XX制造質(zhì)量2024/4/16XX制造質(zhì)量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

StorageFixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementManufacturing

Process

Validation制造工藝認證In-ProcessControl&Verification工藝控制與確認Quality

System

Management質(zhì)量體系管理Quality

Feedback/

Feed-forward質(zhì)量反饋/前饋ProductQualityStandards產(chǎn)品質(zhì)量標準Built-InQuality制造質(zhì)量精品資料網(wǎng)XX制造質(zhì)量Built-In-Quality

制造質(zhì)量WhatIsQuality?

什么是質(zhì)量？GroupDiscussion小組討論精品資料網(wǎng)XX制造質(zhì)量Definitions定義Qualityiswhatthecustomerperceivestobeacceptabletoachievehis/herenthusiasm質(zhì)量是客戶感覺能夠接受并滿足其熱忱的東西精品資料網(wǎng)XX制造質(zhì)量MadCow瘋牛(DiseasedMeat病牛肉)PoorQualityMeansLostSales質(zhì)量差意味著失去客戶Firestone燧石(UnintendedAccidents)意外事故uninstalledshiftlock漏裝移位鎖定(SuddenAcceleration)突然加速精品資料網(wǎng)XX制造質(zhì)量PP100:NotReportedDueToInsufficientSample樣品不足不匯報()J.D.PowerIQSTrendByBrand

精品資料網(wǎng)XX制造質(zhì)量NCSIByMakers-2002

2002????NCSICustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客戶期望值感知質(zhì)量感知價值客戶埋怨客戶忠誠客戶保持力精品資料網(wǎng)XX制造質(zhì)量精品資料網(wǎng)XX制造質(zhì)量VoiceofCustomer客戶意見精品資料網(wǎng)XX制造質(zhì)量VoiceofCustomer客戶意見??????????????1.停車方便(Convenienceofparking)2.外觀式樣(Exteriorstyling)3.內(nèi)部空間(Interiorroominess)4.節(jié)能(Fueleconomy)5.安全(Safety)1.外觀式樣

(Exteriorstyling)2.內(nèi)部空間(Interiorroominess)3.噪音與靜音(Noiseandquietness)4.節(jié)能(Fueleconomy)5.空調(diào)性能(Airconditionerperformance)???1.發(fā)動機性能(EnginePerformance)2.發(fā)動機噪音(EngineNoise)3.外觀式樣

(Exteriorstyling)4.噪音與靜音(Noiseandquietness)5.坐騎(Ride)L6????1.節(jié)能(Fueleconomy)2.噪音與靜音(Noiseandquietness)3.內(nèi)部空間(Interiorroominess)4.坐騎(Ride)5.外觀式樣

(Exteriorstyling)??1節(jié)能(Fueleconomy)2.空調(diào)(Airconditioner)3.噪音(Noise)4.發(fā)動機噪音(EngineNoise)5.M/T轉換(M/TShift)1.節(jié)能(Fueleconomy)2.OSRVM手工控制(ManualOSRVMcontrol)3.發(fā)動機噪音(Enginenoise)4.檢查發(fā)動機點火(CheckEnginelight)5.法人形象(CorporateImage)1.節(jié)能(Fueleconomy)2.制動性能(Brakeperformance)3.喇叭性能(Speakerperformance)4.內(nèi)飾品質(zhì)(Interiorquality)5.噴涂質(zhì)量差(Poorpaintquality)1.3排坐椅相稱(Seatscomport:3rdline)2.節(jié)能(Fueleconomy)3.發(fā)動機啟動(Poorenginestart)4.法人形象(CorporateImage)5.級別(Gradablity)精品資料網(wǎng)XX制造質(zhì)量Built-in-Quality

制造質(zhì)量WhatisBuilt-In-Quality?

