1、Built-In Quality制造質(zhì)量GMS不斷改良員工參與規(guī)范化縮短制造周期制造質(zhì)量cnshu 精品資料網(wǎng)ManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly M

2、fg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /Deliv

3、erySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVisionShop FloorManagementManufacturingProcess Validation制造工藝認(rèn)證In-ProcessControl &Verification工藝

4、控制與確認(rèn)QualitySystemManagement質(zhì)量體系管理QualityFeedback/Feed-forward質(zhì)量反響/前饋ProductQualityStandards產(chǎn)質(zhì)量量規(guī)范Built-In Quality制造質(zhì)量cnshu 精品資料網(wǎng)Built-In-Quality制造質(zhì)量What Is Quality? 什么是質(zhì)量？Group Discussion 小組討論cnshu 精品資料網(wǎng)Definitions 定義Quality is what the customer perceives to be acceptable to achieve his/her enthusi

5、asm質(zhì)量是客戶覺得可以接受并滿足其熱忱的東西cnshu 精品資料網(wǎng)Mad Cow 瘋牛(Diseased Meat 病牛肉)Poor Quality Means Lost Sales質(zhì)量差意味著失去客戶Firestone燧石(Unintended Accidents)不測(cè)事故uninstalled shift lock漏裝移位鎖定(Sudden Acceleration)忽然加速cnshu 精品資料網(wǎng)PP100: Not Reported Due To Insufficient Sample 樣品缺乏不匯報(bào)( ) J.D. Power IQS Trend By Brandcnshu 精品資料

6、網(wǎng) NCSI By Makers - 2002 2002 NCSI CustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客戶期望值感知質(zhì)量感知價(jià)值客戶埋怨客戶忠實(shí)客戶堅(jiān)持力cnshu 精品資料網(wǎng)cnshu 精品資料網(wǎng)Voice of Customer 客戶意見cnshu 精品資料網(wǎng)Voice of Customer客戶意見 1. 停車方便 (Convenience of parking)2. 外觀式樣 (Exterior styling)3. 內(nèi)部

7、空間(Interior roominess)4. 節(jié)能 (Fuel economy)5. 平安(Safety)1.外觀式樣 (Exterior styling)2.內(nèi)部空間(Interior roominess)3. 噪音與靜音 (Noise and quietness)4. 節(jié)能 (Fuel economy)5. 空調(diào)性能 (Air conditioner performance)1.發(fā)動(dòng)機(jī)性能 (Engine Performance)2. 發(fā)動(dòng)機(jī)噪音(Engine Noise) 3.外觀式樣 (Exterior styling)4. 噪音與靜音 (Noise and quietness)5

8、. 坐騎 (Ride)L61. 節(jié)能(Fuel economy)2. 噪音與靜音 (Noise and quietness)3. 內(nèi)部空間(Interior roominess)4. 坐騎(Ride)5.外觀式樣 (Exterior styling)1節(jié)能 (Fuel economy)2. 空調(diào) (Air conditioner)3. 噪音 (Noise)4. 發(fā)動(dòng)機(jī)噪音(Engine Noise)5. M/T轉(zhuǎn)換 (M/T Shift)1. 節(jié)能(Fuel economy)2. OSRVM手工控制 (Manual OSRVM control)3. 發(fā)動(dòng)機(jī)噪音(Engine noise)4.

9、檢查發(fā)動(dòng)機(jī)點(diǎn)火 (Check Engine light)5. 法人籠統(tǒng) (Corporate Image) 1. 節(jié)能 (Fuel economy)2. 制動(dòng)性能 (Brake performance) 3. 喇叭性能 (Speaker performance)4. 內(nèi)飾質(zhì)量 (Interior quality)5. 噴涂質(zhì)量差 (Poor paint quality)1. 3排坐椅相稱 (Seats comport : 3rd line)2. 節(jié)能 (Fuel economy)3. 發(fā)動(dòng)機(jī)啟動(dòng)(Poor engine start)4. 法人籠統(tǒng) (Corporate Image) 5. 級(jí)別

10、 (Gradablity)cnshu 精品資料網(wǎng)Built-in-Quality制造質(zhì)量What is Built-In-Quality? 什么是制造質(zhì)量？Group Discussion 小組討論cnshu 精品資料網(wǎng)What is Built-In Quality?什么是制造質(zhì)量？Definition 定義Method by which quality is built into the manufacturing process, so that defects are prevented, detected, and countermeasures are implemented to

