suppliers供应商Production生产人员Dealers经销商Buyers采购员Sales&Marketing销售人员TheCustomerChain...CompanyPerspective客户链…公司远景Built-In-Quality

制造质量DesignersSuppliersProductionDAssembly总装Supplier供应商Paint涂装Body车身TheCustomerChain...ProductionPerspective客户链…公司远景EachProcessHasatLeastOne“Customer”andOne“Supplier”每个阶段至少有一个客户和一个供应商Built-In-Quality

制造质量AssemblySupplierPaintBodyTheCDonot不要Accept接受Build制造Ship传递aDefect!缺陷SolveProblemsThroughTeamwork!团队合作解决问题！Built-In-QualityMotto

制造质量口号SatisfyYourCustomer…满足你的客户DonotAcceptaDefect!SolveProQualityThroughTeamwork–KnowYourCustomer!Whatwaterleaks?Idon’tseeanywaterleaks什么漏雨？我没发现漏雨。Thiscarwasn’tmadeonmyshiftTheproblemisPressShop.Theflangeistoolong.问题出自冲压，边缘过长Iwon’trunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower.Theproblemisthatthepiecesarebadfromthesupplier.问题在于供应商的材料不好。Itisnotfrommyarea,maybeit’sthesealer这辆车不是我轮班造的。在没有工业工程装配方法及人力的情况下，我不做任何试验。这不是我负责的地方，也许是粘胶负责Don’trunawayfromtheproblem!

不要逃避问题!QualityThroughTeamwork–KnoLivinguptotheMotto...符合口号...-

WhatIsaDefect?

什么是缺陷？GroupDiscussion

小组讨论

Defect缺陷LivinguptotheMotto...DeAdefectisaproductthatdoesnotmeettheestablishedqualitystandard.缺陷是不合已定标准的产品。Measurementofaqualitycharacteristic质量性能测量Vehicle#车辆

号UpperSpecificationLimit规格上限LowerSpecificationLimit规格下限QualityStandard质量标准Defect缺陷Defect缺陷xxAdefectisaproductthatdoeWhyaredefectsundesirable?为什么缺陷不受欢迎？Defectsmayalsoresultin…

缺陷还可能导致Highwarrantycosts过高保修成本

Lostcustomersale失去客户DefectsRequireCorrection=CorrectionisWaste

缺陷需要纠正—纠正就是浪费Whyaredefectsundesirable?De

QUALITYISEVERYONE’S

RESPONSIBILITY

质量是每个人的职责Design,Engineering,Production,Quality,SupportDepartmentsandSuppliers.

设计，工程，生产，质量，相关部门及供应商OURBestResources:我们最好的资源:→

PEOPLE

员工OURGoal:我们的目标：

→

EveryoneisaQualityInspector

人人都是质检员

→

EveryoneisaProblemSolver

人人都是问题解决者QUALITYISEVERYONE’S

RESPOWHOISRESPONSIBLEFORQUALITY?谁对质量负责？WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITYME!!!我！ME!!!Healthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessControlled

ExternalTransportationManufacturing

Process

ValidationIn-ProcessControl&VerificationQuality

System

ManagementScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementValuesVision/MissionShopFloor

ManagementInternalPull/DeliveryAndon

ConceptProblem

SolvingSimple

Process

FlowProductQualityStandardsStandardized

WorkSmallLot

PackagingTemporary

Material

StorageQuality

Feedback/

Feed-forwardVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

Maintenance

FixedPeriod

Ordering

System/OrderPartsProductQualityStandards产品质量标准Healthand

SafetyPriorityQualReflectvoiceofthecustomer反映顾客的心声Simple,clear&supportuser简单、清晰，有利操作者ClearlyMeasurableatpointofuse在使用上可明确测量KeyPointsofGoodQualityStandards:

质量标准的要点：

Inuser’sStd.Work&postedvisual在操作者的标准化工作或张贴出来StandardsMustSupporttheOperator,too–NotonlytheEngineer!!!标准不仅有益于设计者，也有益于操作工人ReflectvoiceSimple,clearCleaNottighterthanthoseappliedatthepreviousprocess

