传递特性的管理2013概要.ppt

1、Pass Through Characteristics Management(传递特性的管理）,FoA Supplier Development,Ford Motor Company,What is Pass Through Characteristics?（什么是传递特性）,Pass Through Characteristics are those internal and external supplied characteristics with potential fit or function issues that will not get 100% detected with

2、in 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 Manageme

3、nt(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 the component is 100% fully functional over its entire operating range, i.e. for a sensor, ther

4、mostat, or pump assembly purchased and installed in assembly.,PTC SCOPE AT (传递特性的定义范围） Analyze all T and TR final line stations for possible component, hardware, and installation failure modes and their current detection. Develop short and long-term corrective action plans for high-risk issues that

5、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。 GOAL（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 Process 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 Manage

6、r质量经理,PROJECT TEAM（攻关小组）,PTC PROCESS FLOW 传递特性的工艺流程,个别工位的评审（测量阶段）,分析失效模式（测量和分析阶段）,判定失效模式的优先次序（分析阶段）,分配资源（改进阶段）,临时措施（改进阶段）,永久性措施（改进阶段）,控制阶段,INDIVIDUAL STATION REVIEW 个别工位的评审,INDIVIDUAL STATION REVIEW个别工位的评审,Description Review each assembly & repair station 评审每一个装配和返修工位 * Identify all parts installed

7、识别所有的安装部分 * 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 ver

8、ify assumptions运用测试手段去验证假设,INDIVIDUAL STATION REVIEW个别工位的评审,Responsible 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,PTC PROCESS FLOW 传递特性的工艺流程,MATRIX: ASSESS RISK AND PRIORITIZE 矩阵图： FAILURE MODES 评估失效模式的风险和优先级,MAT

9、RIX REVIEW-ASSESS CUSTOMER RISK,Description 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 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 warra

10、nty 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 to customer (master rank) Responsible Core team plus: * Quality review engineer * Resident engineer * Process engineer,Red,

11、 Yellow, Green Chart GreenError Proofed or Caught in Sta. YellowCaught in Team Caught in next team At Final Test or Air Test RedDetected Less than 100% No Detection,Rank Risk To Customer,FMEA Ranking Warranty Information Master Rank,PTC PROCESS FLOW,CORRECTIVE ACTION PLANS,Short Term Actions Create

12、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 Actions Solicit ideas from manufacturing techs and engineers for error-proofing ideas In-Process Verification

13、 Stations (IPVs),CORRECTIVE ACTION PLANS,BACKUP STATION #109,COMPLETE STATION,SHOWS TORQUE REJECT,CLOSEUP OF STATION,TORQUE ACHIEVED, LIGHT OUT. PALLET WILL NOW RELEASE,Station #350 1/2,SENSOR TO DETECT PRESENCE OF TRANSAXLE,SENSOR TO DETECT CHAIN COVER PLUG,CHAIN COVER PLUG,Control Plan will consist of: Updating dynamic control plans Statistical process control charts FMEA (Living Document),CONTROL PLAN,Machined Part Example,Machined Part Example,KEYS TO REPLICATION,Methodology * Work backward (final assy. to machining) * Test assumptions * Review no more than 5 stations per day *