制造质量培训课件.ppt

1、Built-In Quality制造质量,不断改进,员工参与,标准化,缩短制造周期,制造质量,Built-In Quality 制造质量,Built-In-Quality制造质量,What Is Quality? 什么是质量？ Group Discussion 小组讨论,Definitions 定义,Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm 质量是客户感觉能够接受并满足其热忱的东西,Mad Cow 疯牛 (Diseased Meat 病牛肉),Poor Qualit

2、y Means Lost Sales 质量差意味着失去客户,Firestone 燧石 (Unintended Accidents) 意外事故,uninstalled shift lock 漏装移位锁定 (Sudden Acceleration) 突然加速,PP100,: Not Reported Due To Insufficient Sample 样品不足不汇报,( ),J.D. Power IQS Trend By Brand,NCSI By Makers - 2002 2002 NCSI,Customer Expectations,Perceived Quality,Perceived

3、Value,Customer Loyalty,Customer Retention,Customer Complaints,Voice of Customer 客户意见,Voice of Customer客户意见, , , ,1. 停车方便 (Convenience of parking) 2. 外观式样 (Exterior styling) 3. 内部空间(Interior roominess) 4. 节能 (Fuel economy) 5. 安全(Safety),1.外观式样 (Exterior styling) 2.内部空间(Interior roominess) 3. 噪音与静音 (N

4、oise and quietness) 4. 节能 (Fuel economy) 5. 空调性能 (Air conditioner performance),1.发动机性能 (Engine Performance) 2. 发动机噪音(Engine Noise) 3.外观式样 (Exterior styling) 4. 噪音与静音 (Noise and quietness) 5. 坐骑 (Ride),L6 ,1. 节能(Fuel economy) 2. 噪音与静音 (Noise and quietness) 3. 内部空间(Interior roominess) 4. 坐骑(Ride) 5.外观

5、式样 (Exterior styling),1节能 (Fuel economy) 2. 空调 (Air conditioner) 3. 噪音 (Noise) 4. 发动机噪音(Engine Noise) 5. M/T转换 (M/T Shift),1. 节能(Fuel economy) 2. OSRVM手工控制 (Manual OSRVM control) 3. 发动机噪音(Engine noise) 4. 检查发动机点火 (Check Engine light) 5. 法人形象 (Corporate Image),1. 节能 (Fuel economy) 2. 制动性能 (Brake perf

6、ormance) 3. 喇叭性能 (Speaker performance) 4. 内饰品质 (Interior quality) 5. 喷涂质量差 (Poor paint quality),1. 3排坐椅相称 (Seats comport : 3rd line) 2. 节能 (Fuel economy) 3. 发动机启动(Poor engine start) 4. 法人形象 (Corporate Image) 5. 级别 (Gradablity),Built-in-Quality制造质量,What is Built-In-Quality? 什么是制造质量？ Group Discussion

7、小组讨论,What is Built-In Quality? 什么是制造质量？,Definition 定义 Method by which quality is built into the manufacturing process, so that defects are prevented, detected, and countermeasures are implemented to prevent reoccurrence. 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 Ensures defects are not pa

8、ssed to the customer. 确保不传递缺陷。,Designers 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,The Customer Chain. . . Company Perspective 客户链 公司远景,Built-In-Quality制造质量,Assembly 总装,Supplier 供应商,Paint 涂装,Body 车身,The Customer Chain. . . Production Perspective 客户链 公司远景,Each Pr

9、ocess Has at Least One “Customer” and One “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,Do not 不要,a Defect! 缺陷,Solve Problems Through Teamwork! 团队合作解决问题！,Built-In-Quality Motto制造质量口号,Satisfy Your Customer 满足你的客户,Quality Through Teamwork Know Your Customer!,What water leaks? I dont see any water

10、leaks 什么漏雨？我没发现漏雨。,This car wasnt made on my shift,The problem is Press Shop. The flange is too long. 问题出自冲压，边缘过长,I wont run any trial until I have an assembly method from Industrial Engineering and the manpower.,The problem is that the pieces are bad from the supplier. 问题在于供应商的材料不好。,It is not from

11、my area, maybe its the sealer,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,Dont run away from the problem!不要逃避问题!,Living up to the Motto. . . 符合口号. . . - What Is a Defect? 什么是缺陷？ Group Discussion 小组讨论,Defect 缺陷,A defect is a product that does not meet the established quality standard. 缺

12、陷是不合已定标准的产品。,Measurement of a quality characteristic 质量性能测量,Vehicle # 车辆 号,Upper Specification Limit 规格上限,Lower Specification Limit 规格下限,Quality Standard 质量标准,Defect 缺陷,Defect 缺陷,x,x,Why are defects undesirable? 为什么缺陷不受欢迎？,Defects may also result in 缺陷还可能导致 High warranty costs 过高保修成本 Lost customer s