不要比前道工序的更严格KeyPointsofGoodQualityStandards:

质量标准的要点：

FinalInspectionStandard:Gap+/-1mmFINALINSPECTIONBODYSHOPBodyShopStandard:Gap+/-2mmNottighterthanKeyPointsofUsemasterpartsandboundarysamplesasrequiredtomakevisual标准件与边界样件需要目视化KeyPointsofGoodQualityStandards:

质量标准的要点：

BoundarySamplesshouldvisuallyindicateOK–NotOKconditiontohelpoperatorsmakequick,gooddecisions边界样件应该标明好或不好，以便操作人员迅速且更好地下决定。Visually“describing”thedefectisNotaBoundarySample!目视化标明缺陷不是边界样件！Cratermorethanthissizeisnotacceptable不接受焊口大于此尺寸ExampleofaBoundarySample边界样品的范例UsemasterpartsandKeyPointsCreatea“Standards-Based”Culture

创造一个以标准为基点的文化氛围Iwouldn’tbuythis!Doesn’tlookgoodtome!Myopinionis…Thisdoesnotmeetthestandard..TalkintermsofTheStandard,notopinions!以标准为基点，而非观点！Createa“Standards-Based”CulManufacturing

Process

ValidationQuality

System

ManagementProductQualityStandardsQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&VerificationManufacturing

Process

Validation制造工序认证Manufacturing

Process

ValidatWhatisaprocess?

什么是工序？Inputs投入Outputs输出Aprocessisasetofinter-relatedresourcesandactivitieswhichtransformsinputsintooutputs.工序是集中相关的资源进行一系列活动，把投入转换成输出！Environment环境Process工序Man

MachinesMethodMaterialsWhatisaprocess?

什么是工序？InputWherecanErrorsOccur?

问题会出在哪？Defects缺陷Materials:材料Partsoutofstandard不符标准的零件Wrongparts错误零件Poordesign设计不当

Method:方法Poorstd.Work不好的标准工作LackofTraining缺乏培训

Machine/Process:机器/工序NoTPM没有TPMProcessnotcapable工序不好Improperspecification规格不当

Man:人力Notfollowstd.Work不遵循标准化工作Distractions,Forgetfulness分心、遗忘LackofExperience缺乏经验ErrorsResultInWherecanErrorsOccur?

问题会出在哪ValidatethemanufacturingprocesspriortoStartofProduction!在生产启动前认证制造工艺！Donot切勿Accept

接受Build

制造Ship传递aDefect!

缺陷！LivingUptotheMotto…达到口号“EliminatetheNeedforInspectiononaMassBasisbyBuildingQualityintotheProductintheFirstPlace”-Dr.Deming PFMEAWorkstationReadiness工位准备ProcessControlPlan工艺控制计划Error-proofingPlan防错计划ValidatethemanufacturingproErrorProofingHierarchy防错层次Prevention预防Detection

检测HumanJudgment人为判断None无Product/ProcessDesignChange产品/工艺设计改变DFM/A&D/PFMEARobustDesigns&CapableProcesses机器设计及可行工艺One-WayAssembly同一装配ProcessControls工艺控制LocatingPins&Stops固定点及停点Sensors&ProcessMonitors传感器及工艺监控Electro-MechanicalDevices电子机械仪器ColorCoding颜色信号VisualControls直观控制AndonSystems暗灯系统StandardizedWork标准化工作ErrorsCan’tHappenSmallImprovement小改进SignificantImprovement重大改进IntroductiontoErrorProofing防错介绍ErrorProofingHierarchy防错层次P0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:VisualControlExampleHumanJudgment0515100396OLHM51020150151012457810115Better:0515100396OLHM5102015015101245ABExample:VehicleIdentification车辆认证