什么是制造質(zhì)量？GroupDiscussion

小組討論精品資料網(wǎng)XX制造質(zhì)量WhatisBuilt-InQuality?什么是制造質(zhì)量？Definition定義Methodbywhichqualityisbuiltintothemanufacturingprocess,sothatdefectsareprevented,detected,andcountermeasuresareimplementedtopreventreoccurrence.指質(zhì)量在生產(chǎn)過程中產(chǎn)生，因此可以預防、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

Ensuresdefectsarenotpassedtothecustomer.確保不傳遞缺陷。精品資料網(wǎng)XX制造質(zhì)量Designers設計師Suppliers供應商Production生產(chǎn)人員Dealers經(jīng)銷商Buyers采購員Sales&Marketing銷售人員TheCustomerChain...CompanyPerspective客戶鏈…公司遠景Built-In-Quality

制造質(zhì)量精品資料網(wǎng)XX制造質(zhì)量Assembly總裝Supplier供應商Paint涂裝Body車身TheCustomerChain...ProductionPerspective客戶鏈…公司遠景EachProcessHasatLeastOne“Customer”andOne“Supplier”每個階段至少有一個客戶和一個供應商Built-In-Quality

制造質(zhì)量精品資料網(wǎng)XX制造質(zhì)量Donot不要Accept接受Build制造Ship傳遞aDefect!缺陷SolveProblemsThroughTeamwork!團隊合作解決問題！Built-In-QualityMotto

制造質(zhì)量口號SatisfyYourCustomer…滿足你的客戶精品資料網(wǎng)XX制造質(zhì)量QualityThroughTeamwork–KnowYourCustomer!Whatwaterleaks?Idon’tseeanywaterleaks什么漏雨？我沒發(fā)現(xiàn)漏雨。Thiscarwasn’tmadeonmyshiftTheproblemisPressShop.Theflangeistoolong.問題出自沖壓，邊緣過長Iwon’trunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower.Theproblemisthatthepiecesarebadfromthesupplier.問題在于供應商的材料不好。Itisnotfrommyarea,maybeit’sthesealer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，我不做任何試驗。這不是我負責的地方，也許是粘膠負責Don’trunawayfromtheproblem!

不要逃避問題!精品資料網(wǎng)XX制造質(zhì)量LivinguptotheMotto...符合口號...-WhatIsaDefect?

什么是缺陷？GroupDiscussion小組討論

Defect缺陷精品資料網(wǎng)XX制造質(zhì)量Adefectisaproductthatdoesnotmeettheestablishedqualitystandard.缺陷是不合已定標準的產(chǎn)品。Measurementofaqualitycharacteristic質(zhì)量性能測量Vehicle#車輛號UpperSpecificationLimit規(guī)格上限LowerSpecificationLimit規(guī)格下限QualityStandard質(zhì)量標準Defect缺陷Defect缺陷xx精品資料網(wǎng)XX制造質(zhì)量Whyaredefectsundesirable?為什么缺陷不受歡迎？Defectsmayalsoresultin…

缺陷還可能導致Highwarrantycosts過高保修成本Lostcustomersale失去客戶DefectsRequireCorrection=CorrectionisWaste

缺陷需要糾正—糾正就是浪費精品資料網(wǎng)XX制造質(zhì)量QUALITYISEVERYONE’S

RESPONSIBILITY

質(zhì)量是每個人的職責Design,Engineering,Production,Quality,SupportDepartmentsandSuppliers.

設計，工程，生產(chǎn)，質(zhì)量，相關部門及供應商OURBestResources:我們最好的資源:→

PEOPLE

員工OURGoal:我們的目標：

→ EveryoneisaQualityInspector

人人都是質(zhì)檢員 → EveryoneisaProblemSolver

人人都是問題解決者精品資料網(wǎng)XX制造質(zhì)量WHOISRESPONSIBLEFORQUALITY?誰對質(zhì)量負責？WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?精品資料網(wǎng)XX制造質(zhì)量ME!!!我！精品資料網(wǎng)XX制造質(zhì)量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

MaintenanceFixedPeriod

Ordering

System/OrderPartsProductQualityStandards產(chǎn)品質(zhì)量標準精品資料網(wǎng)XX制造質(zhì)量Reflectvoiceofthecustomer反映顧客的心聲Simple,clear&supportuser簡單、清晰，有利操作者ClearlyMeasurableatpointofuse在使用上可明確測量KeyPointsofGoodQualityStandards:

質(zhì)量標準的要點：

Inuser’sStd.Work&postedvisual在操作者的標準化工作或張貼出來StandardsMustSupporttheOperator,too–NotonlytheEngineer!!!標準不僅有益于設計者，也有益于操作工人精品資料網(wǎng)XX制造質(zhì)量Nottighterthanthoseappliedatthepreviousprocess

不要比前道工序的更嚴格KeyPointsofGoodQualityStandards:

質(zhì)量標準的要點：

FinalInspectionStandard:Gap+/-1mmFINALINSPECTIONBODYSHOPBodyShopStandard:Gap+/-2mm精品資料網(wǎng)XX制造質(zhì)量Usemasterpartsandboundarysamplesasrequiredtomakevisual標準件與邊界樣件需要目視化KeyPointsofGoodQualityStandards:

質(zhì)量標準的要點：

BoundarySamplesshouldvisuallyindicateOK–NotOKconditiontohelpoperatorsmakequick,gooddecisions邊界樣件應該標明好或不好，以便操作人員迅速且更好地下決定。Visually“describing”thedefectisNotaBoundarySample!目視化標明缺陷不是邊界樣件！Cratermorethanthissizeisnotacceptable不接受焊口大于此尺寸ExampleofaBoundarySample邊界樣品的范例精品資料網(wǎng)XX制造質(zhì)量Createa“Standards-Based”Culture

創(chuàng)造一個以標準為基點的文化氛圍Iwouldn’tbuythis!Doesn’tlookgoodtome!Myopinionis…Thisdoesnotmeetthestandard..TalkintermsofTheStandard,notopinions!以標準為基點，而非觀點！精品資料網(wǎng)XX制造質(zhì)量Manufacturing

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

StorageFixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&VerificationManufacturing

Process

Validation制造工序認證精品資料網(wǎng)XX制造質(zhì)量Whatisaprocess?

什么是工序？Inputs投入Outputs輸出Aprocessisasetofinter-relatedresourcesandactivitieswhichtransformsinputsintooutputs.工序是集中相關的資源進行一系列活動，把投入轉換成輸出！Environment環(huán)境Process工序ManMachinesMethodMaterials精品資料網(wǎng)XX制造質(zhì)量WherecanErrorsOccur?

問題會出在哪？Defects缺陷Materials:材料Partsoutofstandard不符標準的零件Wrongparts錯誤零件Poordesign設計不當

Method:方法Poorstd.Work不好的標準工作LackofTraining缺乏培訓

Machine/Process:機器/工序NoTPM沒有TPMProcessnotcapable工序不好Improperspecification規(guī)格不當

Man:人力Notfollowstd.Work不遵循標準化工作Distractions,Forgetfulness分心、遺忘LackofExperience缺乏經(jīng)驗ErrorsResultIn精品資料網(wǎng)XX制造質(zhì)量ValidatethemanufacturingprocesspriortoStartofProduction!在生產(chǎn)啟動前認證制造工藝！Donot切勿Accept

接受Build

制造Ship傳遞aDefect!

缺陷！LivingUptotheMotto…達到口號“EliminatetheNeedforInspectiononaMassBasisbyBuildingQualityintotheProductintheFirstPlace”-Dr.Deming PFMEAWorkstationReadiness工位準備ProcessControlPlan工藝控制計劃Error-proofingPlan防錯計劃精品資料網(wǎng)XX制造質(zhì)量ErrorProofingHierarchy防錯層次Prevention預防Detection檢測HumanJudgment人為判斷None無Product/ProcessDesignChange產(chǎn)品/工藝設計改變DFM/A&D/PFMEARobustDesigns&CapableProcesses機器設計及可行工藝One-WayAssembly同一裝配ProcessControls工藝控制LocatingPins&Stops固定點及停點Sensors&ProcessMonitors傳感器及工藝監(jiān)控Electro-MechanicalDevices電子機械儀器ColorCoding顏色信號VisualControls直觀控制AndonSystems暗燈系統(tǒng)StandardizedWork標準化工作ErrorsCan’tHappenSmallImprovement小改進SignificantImprovement重大改進IntroductiontoErrorProofing防錯介紹精品資料網(wǎng)XX制造質(zhì)量0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:VisualControlExampleHumanJudgment0515100396OLHM51020150151012457810115Better:精品資料網(wǎng)XX制造質(zhì)量ABExample:VehicleIdentification車輛認證