13、ale 失去客户,Defects Require Correction = Correction is Waste 缺陷需要纠正纠正就是浪费,QUALITY IS EVERYONES RESPONSIBILITY质量是每个人的职责,Design, Engineering, Production, Quality, Support Departments and Suppliers. 设计，工程，生产，质量，相关部门及供应商 OUR Best Resources: 我们最好的资源: PEOPLE 员工 OUR Goal : 我们的目标： Everyone is a Quality Inspect

14、or 人人都是质检员 Everyone is a Problem Solver 人人都是问题解决者,WHO IS RESPONSIBLE FOR QUALITY? 谁对质量负责？,ME! 我！,Reflect voice of the customer 反映顾客的心声,Simple, clear & support user 简单、清晰， 有利操作者,Clearly Measurable at point of use 在使用上可明确测量,Key Points of Good Quality Standards:质量标准的要点：,In users Std. Work & posted visu

15、al 在操作者的标准化 工作或张贴出来,Standards Must Support the Operator, too Not only the Engineer! 标准不仅有益于设计者， 也有益于操作工人,Not tighter than those applied at the previous process 不要比前道工序的更严格,Key Points of Good Quality Standards:质量标准的要点：,Use master parts and boundary samples as required to make visual 标准件与边界样件需要目视化,Key

16、 Points of Good Quality Standards:质量标准的要点：,Boundary Samples should visually indicate OK Not OK condition to help operators make quick, good decisions 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” the defect is Not a Boundary Sample! 目视化标明缺陷不是边界样件！,Create a “Standards-Based” Culture创造一个以标准为基点的

17、文化氛围,Talk in terms of The Standard, not opinions! 以标准为基点，而非观点！,Product Quality Standards,Lean Design of Facilities, Equipment,Tooling and Layout,Health andSafety Priority,In-Process Control& Verification,What is a process?什么是工序？,Inputs 投入,Outputs 输出,A process is a set of inter-related resources and

18、activities which transforms inputs into outputs. 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 Machines Method Materials,Where can Errors Occur?问题会出在哪？,Defects 缺陷,Materials:材料 Parts out of standard 不符标准的零件 Wrong parts错误零件 Poor design 设计不当,Method: 方法 Poor std. Work 不好的标准工作 Lack of Trainin

19、g 缺乏培训,Machine/Process: 机器/工序 No TPM 没有TPM Process not capable 工序不好 Improper specification 规格不当,Man:人力 Not follow std. Work 不遵循标准化工作 Distractions, Forgetfulness 分心、遗忘 Lack of Experience 缺乏经验,Errors Result In,Validate the manufacturing process prior to Start of Production! 在生产启动前认证制造工艺！,Do not 切勿,a D

20、efect! 缺陷！,Living Up to the Motto 达到口号,“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place” - Dr. Deming,PFMEA,Workstation Readiness 工位准备,Process Control Plan 工艺控制计划,Error-proofing Plan 防错计划,Error Proofing Hierarchy 防错层次,Product / Process Design

21、 Change 产品/工艺设计改变 DFM/A & D/PFMEA Robust Designs & Capable Processes 机器设计及可行工艺 One-Way Assembly 同一装配 Process Controls 工艺控制 Locating Pins & Stops 固定点及停点 Sensors & Process Monitors 传感器及工艺监控 Electro - Mechanical Devices 电子机械仪器 Color Coding 颜色信号 Visual Controls 直观控制 Andon Systems 暗灯系统 Standardized Work

22、标准化工作,Errors Cant Happen,Small Improvement 小改进,Significant Improvement 重大改进,Introduction to Error Proofing 防错介绍,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,Original:,Best:,Visual Control Example,Human Judgment,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,Bett

23、er:,A,B,Example: Vehicle Identification 车辆认证 (Mutilation Cover Color) (盖板颜色毁损),Human Judgment 人为判断,Visual Control Example,Vertical Plate 垂直板,Battery Post 电池接头,Process Control Example,Detection 检测,X,Work Piece 加工件,Work Piece 加工件,Fixture 夹具,Fixture 夹具,Process Control Example,Prevention 预防,Product Desi

24、gn Example (Before),REC STOP PAUSE,REC STOP PAUSE,OLD DESIGN 老设计,Can be Installed Upside Down 可以反安装,Application of Labels on Cassette Decks.门板标签,Prevention 预防,REC STOP PAUSE,NEW DESIGN 新设计,Application of Labels on Cassette Decks.门板标签,Can Only Be Installed Correctly!,Product Design Example (After),Pr