11、 prevent reoccurrence.指質(zhì)量在消費(fèi)過程中產(chǎn)生，因此可以預(yù)防、發(fā)現(xiàn)缺陷，以及采取措施防止缺陷再發(fā)生的方法。Purpose 意圖 Ensures defects are not passed to the customer.確保不傳送缺陷。cnshu 精品資料網(wǎng)Designers設(shè)計(jì)師Suppliers 供應(yīng)商Production消費(fèi)人員Dealers經(jīng)銷商Buyers采購(gòu)員Sales & Marketing銷售人員The Customer Chain. . . Company Perspective客戶鏈 公司遠(yuǎn)景Built-In-Quality制造質(zhì)量cnshu 精品資料

12、網(wǎng)Assembly總裝Supplier供應(yīng)商Paint涂裝Body車身The Customer Chain. . . Production Perspective客戶鏈 公司遠(yuǎn)景Each Process Has at Least One “Customer and One “Supplier每個(gè)階段至少有一個(gè)客戶和一個(gè)供應(yīng)商Built-In-Quality制造質(zhì)量cnshu 精品資料網(wǎng)Do not不要Accept接受Build制造Ship傳送a Defect!缺陷Solve Problems Through Teamwork!團(tuán)隊(duì)協(xié)作處理問題！Built-In-Quality Motto制造質(zhì)

13、量口號(hào)Satisfy Your Customer滿足他的客戶cnshu 精品資料網(wǎng)Quality Through Teamwork Know Your Customer!What water leaks?I dont see any water leaks什么漏雨？我沒發(fā)現(xiàn)漏雨。This car wasnt made on my shiftThe problem is Press Shop. The flange is too long.問題出自沖壓，邊緣過長(zhǎng)I wont run any trial until I have an assembly method from Industrial

14、 Engineering and the manpower.The problem is that the pieces are bad from the supplier. 問題在于供應(yīng)商的資料不好。It is not from my area, maybe its the sealer這輛車不是我輪班造的。在沒有工業(yè)工程裝配方法及人力的情況下，我不做任何實(shí)驗(yàn)。這不是我擔(dān)任的地方，也許是粘膠擔(dān)任Dont run away from the problem!不要逃避問題!cnshu 精品資料網(wǎng)Living up to the Motto. . . 符合口號(hào). . . - What Is a D

15、efect? 什么是缺陷？Group Discussion 小組討論 Defect 缺陷cnshu 精品資料網(wǎng)A defect is a product that does not meet the established quality standard.缺陷是不合已定規(guī)范的產(chǎn)品。Measurement of a quality characteristic質(zhì)量性能丈量Vehicle #車輛 號(hào)Upper Specification Limit規(guī)格上限Lower Specification Limit規(guī)格下限Quality Standard質(zhì)量規(guī)范Defect 缺陷Defect 缺陷xxcn

16、shu 精品資料網(wǎng)Why are defects undesirable?為什么缺陷不受歡迎？Defects may also result in 缺陷還能夠?qū)е?High warranty costs 過高保修本錢 Lost customer sale 失去客戶Defects Require Correction = Correction is Waste 缺陷需求糾正糾正就是浪費(fèi)cnshu 精品資料網(wǎng) QUALITY IS EVERYONES RESPONSIBILITY質(zhì)量是每個(gè)人的職責(zé)Design, Engineering, Production, Quality, Support D

17、epartments and Suppliers. 設(shè)計(jì)，工程，消費(fèi)，質(zhì)量，相關(guān)部門及供應(yīng)商OUR Best Resources:我們最好的資源: PEOPLE 員工OUR Goal :我們的目的： Everyone is a Quality Inspector 人人都是質(zhì)檢員 Everyone is a Problem Solver 人人都是問題處理者cnshu 精品資料網(wǎng)WHO IS RESPONSIBLE FOR QUALITY? 誰對(duì)質(zhì)量擔(dān)任？WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RES

18、PONSIBLE FOR QUALITY?cnshu 精品資料網(wǎng)ME!我！cnshu 精品資料網(wǎng)Health andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturingProcess ValidationIn-ProcessControl & VerificationQualitySystemManagementScheduledShipping /ReceivingLevel Vehic

19、leOrder SchedulesSupplyChainManagementValuesVision/MissionShop FloorManagementInternal Pull /DeliveryAndonConceptProblemSolvingSimpleProcessFlowProduct Quality StandardsStandardizedWorkSmall LotPackagingTemporaryMaterialStorageQualityFeedback/Feed-forwardVisualManagementManagementby TAKT TimeWork-pl