(MutilationCoverColor)(盖板颜色毁损)HumanJudgment人为判断VisualControlExampleABExample:VehicleIdentificatVerticalPlate垂直板BatteryPost电池接头ProcessControlExampleDetection检测VerticalPlateBatteryPostProcXWorkPiece加工件WorkPiece加工件Fixture夹具Fixture夹具ProcessControlExamplePrevention预防XWorkPiece加工件WorkPiece加工ProductDesignExample(Before)REC<<>>>STOPPAUSEREC<<>>>STOPPAUSEOLDDESIGN老设计CanbeInstalledUpsideDown可以反安装ApplicationofLabelsonCassetteDecks.门板标签Prevention预防ProductDesignExample(BeforeREC<<>>>STOPPAUSENEWDESIGN新设计ApplicationofLabelsonCassetteDecks.门板标签CanOnlyBeInstalledCorrectly!ProductDesignExample(After)PreventionREC<<>>>STOPLeftHandLocatorTabRightHandLocatorTabExample--ProductErrorProofing(OneWaytoInstallSeatBelt)防错样品—只有一种安全带安装方法ProductDesignExample产品设计范例PreventionLeftHandLocatorTabRightHanSimpleEverydayExamples1)ErrorPrevention실수방지Automaticshut-off自动断电SimpleEverydayExamples1)ErrErrorProofingExerciseThinkofanexampleatworkorathomewhereerrorproofingcanpreventanundesirablethingfromhappening想想工作或生活中使用防错措施避免不好事情发生的例子Discussasateamandreport–Take5minutes小组讨论、汇报—5分钟ErrorProofingExerciseThinkManufacturing

Process

ValidationProduct

Quality

StandardsQuality

System

ManagementQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&Verification工序控制与认证ProductQualityStandardsManufacturing

Process

ValidatIn-ProcessControl&Verification–(3)Elements工序控制与认证1.PreventionOutputs输出Inputs投入NOK2.DetectionOKNextProcess下道工序Feedback反馈Donot不要Accept

接受Build

制造Ship

传递aDefect!

缺陷！LivingUptotheMotto…符合标准3.Containment包容In-ProcessControl&Verificat1)StandardizedWork标准化工作FollowandContinuouslyImproveStandardizedWork!!!遵守及不断改进标准化工作！！In-ProcessControl&Verification–1)PREVENTIONPreventionVehicleManifestManual2-DoorSunroof1)StandardizedFollowandIn-P2)FocusonOperation集中精力生产KeepYourConcentration&RespectStandardizedWorkofOthers!注意及尊重他人的标准化工作In-ProcessControl&Verification–1)PREVENTIONPrevention2)FocusonKeepYourIn-Proces3)ErrorProofingPrevention&OperatorAids防错预防与操作者支持TheBestProcessisOneThatCannotFail!最好工序就是不会失败的！In-ProcessControl&Verification–1)PREVENTIONPreventionDAEWOO3)ErrorProofingTheBestProc4)RegularChecksofSystems&Processes定时检查系统与工艺Std.WorkChecks!检查标准化工作In-ProcessControl&Verification–1)PREVENTIONPreventionCHECKCHECK???????CHECKProcessControlChecks!检查工序控制！TPMChecks!检查TPMSafety/5SChecks!检查安全/5S4)RegularChecksStd.WorkIn-PSelf-Checks自检IncludeQualityChecksinStandardizedWork!把质检作为标准化工作的一部分In-ProcessControl&Verification–2)DETECTIONDetectionCheckMethods:POINTTOUCHLISTENCOUNTSelf-ChecksIncludeQualityChe2)ErrorProofingDetection检测防错UseVisualandAudioSignals!使用视觉、听觉信号！In-ProcessControl&Verification–2)DETECTIONDetectionStoptheLine,or停线或UseAlarms,or使用警报或CombinationofBoth,dependingonCriticality根据危险程度兼用两种方法2)ErrorProofingUseVisualan3)In-ProcessVerification工序认证Inspectorsarenotthereasapoliceman,theysupportproductionbyconfirmingtheprocess!检察员不充当警察角色，而是作为确定工序的生产支持者In-ProcessControl&Verification–2)DETECTIONDetectionVerificationStationsFinalLineC.A.R.E.3)In-ProcessInspectorsareno3a)FocusonCriticalitems集中注意重大问题FrequencyofcheckstonotallowCriticaldefectstoleavetheshop!经常检查，不让重大缺陷走出车间！In-ProcessControl&Verification–2)DETECTIONDetectionSafetyItems“Walk-Home”ItemsMajorCustomerDissatisfierS/CF/F3a)FocusonFrequencyofcheck4)DefectEscalation缺陷逐层汇报Escalatedefectstoleadershipforsupportdependingonfrequencyandcriticality!根据缺陷出现频率与严重程度逐层向领导汇报以寻求支持！In-ProcessControl&Verification–2)DETECTIONDetectionExample:TeamLeaderSectionLeaderGroupLeader2defects/1hour4defects/1hour4)DefectEscalatedefectstoIn1)UseAndon(taughtmorelater)使用暗灯Makeproblemsvisual&pullinsupport!问题直观，拉线寻求帮助！In-ProcessControl&Verification–3)CONTAINMENTAlwaysRememberthePriorities:一定要牢记：1)Safety安全2)Quality质量3)Responsiveness(Throughput)响应Containment包容1)UseAndonMakeproblemsvisu2)FollowContainmentProcess遵循包容程序Extraordinaryactionstopreventdefectsfrombeingpassed!采取特别行动防止缺陷传递！In-ProcessControl&Verification–3)CONTAINMENTSomeexamples:1)Stoptheline停线2)100%checks100%检查3)On-linerepair线上维修4)Reworks返工5)Sorting整理Containment包容2)FollowExtraordinaryactionsHowDoesourQualityMottorelatetoContainment?Donot不要Accept

