夾具重復(fù)性試驗(yàn)轉(zhuǎn)孔TOMOANAEnglish-Chinese課件

全員參與標(biāo)準(zhǔn)化作業(yè)持續(xù)改進(jìn)縮短制造周期造入質(zhì)量通用-全球制造系統(tǒng)Principle:BuiltInQuality

原則：造入質(zhì)量Element:14ManufacturingProcessValidation

元素：14個(gè)制造工藝驗(yàn)證GM-GMSOperatingTool

通用-全球制造系統(tǒng)操作工具14.5TOMOANA僅供通用內(nèi)部使用2010年8月全員參與標(biāo)準(zhǔn)化作業(yè)持續(xù)改進(jìn)縮短制造周期造入質(zhì)量通用-全球制造1CopyrightNotice版權(quán)聲明?August,2000GeneralMotorsCorporation(GM).2000年8月，通用汽車公司Allrightsreserved.版權(quán)所有Nopartofthismaterialmaybereproducedinanyformorbyanymethod(photocopy,microfilm,digital,etc.)withoutthewrittenpermissionofGeneralMotorsCorporation,educationalpurposesincluded.本資料中的任何部分在沒(méi)有通用汽車公司書面許可證的情況下不得以任何形式或任何方式（復(fù)印，縮微拍攝，數(shù)碼拍照等等）復(fù)制，包括教育用途。CopyrightNotice2Scope范圍Thisoperatingtooldefinesroles&responsibilitiesforTOMOANAactivitiesappliedtoallGMSouthAmericaandAfricanAssemblyPlants.本操作工具為應(yīng)用于所有通用南美和非洲的組裝工廠的TOMOANA活動(dòng)定義了角色和責(zé)任。Definition定義TOMOANAisamethodtoensuretheprocessrepeatabilityinweldingfixturesforweldedsubassembliesandreducedimensionalvariationinBody-in-whitebuildupprocess.TOMOANA是一種確認(rèn)焊接夾具工藝復(fù)現(xiàn)性和在白車身制造過(guò)程中減少尺寸變化的方法。Purpose目的▲

SupportGM-GMSprinciple:¨Built-in-Quality〃;

支持通用-全球制造系統(tǒng)原則：制造質(zhì)量；▲

SupportdeliverableexecutionasrequiredinMQRR(ManufacturingQualityReadinessReview);

支持根據(jù)MQRR（制造質(zhì)量準(zhǔn)備評(píng)審）要求的交付運(yùn)行；▲

Definethestandardizedprocessforvalidationandcontrolandverificationofstabilityforweldingfixture.

確定驗(yàn)證和控制標(biāo)準(zhǔn)化程序和焊接夾具穩(wěn)定性驗(yàn)證。Scope范圍3Responsibility責(zé)任TheManufacturingEngineering(DimensionalEngineering)istheprocessownerforimplementationofthisprocessduringtheLaunch.TheBodyShopManageristheprocessownerforexecutionofthisprocedureinregularproduction.工藝（尺寸工程師）是負(fù)責(zé)在產(chǎn)品啟動(dòng)過(guò)程中實(shí)施流程。車身車間經(jīng)理是在量產(chǎn)時(shí)運(yùn)行這個(gè)過(guò)程的負(fù)責(zé)人。IntroductionTOMOANAisatoolappliedtoensurethedimensionalrepeatabilityinweldedsubassembliesanditiseffectivepreventivetooltosupporttheQualityMotto;Donotaccept,buildandshipDefects.TOMOANA是適用于焊接總成部件時(shí)相關(guān)尺寸的確認(rèn)，是一種預(yù)防性的工具，它是有效來(lái)支持質(zhì)量格言的預(yù)防工具：絕不接受，制造，傳遞缺陷。ItisamethodologyappliedtoreducedimensionalvariationinBodyShopandcontinuouslyimprovetheDimensionalQualityofBIWandAssemblies(Arateand6Sigma).它是適用于在車身車間減少尺寸變化和持續(xù)改進(jìn)白車身和裝配的尺寸質(zhì)量的方法論（等級(jí)A和6Sigma）。DonotDefects絕不接受制造傳遞缺陷Responsibility責(zé)任Donot4Enablers要素?Standardparts;

標(biāo)準(zhǔn)件；?Weldingfixtures;

焊接夾具；?Measurementsystem(GaugePass-no-Pass);

測(cè)量系統(tǒng)（測(cè)量及格不及格）?StandardizeWork;

標(biāo)準(zhǔn)化工作；?Records(validationanddailyrecord);