(MutilationCoverColor)(蓋板顏色毀損)HumanJudgment人為判斷VisualControlExample精品資料網(wǎng)XX制造質(zhì)量VerticalPlate垂直板BatteryPost電池接頭ProcessControlExampleDetection檢測精品資料網(wǎng)XX制造質(zhì)量XWorkPiece加工件WorkPiece加工件Fixture夾具Fixture夾具ProcessControlExamplePrevention預防精品資料網(wǎng)XX制造質(zhì)量ProductDesignExample(Before)REC<<>>>STOPPAUSEREC<<>>>STOPPAUSEOLDDESIGN老設計CanbeInstalledUpsideDown可以反安裝ApplicationofLabelsonCassetteDecks.門板標簽Prevention預防精品資料網(wǎng)XX制造質(zhì)量REC<<>>>STOPPAUSENEWDESIGN新設計ApplicationofLabelsonCassetteDecks.門板標簽CanOnlyBeInstalledCorrectly!ProductDesignExample(After)Prevention精品資料網(wǎng)XX制造質(zhì)量LeftHandLocatorTabRightHandLocatorTabExample--ProductErrorProofing(OneWaytoInstallSeatBelt)防錯樣品—只有一種安全帶安裝方法ProductDesignExample產(chǎn)品設計范例Prevention精品資料網(wǎng)XX制造質(zhì)量SimpleEverydayExamples1)ErrorPrevention????Automaticshut-off自動斷電精品資料網(wǎng)XX制造質(zhì)量ErrorProofingExerciseThinkofanexampleatworkorathomewhereerrorproofingcanpreventanundesirablethingfromhappening想想工作或生活中使用防錯措施避免不好事情發(fā)生的例子Discussasateamandreport–Take5minutes小組討論、匯報—5分鐘精品資料網(wǎng)XX制造質(zhì)量Manufacturing

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

StorageFixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&Verification工序控制與認證ProductQualityStandards精品資料網(wǎng)XX制造質(zhì)量In-ProcessControl&Verification–(3)Elements工序控制與認證1.PreventionOutputs輸出Inputs投入NOK2.DetectionOKNextProcess下道工序Feedback反饋Donot不要Accept

接受Build

制造Ship

傳遞aDefect!

缺陷！LivingUptotheMotto…符合標準3.Containment包容精品資料網(wǎng)XX制造質(zhì)量1)StandardizedWork標準化工作FollowandContinuouslyImproveStandardizedWork!!!遵守及不斷改進標準化工作??！In-ProcessControl&Verification–1)PREVENTIONPreventionVehicleManifestManual2-DoorSunroof精品資料網(wǎng)XX制造質(zhì)量2)FocusonOperation集中精力生產(chǎn)KeepYourConcentration&RespectStandardizedWorkofOthers!注意及尊重他人的標準化工作In-ProcessControl&Verification–1)PREVENTIONPrevention精品資料網(wǎng)XX制造質(zhì)量3)ErrorProofingPrevention&OperatorAids防錯預防與操作者支持TheBestProcessisOneThatCannotFail!最好工序就是不會失敗的！In-ProcessControl&Verification–1)PREVENTIONPreventionDAEWOO精品資料網(wǎng)XX制造質(zhì)量4)RegularChecksofSystems&Processes定時檢查系統(tǒng)與工藝Std.WorkChecks!檢查標準化工作In-ProcessControl&Verification–1)PREVENTIONPreventionCHECKCHECK???????CHECKProcessControlChecks!檢查工序控制！TPMChecks!檢查TPMSafety/5SChecks!檢查安全/5S精品資料網(wǎng)XX制造質(zhì)量Self-Checks自檢IncludeQualityChecksinStandardizedWork!把質(zhì)檢作為標準化工作的一部分In-ProcessControl&Verification–2)DETECTIONDetectionCheckMethods:POINTTOUCHLISTENCOUNT精品資料網(wǎng)XX制造質(zhì)量2)ErrorProofingDetection檢測防錯UseVisualandAudioSignals!使用視覺、聽覺信號！In-ProcessControl&Verification–2)DETECTIONDetectionStoptheLine,or停線或UseAlarms,or使用警報或CombinationofBoth,dependingonCriticality根據(jù)危險程度兼用兩種方法精品資料網(wǎng)XX制造質(zhì)量3)In-ProcessVerification工序認證Inspectorsarenotthereasapoliceman,theysupportproductionbyconfirmingtheprocess!檢察員不充當警察角色，而是作為確定工序的生產(chǎn)支持者In-ProcessControl&Verification–2)DETECTIONDetectionVerificationStationsFinalLineC.A.R.E.精品資料網(wǎng)XX制造質(zhì)量3a)FocusonCriticalitems集中注意重大問題FrequencyofcheckstonotallowCriticaldefectstoleavetheshop!經(jīng)常檢查，不讓重大缺陷走出車間！In-ProcessControl&Verification–2)DETECTIONDetectionSafetyItems“Walk-Home”ItemsMajorCustomerDissatisfierS/CF/F精品資料網(wǎng)XX制造質(zhì)量4)DefectEscalation缺陷逐層匯報Escalatedefectstoleadershipforsupportdependingonfrequencyandcriticality!根據(jù)缺陷出現(xiàn)頻率與嚴重程度逐層向領導匯報以尋求支持！In-ProcessControl&Verification–2)DETECTIONDetectionExample:TeamLeaderSectionLeaderGroupLeader2defects/1hour4defects/1hour精品資料網(wǎng)XX制造質(zhì)量1)UseAndon(taughtmorelater)使用暗燈Makeproblemsvisual&pullinsupport!問題直觀，拉線尋求幫助！In-ProcessControl&Verification–3)CONTAINMENTAlwaysRememberthePriorities:一定要牢記：1)Safety安全2)Quality質(zhì)量3)Responsiveness(Throughput)響應Containment包容精品資料網(wǎng)XX制造質(zhì)量2)FollowContainmentProcess遵循包容程序Extraordinaryactionstopreventdefectsfrombeingpassed!采取特別行動防止缺陷傳遞！In-ProcessControl&Verification–3)CONTAINMENTSomeexamples:1)Stoptheline停線2)100%checks100%檢查3)On-linerepair線上維修4)Reworks返工5)Sorting整理Containment包容精品資料網(wǎng)XX制造質(zhì)量HowDoesourQualityMottorelatetoContainment?Donot不要Accept