25、evention,Example - Product Error Proofing (One Way to Install Seat Belt) 防错样品只有一种安全带安装方法,Product Design Example 产品设计范例,Prevention,Simple Everyday Examples,1) Error Prevention ,Automatic shut-off 自动断电,Error Proofing Exercise,Think of an example at work or at home where error proofing can prevent an u

26、ndesirable thing from happening 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 Discuss as a team and report Take 5 minutes 小组讨论、汇报5分钟,Lean Design of Facilities, Equipment,Tooling and Layout,Health andSafety Priority,Product Quality Standards,In-Process Control & Verification (3) Elements 工序控制与认证,1. Prevention,2. Detecti

27、on,Do not 不要,a Defect! 缺陷！,Living Up to the Motto 符合标准,3. Containment 包容,1) Standardized Work 标准化工作,Follow and Continuously Improve Standardized Work! 遵守及不断 改进标准化工作！,In-Process Control & Verification 1) PREVENTION,Prevention,2) Focus on Operation 集中精力生产,Keep Your Concentration & Respect Standardized

28、 Work of Others! 注意及尊重他人的 标准化工作,In-Process Control & Verification 1) PREVENTION,Prevention,3) Error Proofing Prevention & Operator Aids 防错预防与操作者支持,The Best Process is One That Cannot Fail! 最好工序就是不会失败的！,In-Process Control & Verification 1) PREVENTION,Prevention,4) Regular Checks of Systems & Processe

29、s 定时检查系统与工艺,Std. Work Checks! 检查标准化工作,In-Process Control & Verification 1) PREVENTION,Prevention,CHECK,CHECK,?,CHECK,Process Control Checks! 检查工序控制！,TPM Checks! 检查TPM,Safety/5S Checks! 检查安全/5S,Self-Checks 自检,Include Quality Checks in Standardized Work! 把质检作为标准化工作 的一部分,In-Process Control & Verificati

30、on 2) DETECTION,Detection,Check Methods: POINT TOUCH LISTEN COUNT,2) Error Proofing Detection 检测防错,Use Visual and Audio Signals! 使用视觉、 听觉信号！,In-Process Control & Verification 2) DETECTION,Detection,Stop the Line, or 停线或 Use Alarms, or 使用警报或 Combination of Both, depending on Criticality 根据危险程度兼用两种方法,

31、3) In-Process Verification 工序认证,Inspectors are not there as a policeman, they support production by confirming the process! 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-Process Control & Verification 2) DETECTION,Detection,Verification Stations Final Line C.A.R.E.,3a) Focus on Critical items 集中注意重大问题,Frequency of

32、checks to not allow Critical defects to leave the shop! 经常检查，不让重大缺陷 走出车间！,In-Process Control & Verification 2) DETECTION,Detection,Safety Items “Walk-Home” Items Major Customer Dissatisfier,S/C,F/F,4) Defect Escalation 缺陷逐层汇报,Escalate defects to leadership for support depending on frequency and crit

33、icality! 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-Process Control & Verification 2) DETECTION,Detection,Example:,Team Leader,Section Leader,Group Leader,2 defects/ 1 hour,4 defects/ 1 hour,1) Use Andon (taught more later) 使用暗灯,Make problems visual & pull in support! 问题直观， 拉线寻求帮助！,In-Process Control & Verifica

34、tion 3) CONTAINMENT,Always Remember the Priorities:一定要牢记： 1) Safety安全 2) Quality质量 3) Responsiveness (Throughput)响应,Containment 包容,2) Follow Containment Process 遵循包容程序,Extraordinary actions to prevent defects from being passed! 采取特别行动防止 缺陷传递！,In-Process Control & Verification 3) CONTAINMENT,Some exa

35、mples: 1) Stop the line停线 2) 100% checks 100%检查 3) On-line repair 线上维修 4) Reworks返工 5) Sorting 整理,Containment 包容,How Does our Quality Motto relate to Containment?,Do not 不要,a Defect! 缺陷！,It means empowered leaders make judgments how to control quality while trying to keep the line running! 意味着领导有权作出

36、决定：在尽量不停线的情况下， 怎样控制好质量！,Does this mean we stop the line every time we have a problem? 这是不是意味着一有问题就停线呢？,How Does our Quality Motto relate to Containment?,Sometimes the best decision may be to let a defect pass to the next process, but有时最好的办法是让差错转到下工序，但是 It is a conscious decision made by the appropri

37、ate level Action must be communicated to next “customer” Defect must be clearly identified on vehicle Containment must be in place to prevent further defects,Examples of Some Andon Guidelines: 暗灯使用的指导方针 1) Will the problem affect the next process? 问题会不会影响下道工序？ 2) Can I effectively repair the defect

38、out of station? 能不能在工位外有效解决问题？ 3) What is the status of my decouplers? 自己的切断器是什么状态？ 4) Others 其他,Andon Discussion Hoods,Situation: At the Body Shop end-of-line Quality station it is discovered that there is a problem with cracked hoods. After working the line back we know that every car in the syste