20、aceOrganizationEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenance Fixed Period Ordering System/ Order PartsProductQualityStandards產(chǎn)質(zhì)量量規(guī)范cnshu 精品資料網(wǎng)Reflect voice of the custo

21、mer反映顧客的心聲Simple, clear & support user簡(jiǎn)單、明晰，有利操作者Clearly Measurable at point of use在運(yùn)用上可明確丈量Key Points of Good Quality Standards:質(zhì)量規(guī)范的要點(diǎn)： In users Std. Work & posted visual在操作者的規(guī)范化任務(wù)或張貼出來Standards Must Support the Operator, too Not only the Engineer!規(guī)范不僅有益于設(shè)計(jì)者，也有益于操作工人cnshu 精品資料網(wǎng)Not tighter than tho

22、se applied at the previous process 不要比前道工序的更嚴(yán)厲Key Points of Good Quality Standards:質(zhì)量規(guī)范的要點(diǎn)： Final Inspection Standard:Gap +/- 1mmFINAL INSPECTIONBODY SHOPBody ShopStandard:Gap +/- 2mmcnshu 精品資料網(wǎng)Use master parts and boundary samples as required to make visual規(guī)范件與邊境樣件需求目視化Key Points of Good Quality St

23、andards:質(zhì)量規(guī)范的要點(diǎn)： Boundary Samples should visually indicate OK Not OK condition to help operators make quick, good decisions邊境樣件應(yīng)該標(biāo)明好或不好，以便操作人員迅速且更好地下決議。Visually “describing the defect is Not a Boundary Sample! 目視化標(biāo)明缺陷不是邊境樣件！Crater more than this size is not acceptable不接受焊口大于此尺寸Example of a Boundary

24、Sample邊境樣品的范例cnshu 精品資料網(wǎng)Create a “Standards-Based Culture發(fā)明一個(gè)以規(guī)范為基點(diǎn)的文化氣氛I wouldnt buy this!Doesnt look good to me!My opinion isThis does not meet the standard.Talk in terms of The Standard, not opinions! 以規(guī)范為基點(diǎn)，而非觀念！cnshu 精品資料網(wǎng)ManufacturingProcess ValidationQualitySystemManagementProduct Quality Sta

25、ndardsQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal Producti

26、veMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam Concept

27、PeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl&VerificationManufacturingProcess Validation制造工序認(rèn)證cnshu 精品資料網(wǎng)What is a process?什么是工序？Inputs投入Outputs輸出A process is a set of inter-related resources and activities which transforms inputs into outputs.工序

28、是集中相關(guān)的資源進(jìn)展一系列活動(dòng)，把投入轉(zhuǎn)換成輸出！Environment環(huán)境Process 工序 Man MachinesMethod Materialscnshu 精品資料網(wǎng)Where can Errors Occur?問題會(huì)出在哪？Defects缺陷Materials:資料Parts out of standard 不符規(guī)范的零件Wrong parts錯(cuò)誤零件Poor design 設(shè)計(jì)不當(dāng) Method: 方法Poor std. Work 不好的規(guī)范任務(wù)Lack of Training 缺乏培訓(xùn) Machine/Process: 機(jī)器/工序No TPM 沒有TPMProcess not

29、capable 工序不好Improper specification 規(guī)格不當(dāng) Man:人力Not follow std. Work 不遵照規(guī)范化任務(wù)Distractions, Forgetfulness 分心、遺忘Lack of Experience 缺乏閱歷Errors Result Incnshu 精品資料網(wǎng)Validate the manufacturing process prior to Start of Production! 在消費(fèi)啟動(dòng)前認(rèn)證制造工藝！Do not切勿Accept 接受Build 制造Ship 傳送a Defect! 缺陷！Living Up to the Mo

30、tto到達(dá)口號(hào)“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place - Dr. DemingPFMEAWorkstationReadiness工位預(yù)備Process ControlPlan 工藝控制方案Error-proofing Plan防錯(cuò)方案cnshu 精品資料網(wǎng)Error Proofing Hierarchy 防錯(cuò)層次Prevention 預(yù)防Detection 檢測(cè)HumanJudgment人為判別None無Product /

31、 Process Design Change 產(chǎn)品/工藝設(shè)計(jì)改動(dòng) DFM/A & D/PFMEA Robust Designs & Capable Processes 機(jī)器設(shè)計(jì)及可行工藝 One-Way Assembly 同一裝配Process Controls 工藝控制Locating Pins & Stops 固定點(diǎn)及停點(diǎn)Sensors & Process Monitors 傳感器及工藝監(jiān)控Electro - Mechanical Devices 電子機(jī)械儀器Color Coding 顏色信號(hào)Visual Controls 直觀控制Andon Systems 暗燈系統(tǒng)Standardize