接受Build

制造Ship

传递aDefect!

缺陷！Itmeansempoweredleadersmakejudgmentshowtocontrolqualitywhiletryingtokeepthelinerunning!!意味着领导有权作出决定：在尽量不停线的情况下，怎样控制好质量！Doesthismeanwestopthelineeverytimewehaveaproblem?这是不是意味着一有问题就停线呢？HowDoesourQualityMottorelHowDoesourQualityMottorelatetoContainment?Sometimesthebestdecisionmaybetoletadefectpasstothenextprocess,but…有时最好的办法是让差错转到下工序，但是……ItisaconsciousdecisionmadebytheappropriatelevelActionmustbecommunicatedtonext“customer”DefectmustbeclearlyidentifiedonvehicleContainmentmustbeinplacetopreventfurtherdefects

ExamplesofSomeAndonGuidelines:暗灯使用的指导方针1)Willtheproblemaffectthenextprocess?问题会不会影响下道工序？2)CanIeffectivelyrepairthedefectoutofstation?能不能在工位外有效解决问题？3)Whatisthestatusofmydecouplers?自己的切断器是什么状态？4)Others…其他……HowDoesourQualityMottorelAndonDiscussion–HoodsSituation:AttheBodyShopend-of-lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods.AfterworkingthelinebackweknowthateverycarinthesystemhastheconditionallthewaytoHoodInstall.Aftersortingtherawhoods,itisfoundthatthereareenoughgoodhoodstokeepproducingcars,howevertherearenotenoughgoodhoodstorepairthedefectivecarson-line.Thesupplersaysnewhoodswillarrivein6hours.TheoperatorsatendoflinehavepulledtheAndonandtheescalationprocesshaspulledintheBodyShopManagerandQualityManager.Considerationsare:1)ThedecouplerbetweenBodyandPaintisalmostempty,2)Hoodswithcrackedmetalwillnotaffectanyofthesubsequentprocesses,and3)Hoodscanbechangedoutofstationrelativelyeasily.Discussion:YouarethePlantQualityManager–whatisyourdecision?Discussasagroup!