接受Build

制造Ship

傳遞aDefect!

缺陷！Itmeansempoweredleadersmakejudgmentshowtocontrolqualitywhiletryingtokeepthelinerunning!!意味著領導有權作出決定：在盡量不停線的情況下，怎樣控制好質(zhì)量！Doesthismeanwestopthelineeverytimewehaveaproblem?這是不是意味著一有問題就停線呢？精品資料網(wǎng)XX制造質(zhì)量HowDoesourQualityMottorelatetoContainment?Sometimesthebestdecisionmaybetoletadefectpasstothenextprocess,but…有時最好的辦法是讓差錯轉到下工序，但是……ItisaconsciousdecisionmadebytheappropriatelevelActionmustbecommunicatedtonext“customer”DefectmustbeclearlyidentifiedonvehicleContainmentmustbeinplacetopreventfurtherdefects

ExamplesofSomeAndonGuidelines:暗燈使用的指導方針1)Willtheproblemaffectthenextprocess?問題會不會影響下道工序？2)CanIeffectivelyrepairthedefectoutofstation?能不能在工位外有效解決問題？3)Whatisthestatusofmydecouplers?自己的切斷器是什么狀態(tài)？4)Others…其他……精品資料網(wǎng)XX制造質(zhì)量AndonDiscussion–HoodsSituation:AttheBodyShopend-of-lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods.AfterworkingthelinebackweknowthateverycarinthesystemhastheconditionallthewaytoHoodInstall.Aftersortingtherawhoods,itisfoundthatthereareenoughgoodhoodstokeepproducingcars,howevertherearenotenoughgoodhoodstorepairthedefectivecarson-line.Thesupplersaysnewhoodswillarrivein6hours.TheoperatorsatendoflinehavepulledtheAndonandtheescalationprocesshaspulledintheBodyShopManagerandQualityManager.Considerationsare:1)ThedecouplerbetweenBodyandPaintisalmostempty,2)Hoodswithcrackedmetalwillnotaffectanyofthesubsequentprocesses,and3)Hoodscanbechangedoutofstationrelativelyeasily.Discussion:YouarethePlantQualityManager–whatisyourdecision?Discussasagroup!