32、d Work 規(guī)范化任務(wù)Errors Cant Happen Small Improvement小改良Significant Improvement 艱苦改良Introduction to Error Proofing防錯(cuò)引見cnshu 精品資料網(wǎng)0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:Visual Control ExampleHuman Judgment0515100396OLHM51020150151012457810115Better:cnshu 精品

33、資料網(wǎng)ABExample: Vehicle Identification車輛認(rèn)證 (Mutilation Cover Color)(蓋板顏色毀損)Human Judgment 人為判別Visual Control Examplecnshu 精品資料網(wǎng)Vertical Plate垂直板Battery Post電池接頭Process Control ExampleDetection 檢測(cè)cnshu 精品資料網(wǎng)XWork Piece 加工件Work Piece 加工件Fixture 夾具Fixture 夾具Process Control ExamplePrevention 預(yù)防cnshu 精品資料網(wǎng)

34、Product Design Example (Before)REC STOP PAUSEREC STOP PAUSEOLDDESIGN老設(shè)計(jì)Can be Installed Upside Down 可以反安裝 Application of Labels on Cassette Decks.門板標(biāo)簽Prevention 預(yù)防cnshu 精品資料網(wǎng)REC STOP PAUSENEWDESIGN新設(shè)計(jì)Application of Labels on Cassette Decks.門板標(biāo)簽Can Only Be Installed Correctly!Product Design Example (

35、After)Preventioncnshu 精品資料網(wǎng)Left Hand Locator TabRight Hand Locator Tab Example - Product Error Proofing (One Way to Install Seat Belt)防錯(cuò)樣品只需一種平安帶安裝方法Product Design Example 產(chǎn)品設(shè)計(jì)范例Preventioncnshu 精品資料網(wǎng)Simple Everyday Examples1) Error Prevention Automatic shut-off自動(dòng)斷電cnshu 精品資料網(wǎng)Error Proofing Exercise

36、Think of an example at work or at home where error proofing can prevent an undesirable thing from happening 想想任務(wù)或生活中運(yùn)用防錯(cuò)措施防止不好事情發(fā)生的例子 Discuss as a team and report Take 5 minutes 小組討論、匯報(bào)5分鐘cnshu 精品資料網(wǎng)ManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementQualityFeedback/Feed-for

37、wardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExterna

38、l TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunica

39、tionProcessValuesVision/MissionShop FloorManagementIn-ProcessControl & Verification工序控制與認(rèn)證Product Quality Standardscnshu 精品資料網(wǎng)In-Process Control & Verification (3) Elements 工序控制與認(rèn)證1. PreventionOutputs輸出Inputs投入NOK2. DetectionOKNext Process下道工序Feedback 反響Do not不要Accept 接受Build 制造Ship 傳送a Defect! 缺陷！L

40、iving Up to the Motto符合規(guī)范3. Containment包容cnshu 精品資料網(wǎng)1) StandardizedWork 規(guī)范化任務(wù)Follow and Continuously Improve Standardized Work!遵守及不斷改良規(guī)范化任務(wù)！In-Process Control & Verification 1) PREVENTIONPreventionVehicle ManifestManual 2-DoorSunroofcnshu 精品資料網(wǎng)2) Focus on Operation 集中精神消費(fèi)Keep Your Concentration & Re

41、spect Standardized Work of Others!留意及尊重他人的規(guī)范化任務(wù)In-Process Control & Verification 1) PREVENTIONPreventioncnshu 精品資料網(wǎng)3) Error Proofing Prevention & Operator Aids 防錯(cuò)預(yù)防與操作者支持The Best Process is One That Cannot Fail!最好工序就是不會(huì)失敗的！In-Process Control & Verification 1) PREVENTIONPreventionDAEWOOcnshu 精品資料網(wǎng)4)

42、Regular Checks of Systems & Processes定時(shí)檢查系統(tǒng)與工藝Std. WorkChecks!檢查規(guī)范化任務(wù)In-Process Control & Verification 1) PREVENTIONPreventionCHECKCHECK?CHECKProcess Control Checks!檢查工序控制！TPM Checks!檢查TPMSafety/5SChecks!檢查平安/5Scnshu 精品資料網(wǎng)Self-Checks自檢Include Quality Checksin Standardized Work!把質(zhì)檢作為規(guī)范化任務(wù)的一部分In-Proce