39、m has the condition all the way to Hood Install. After sorting the raw hoods, it is found that there are enough good hoods to keep producing cars, however there are not enough good hoods to repair the defective cars on-line. The suppler says new hoods will arrive in 6 hours. The operators at end of

40、line have pulled the Andon and the escalation process has pulled in the Body Shop Manager and Quality Manager. Considerations are: 1) The decoupler between Body and Paint is almost empty, 2) Hoods with cracked metal will not affect any of the subsequent processes, and 3) Hoods can be changed out of

41、station relatively easily.,Discussion: You are the Plant Quality Manager what is your decision? Discuss as a group!,Background: In this case, the decision is is shut down the line for (6) hours and wait for parts or run the line and make a containment plan. Since the decoupler between Body and Paint

42、 is almost empty, this means all Body, Paint and GA will all eventually shut down.,Potential Decision: In this case, Quality can still be achieved while maintaining our Responsiveness targets mostly because the hoods do not affect the next process. The Cost of stopping the line will not result in be

43、tter Quality or Responsiveness. Thus, a good decision would probably be to run the line and make a containment plan: All cars with bad hoods to be specially identified. Production and Quality in Paint and GA notified of the situation, know the vehicle numbers and identification method. 100% check at

44、 Hood Install operation until process capability is assured. Paint and Final Process notified that new hoods to be painted in Paint and will be swapped in Final Process area and have time to make a plan how to accommodate that.,Andon Discussion - Hoods,Situation: At the Cockpit Load station in GA it

45、 is discovered that there is a problem with one of the electrical harnesses within the cockpit. The cockpits are built as a module by an outside supplier. After working the line back we know that several cockpits in the system have the condition. The operators at Cockpit Load have pulled the Andon a

46、nd the escalation process has pulled in the Trim Line Section Leader, who consults with the Chassis Line Section Leader. Considerations are: 1) The decoupler between Trim and Chassis about half full, 2) The electrical harness will affect the next assembly process, 3) Repairing the harnesses on-line

47、will take approximately one hour, and 4) Repairing the Cockpit later in the process is difficult and very time consuming.,Discussion: You are the Trim Section Leader what is your decision? Discuss as a group!,Andon Discussion - Cockpits,Background: In this case, the decision is is shut down the line

48、 for (1) hour and repair the harnesses prior to Cockpit Load or run the line and repair the cockpits out-of-station. Since the decoupler between Trim and Chassis is about half full, this means that Chassis can continue running for a short while and then eventually shut down.,Potential Decision: In t

49、his case, Quality cannot be achieved while maintaining our Responsiveness targets mostly because the bad cockpits affect the next process and are extremely difficult to repair later. The Cost of stopping the line is more desirable than the cost of repairing them later and the potential to create mor

50、e defects. In this case, the decoupler status does not really impact the final decision too much. Thus, a good decision would probably be to stop the line and fix the harnesses prior to Cockpit Install. The Trim Line Section Leader will inform the GA Area Manager of this decision and the impact on o

51、ur Responsiveness target.,Andon Discussion - Cockpits,Lean Design of Facilities, Equipment,Tooling and Layout,Health andSafety Priority,Product Quality Standards,In-Process Control& Verification,“Customer” 客户,Quality Information Feedback/Feedforward质量反馈与前馈,“Suppliers” 供应商,You 你,Process A Process B P

52、rocess C,back,Defect flowing from A to B 缺陷从A流到B Status on Problem Resolution 问题解决状态,forward,Escaped defect flowing to Process C 避免缺陷流到C Temporary process being used in Process B 过程B的暂时方案 Process/product change with time 工艺/产品随时间改变 Status on Problem Resolution 问题解决状态,Motivation for Timely Feedback及时

53、反馈的动机,Immediate 1 Day 1 Year High Medium Low 1s 100s 1000s,Time to Discover Defect 发现缺陷的时间,Ability to Discover Root Cause 发现根源的能力,Number of Defective Vehicles Built 已经生产的缺陷产品,Example - Daily Reporting Metrics (Direct Run)每天汇报制度,Definition Percentage of vehicles that made it through to the End-of-Lin

54、e inspection processes with no defects. This is a common, global metric that is computed daily by all Assembly Plants. 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。,Final Inspection (End-of-Line) 下线检测,Dynamic Vehicle Test or equivalent 动态测试,Other 100% Inspections * 其他10%检测 (i.e.U/B Check),Total Direct Run = ( 92% * 98% * 96% * 99%) = 86% vehicles with no defect,Repair,CARE Line,# of first time vehicles with at least one defect 至少有一个缺陷的第一次认证,80,20,40,10,% Fir