記錄（確認(rèn)及日記錄）Enablers要素5TOMOANA:PDCAcycle6.ProblemSolving;7.Effectiveness&Efficiency.1.TOMOANAplanning;2.TOMOANAvalidation5.Alarm&Escalation;3.DailyControl(Productioncore)4.WeeklyMonitoring(Qualitycore)PDCA周期計(jì)劃驗(yàn)證問(wèn)題解決效力與效率報(bào)警升級(jí)日常管理（生產(chǎn)核心）周監(jiān)督（質(zhì)量核心）TOMOANA:PDCAcycle6.Problem61-Planning:Launchprocess計(jì)劃：流程啟動(dòng)TheTOMOANAmustbedevelopedforalltheintheBodyShopProcess.Geo-stationsmeansanysub-assembledpartsthatimpactthegeometryofthevehicleandstillcanbeapplicableforanysub-assembledpartthatiscausingdownstreamqualityissues(noise,waterintrusion,fits)orthatisknownascritical.

TOMOANA必須在車身車間程序中為所有GEO-STATIONS發(fā)展。Geo-stations意味著任何影響車輛幾何學(xué)的初級(jí)裝配零件并且仍然適用于引起質(zhì)量問(wèn)題（異響，水浸，匹配問(wèn)題）或者是危險(xiǎn)的初級(jí)裝配零件。DuringtheBodyShopReadinessthistoolshouldbeinitiatedtogetherwithIterativematchingactivities(53weekspriortoSORP)andachieve100%approvedbyEndofMVBns.

在車身車間準(zhǔn)備期間，此工具應(yīng)該和反復(fù)的匹配活動(dòng)一起啟動(dòng)（在SORP階段53周前）并且在MVBns結(jié)束時(shí)得到100%通過(guò)。TOMOANATimeline時(shí)間軸技術(shù)規(guī)格檢驗(yàn)感覺(jué)特性設(shè)計(jì)研究生產(chǎn)裝配文件下發(fā)100%通過(guò)第一圈1-Planning:Launchprocess計(jì)71-Planning:Currentprocess計(jì)劃：目前工藝TOMOANAisalsoappliedindimensionalcontinuousimprovementprocessforcurrentprograms.BasedontheGCA,VerificationStationandCMMfeedbacksTOMOANAcansupportamethodtoeliminatethevariabilityexistingonweldedsubassemblyfixtureaftertherootcausedanalyzed.TOMOANA也適用于目前項(xiàng)目的空間持續(xù)改進(jìn)程序。根據(jù)GCA、檢驗(yàn)站和CMM回饋，TOMOAMA可以在分析根本原因之后，支持消除存在于焊接部件夾具變異性的方式。偏差1-Planning:Currentprocess8TOMOANAPlanning計(jì)劃

TheTOMOANAmusthaveadeploymentplandeveloped,whichincludesfourkeyattributes(4Ms)toensuretheadequateexecutionlevelfromtheTOMOANAactivities:

TOMOANA必須發(fā)展部署計(jì)劃，包括4個(gè)保證TOMOANA行為適當(dāng)運(yùn)行水平的關(guān)鍵屬性：1.Man:

人員1.1Defineteamtoperformthevalidationprocess;

明確小組實(shí)施驗(yàn)證程序；Dimensionalexpertshouldleadorsupportteam;

空間專家應(yīng)該領(lǐng)導(dǎo)或支持小組；1.2DefinebywhomtheDailyControlwillbeconducted;

明確誰(shuí)來(lái)執(zhí)行日常管理；1.3Developtrainingforthedifferentlevelsofpeopleinvolvementanddeployit;

為各階層的參與人員開(kāi)展并部署培訓(xùn)；2.Material:材料2.1Definehowstandardpartswillbeavailable;

明確標(biāo)準(zhǔn)件如何可用；2.2Definewhereandhowthestandardpartswillbestorage,includewhoismakethesupports;

明確標(biāo)準(zhǔn)件應(yīng)該如何存放并存放在哪里，包括誰(shuí)來(lái)支持；2.3Definewhenthestandardpartsshouldbeexchanged(date);

明確何時(shí)交換標(biāo)準(zhǔn)件（日期）；3.Machine:機(jī)器3.1Definewhichweldingfixturewillbeimplementedandwhen;

明確適用哪個(gè)焊接夾具，何時(shí)適用；4.Method:

方案4.1Deploymeasurementprocessandpingagemustbeenoughforalltheareas;

部署測(cè)量程序，全部地區(qū)的定位銷板必須充足；4.2DevelopStandardizedWork(STS/TIS)andapplyJIT.