43、ss Control & Verification 2) DETECTIONDetectionCheck Methods:POINTTOUCHLISTENCOUNTcnshu 精品資料網(wǎng)2) Error ProofingDetection 檢測(cè)防錯(cuò)Use Visual and Audio Signals!運(yùn)用視覺、聽覺信號(hào)！In-Process Control & Verification 2) DETECTIONDetectionStop the Line, or停線或Use Alarms, or運(yùn)用警報(bào)或Combination of Both, depending on Criticali

44、ty 根據(jù)危險(xiǎn)程度兼用兩種方法cnshu 精品資料網(wǎng)3) In-ProcessVerification 工序認(rèn)證Inspectors are not there as a policeman, theysupport production byconfirming the process!檢察員不充任警察角色，而是作為確定工序的消費(fèi)支持者In-Process Control & Verification 2) DETECTIONDetectionVerification Stations Final LineC.A.R.E.cnshu 精品資料網(wǎng)3a) Focus onCritical ite

45、ms 集中留意艱苦問題Frequency of checks to not allow Critical defects to leave the shop!經(jīng)常檢查，不讓艱苦缺陷走出車間！In-Process Control & Verification 2) DETECTIONDetectionSafety Items“Walk-Home ItemsMajor Customer DissatisfierS/CF/Fcnshu 精品資料網(wǎng)4) Defect Escalation缺陷逐層匯報(bào)Escalate defects to leadership for support depending

46、 on frequency and criticality!根據(jù)缺陷出現(xiàn)頻率與嚴(yán)重程度逐層向指點(diǎn)匯報(bào)以尋求支持！In-Process Control & Verification 2) DETECTIONDetectionExample:Team LeaderSection LeaderGroup Leader2 defects/ 1 hour4 defects/ 1 hourcnshu 精品資料網(wǎng)1) Use Andon (taught morelater) 運(yùn)用暗燈Make problems visual & pull in support!問題直觀，拉線尋求協(xié)助！In-Process C

47、ontrol & Verification 3) CONTAINMENTAlways Remember the Priorities:一定要牢記：1) Safety平安2) Quality質(zhì)量3) Responsiveness (Throughput)呼應(yīng)Containment包容cnshu 精品資料網(wǎng)2) Follow Containment Process 遵照包容程序Extraordinary actionsto prevent defects frombeing passed!采取特別行動(dòng)防止缺陷傳送！In-Process Control & Verification 3) CONTA

48、INMENTSome examples:1) Stop the line停線2) 100% checks100%檢查3) On-line repair 線上維修4) Reworks返工5) Sorting 整理Containment包容cnshu 精品資料網(wǎng)How Does our Quality Motto relate to Containment?Do not不要Accept 接受Build 制造Ship 傳送a Defect! 缺陷！It means empowered leaders make judgments how to control quality while trying

49、 to keep the line running!意味著指點(diǎn)有權(quán)作出決議：在盡量不停線的情況下，怎樣控制好質(zhì)量！Does this mean we stop the line every time we have a problem?這是不是意味著一有問題就停線呢？cnshu 精品資料網(wǎng)How Does our Quality Motto relate to Containment?Sometimes the best decision may be to let a defect pass to the next process, but有時(shí)最好的方法是讓過失轉(zhuǎn)到下工序，但是It is a

50、 conscious decision made by the appropriate level Action must be communicated to next “customerDefect must be clearly identified on vehicleContainment must be in place to prevent further defects Examples of Some Andon Guidelines: 暗燈運(yùn)用的指點(diǎn)方針1) Will the problem affect the next process? 問題會(huì)不會(huì)影響下道工序？2) C

51、an I effectively repair the defect out of station? 能不能在工位外有效處理問題？3) What is the status of my decouplers? 本人的切斷器是什么形狀？4) Others 其他cnshu 精品資料網(wǎng)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 li

52、ne back we know that every car in the system 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

53、arrive in 6 hours. The operators at end of 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 pro

54、cesses, and 3) Hoods can be changed out of station relatively easily. Discussion:You are the Plant Quality Manager what is your decision?Discuss as a group! cnshu 精品資料網(wǎng)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 containm

55、ent plan. Since the decoupler between Body and Paint 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.

56、 The Cost of stopping the line will not result in better 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 vehi

57、cle numbers and identification method.100% check at 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 - Hoo

58、ds cnshu 精品資料網(wǎng)Situation: At the Cockpit Load station in GA it 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 con

59、dition. The operators at Cockpit Load have pulled the Andon and 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 t

60、he next assembly process, 3) Repairing the harnesses on-line 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 cnshu