AndonDiscussion–HoodsSituaBackground:Inthiscase,thedecisionisisshutdownthelinefor(6)hoursandwaitforpartsorrunthelineandmakeacontainmentplan.SincethedecouplerbetweenBodyandPaintisalmostempty,thismeansallBody,PaintandGAwillalleventuallyshutdown.PotentialDecision:Inthiscase,QualitycanstillbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethehoodsdonotaffectthenextprocess.TheCostofstoppingthelinewillnotresultinbetterQualityorResponsiveness.Thus,agooddecisionwouldprobablybetorunthelineandmakeacontainmentplan:Allcarswithbadhoodstobespeciallyidentified.ProductionandQualityinPaintandGAnotifiedofthesituation,knowthevehiclenumbersandidentificationmethod.100%checkatHoodInstalloperationuntilprocesscapabilityisassured.PaintandFinalProcessnotifiedthatnewhoodstobepaintedinPaintandwillbeswappedinFinalProcessareaandhavetimetomakeaplanhowtoaccommodatethat.AndonDiscussion-HoodsBackground:Inthiscase,theSituation:AttheCockpitLoadstationinGAitisdiscoveredthatthereisaproblemwithoneoftheelectricalharnesseswithinthecockpit.Thecockpitsarebuiltasamodulebyanoutsidesupplier.Afterworkingthelinebackweknowthatseveralcockpitsinthesystemhavethecondition.TheoperatorsatCockpitLoadhavepulledtheAndonandtheescalationprocesshaspulledintheTrimLineSectionLeader,whoconsultswiththeChassisLineSectionLeader.Considerationsare:1)ThedecouplerbetweenTrimandChassisabouthalffull,2)Theelectricalharnesswillaffectthenextassemblyprocess,3)Repairingtheharnesseson-linewilltakeapproximatelyonehour,and4)RepairingtheCockpitlaterintheprocessisdifficultandverytimeconsuming.Discussion:YouaretheTrimSectionLeader–whatisyourdecision?Discussasagroup!

AndonDiscussion-CockpitsSituation:Discussion:AndonDiBackground:Inthiscase,thedecisionisisshutdownthelinefor(1)hourandrepairtheharnessespriortoCockpitLoadorrunthelineandrepairthecockpitsout-of-station.SincethedecouplerbetweenTrimandChassisisabouthalffull,thismeansthatChassiscancontinuerunningforashortwhileandtheneventuallyshutdown.PotentialDecision:Inthiscase,QualitycannotbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethebadcockpitsaffectthenextprocessandareextremelydifficulttorepairlater.TheCostofstoppingthelineismoredesirablethanthecostofrepairingthemlaterandthepotentialtocreatemoredefects.Inthiscase,thedecouplerstatusdoesnotreallyimpactthefinaldecisiontoomuch.Thus,agooddecisionwouldprobablybetostopthelineandfixtheharnessespriortoCockpitInstall.TheTrimLineSectionLeaderwillinformtheGAAreaManagerofthisdecisionandtheimpactonourResponsivenesstarget.AndonDiscussion-CockpitsBackground:Inthiscase,theManufacturing

Process

ValidationQuality

System

ManagementQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementQuality

Feedback/

Feedforward质量反馈与前馈ProductQualityStandardsIn-ProcessControl&VerificationManufacturing

Process

Validat

“Customer”客户QualityInformationFeedback/Feedforward

质量反馈与前馈“Suppliers”供应商You你ProcessAProcessBProcessCbackDefectflowingfromAtoB

缺陷从A流到B

StatusonProblemResolution

问题解决状态forwardEscapeddefectflowingtoProcessC避免缺陷流到CTemporaryprocessbeingusedinProcessB

过程B的暂时方案Process/productchangewithtime

工艺/产品随时间改变StatusonProblemResolution

问题解决状态“Customer”QualityInformationMotivationforTimelyFeedback

及时反馈的动机Immediate1Day1YearHighMediumLow1s100s1000sTimetoDiscoverDefect发现缺陷的时间AbilitytoDiscoverRootCause发现根源的能力NumberofDefectiveVehiclesBuilt已经生产的缺陷产品MotivationforTimelyFeedbackExample--DailyReportingMetrics(DirectRun)

每天汇报制度DefinitionPercentageofvehiclesthatmadeitthroughtotheEnd-of-Lineinspectionprocesseswithnodefects.Thisisacommon,globalmetricthatiscomputeddailybyallAssemblyPlants.