精品資料網(wǎng)XX制造質(zhì)量Background:Inthiscase,thedecisionisisshutdownthelinefor(6)hoursandwaitforpartsorrunthelineandmakeacontainmentplan.SincethedecouplerbetweenBodyandPaintisalmostempty,thismeansallBody,PaintandGAwillalleventuallyshutdown.PotentialDecision:Inthiscase,QualitycanstillbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethehoodsdonotaffectthenextprocess.TheCostofstoppingthelinewillnotresultinbetterQualityorResponsiveness.Thus,agooddecisionwouldprobablybetorunthelineandmakeacontainmentplan:Allcarswithbadhoodstobespeciallyidentified.ProductionandQualityinPaintandGAnotifiedofthesituation,knowthevehiclenumbersandidentificationmethod.100%checkatHoodInstalloperationuntilprocesscapabilityisassured.PaintandFinalProcessnotifiedthatnewhoodstobepaintedinPaintandwillbeswappedinFinalProcessareaandhavetimetomakeaplanhowtoaccommodatethat.AndonDiscussion-Hoods精品資料網(wǎng)XX制造質(zhì)量Situation:AttheCockpitLoadstationinGAitisdiscoveredthatthereisaproblemwithoneoftheelectricalharnesseswithinthecockpit.Thecockpitsarebuiltasamodulebyanoutsidesupplier.Afterworkingthelinebackweknowthatseveralcockpitsinthesystemhavethecondition.TheoperatorsatCockpitLoadhavepulledtheAndonandtheescalationprocesshaspulledintheTrimLineSectionLeader,whoconsultswiththeChassisLineSectionLeader.Considerationsare:1)ThedecouplerbetweenTrimandChassisabouthalffull,2)Theelectricalharnesswillaffectthenextassemblyprocess,3)Repairingtheharnesseson-linewilltakeapproximatelyonehour,and4)RepairingtheCockpitlaterintheprocessisdifficultandverytimeconsuming.Discussion:YouaretheTrimSectionLeader–whatisyourdecision?Discussasagroup!

AndonDiscussion-Cockpits精品資料網(wǎng)XX制造質(zhì)量Background:Inthiscase,thedecisionisisshutdownthelinefor(1)hourandrepairtheharnessespriortoCockpitLoadorrunthelineandrepairthecockpitsout-of-station.SincethedecouplerbetweenTrimandChassisisabouthalffull,thismeansthatChassiscancontinuerunningforashortwhileandtheneventuallyshutdown.PotentialDecision:Inthiscase,QualitycannotbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethebadcockpitsaffectthenextprocessandareextremelydifficulttorepairlater.TheCostofstoppingthelineismoredesirablethanthecostofrepairingthemlaterandthepotentialtocreatemoredefects.Inthiscase,thedecouplerstatusdoesnotreallyimpactthefinaldecisiontoomuch.Thus,agooddecisionwouldprobablybetostopthelineandfixtheharnessespriortoCockpitInstall.TheTrimLineSectionLeaderwillinformtheGAAreaManagerofthisdecisionandtheimpactonourResponsivenesstarget.AndonDiscussion-Cockpits精品資料網(wǎng)XX制造質(zhì)量Manufacturing

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

StorageFixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVisionShopFloor

ManagementQuality

Feedback/

Feedforward質(zhì)量反饋與前饋ProductQualityStandardsIn-ProcessControl&Verification精品資料網(wǎng)XX制造質(zhì)量“Customer”客戶QualityInformationFeedback/Feedforward

質(zhì)量反饋與前饋“Suppliers”供應商You你ProcessAProcessBProcessCbackDefectflowingfromAtoB

缺陷從A流到BStatusonProblemResolution

問題解決狀態(tài)forwardEscapeddefectflowingtoProcessC避免缺陷流到CTemporaryprocessbeingusedinProcessB

過程B的暫時方案Process/productchangewithtime

工藝/產(chǎn)品隨時間改變StatusonProblemResolution

問題解決狀態(tài)精品資料網(wǎng)XX制造質(zhì)量MotivationforTimelyFeedback

及時反饋的動機Immediate1Day1YearHighMediumLow1s100s1000sTimetoDiscoverDefect發(fā)現(xiàn)缺陷的時間AbilitytoDiscoverRootCause發(fā)現(xiàn)根源的能力NumberofDefectiveVehiclesBuilt已經(jīng)生產(chǎn)的缺陷產(chǎn)品精品資料網(wǎng)XX制造質(zhì)量Example--DailyReportingMetrics(DirectRun)

每天匯報制度DefinitionPercentageofvehiclesthatmadeitthroughtotheEnd-of-Lineinspectionprocesseswithnodefects.Thisisacommon,globalmetricthatiscomputeddailybyallAssemblyPlants.

下線檢查合格的車輛百分比，這是全球統(tǒng)一在所有總裝廠每天用電腦記錄的制度。FinalInspection(End-of-Line)下線檢測DynamicV