下线检查合格的车辆百分比，这是全球统一在所有总装厂每天用电脑记录的制度。FinalInspection(End-of-Line)下线检测DynamicVehicleTestorequivalent动态测试Other100%Inspections**其他10%检测(i.e.U/BCheck)TotalDirectRun=(92%*98%*96%*99%)

=86%vehicleswithnodefectRepairCARELine#offirsttimevehicleswithatleastonedefect至少有一个缺陷的第一次认证

80204010%FirstTimeQuality一次质量认证百分比92%98%96%99%Totalfirsttimevehiclesthroughthestationonagivenday在特定时间工位的第一次认证1000100010001000RepairRepairRepair**100%WaterTestand100%SqueakandRattleTestresultsarenotcurrently(3/2000)includedinDirectRun**100%的漏雨测试与异响测试并不包含在DirectRunExample--DailyReportingMetManufacturing

Process

ValidationQuality

System

ManagementQuality

Feedback/

Feed-forwardStandardized

WorkVisual

ManagementManagement

byTAKTTimeWork-place

OrganizationAndon

ConceptProblem

SolvingEarlyMfg.andDesign

Integration(DFM/DFA)Continuous

Improvement

ProcessLeanDesignofFacilities,Equipment,

ToolingandLayoutBusinessPlanDeploymentTotalProductive

MaintenanceControlled

ExternalTransportationScheduled

Shipping/ReceivingLevelVehicle

OrderSchedulesSupply

ChainManagementInternalPull/DeliverySimple

Process

FlowSmallLot

PackagingTemporary

Material

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementQuality

System

Management质量体系管理ProductQualityStandardsIn-ProcessControl&VerificationManufacturing

Process

ValidatGMS

OperatingStandards+CorporateQualityProceduresAssemblyPlantProceduresWorkInstructionsRecordsandOtherDocumentationISOPlantQualityManualISO工厂质量手册QualitySystem质量体系GMS

制造标准+公司质量程序总装工厂程序工作指导记录及其他文件GMS

OperatingStandards+CorpQualitySystemModelDon’t

adefectAcceptBuildShipMANUFACTURINGAREAQUALITYDPT.CUSTOMERProductionProductionQualityControlSIPStandardizedInspectionProcessDIQS/GCAContinuousImprovementsFeedbackResponsibleforproducingfirsttimequalityConfirmprocessandproduct.Providetechnicalsupport.Supportproblemresolution.ExpectationGDSIPTVJDPetc.ProcessStandard(StandardizedWork)ProductQualityStandards(CVIS)DAILYMANAGEMENT&MANAGEMENTBYBUSINESSPLANDEPLOYMENTPrinciple:QualitySystemModelDon’tad质量体系样式不

缺陷!接收制造传递生产部门质量部门顾客生产生产质量控制SIP标准检测程序DIQS/GCACIPFeedback负责首次质量检查确定工艺及产品提供技术支持帮助解决问题期望GDSIPTVJDPetc.工艺标准（标准化操作）生产质量标准CVIS业务计划实施的日常管理与维护原则:质量体系样式不缺陷!接收生产部门质量部门顾客生产SIPDIHowdoesBuilt-InQualityapply

totheotherGMSPrinciples?

制造质量与其他GMS原则的关系Standardization:Pre-requisiteforachievingbuilt-inqualityContinuousImprovement:StabilizestheprocesssothatContinuousImprovementscantakeplace.ShortLeadTime:Drivesfirsttimequality,thereby,enablingshorterleadtimestodelivervehicletothecustomer

PeopleInvolvement:Everyoneisr