開(kāi)展標(biāo)準(zhǔn)化工作（STS/TIS）并且應(yīng)用JIT.TOMOANAPlanning計(jì)劃1.Man:人員91.TOMOANAPlanning計(jì)劃MeasurementSystem;測(cè)量系統(tǒng)Gaugesin3.0-3.5and4.0mmareappliedtomeasurethediametersofholespreviouslyidentified.3.0-3.5mm和4.0mm的測(cè)量?jī)x器應(yīng)用于以前確定的孔的直徑。測(cè)量?jī)x器測(cè)量系統(tǒng)1.TOMOANAPlanning計(jì)劃Measurem10驗(yàn)證流程：TOMOANA驗(yàn)證標(biāo)記并打4.0mm的孔打開(kāi)夾鉗，移動(dòng)零件，放下零件，關(guān)閉夾鉗測(cè)量孔的直徑并記錄每10個(gè)重復(fù)項(xiàng)目3和4結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？分析并做調(diào)整?；氐巾?xiàng)目1階段1階段2打開(kāi)夾鉗，移動(dòng)零件，放下零件，夾緊夾鉗測(cè)量孔的直徑并記錄每5個(gè)重復(fù)項(xiàng)目7和8結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？打開(kāi)夾鉗，移動(dòng)零件，放下零件，關(guān)閉夾鉗測(cè)量孔的直徑并記錄階段3結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？結(jié)束驗(yàn)證。存檔文件驗(yàn)證流程：TOMOANA驗(yàn)證標(biāo)記并打4.0mm的孔打開(kāi)夾鉗，112-ValidationProcess;驗(yàn)證程序Theinitialvalidationprocessmustbeconductedinfourstepsasfollows:最初的驗(yàn)證程序必須按照以下四個(gè)步驟執(zhí)行：3.1Defineholepositionsandmaketheholes;

確定孔位并打孔；3.2Repeatabilityoftheweldingfixtureclamping;

焊接夾具鉗位重復(fù)定位；3.3Repeatabilitywith“cold”welding;

用冷焊重復(fù)定位；3.4Studyinweldedsubstructure;

研究焊接底層結(jié)構(gòu)；Duringthevalidationprocessisimportanttomention;驗(yàn)證程序的重點(diǎn)：?Thesamesubassemblypartswillbeusedforallphase(I,IIandIII);

相同組件應(yīng)該應(yīng)用于各個(gè)階段（I,II和

III）?Afterrunsprocessvalidationtheweldedsubassembliesshallbedisposalforscraporifnodamagewasdone,canbeusedasnormalproductionparts,aslongproductengineeringapproves.

運(yùn)行驗(yàn)證程序之后，焊接組件應(yīng)該處理廢料，或者如果沒(méi)有損壞，可以作為正常生產(chǎn)零件使用，只要產(chǎn)品工程批準(zhǔn)。2-ValidationProcess;驗(yàn)證程序122-ValidationProcess;驗(yàn)證程序3.1Defineholepositionsandmaketheholes;

確定孔位并打孔；It’s

thefirststepfortheTomoanavalidation.EnsurethatweldingfixtureisOKandthereisnotpotentialvariationrelatedtofixtures.Makesurethatallholesdefinedareabletoidentifyanyvariationonsubassemblyprocessand:這是Tomoana驗(yàn)證的第一步。確保焊接夾具沒(méi)問(wèn)題，并且沒(méi)有涉及到夾具的潛在變化。確保所有確定的孔都能夠在分部裝配過(guò)程中鑒定任何變化并且：?analyzeallthevariationtobestudied(x,yandzaxles)betweentwoormoreparts;

分析全部要研究的兩個(gè)或多個(gè)零件之間的變化（x,y和z軸）；?defineaminimumoftwopointsthatguaranteethisvariation;

確定最小的保證這個(gè)變化的兩點(diǎn)；?definethelocationoftheperforationconsidering:

確定穿孔位置時(shí)考慮到：?mustnotcoincidewithweldingspotposition;

一定不要和焊點(diǎn)位置一致；?mustbeaccessibleformeasuringontheweldingfixture;

一定在焊接夾具上能夠測(cè)量；?eliminatetheburrsontheholes;

去除孔邊的毛刺；?identifytheholeswithnumbers;

確定孔的編號(hào)；見(jiàn)附件A2-ValidationProcess;驗(yàn)證程序3.113確定孔位并打孔（繼續(xù)部分）例如：基準(zhǔn)面注意孔的質(zhì)量！穿孔直徑：4mm確定孔位并打孔（繼續(xù)部分）例如：基準(zhǔn)面注意孔的質(zhì)量！穿孔直徑14確定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外部部件聯(lián)合區(qū)域右邊左邊確定零件上的部件聯(lián)合區(qū)域以確保適當(dāng)?shù)拇┛状_定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外部152.2RepeatabilityofWeldingFixturesClamping(phaseI)

焊接夾具鉗位的重復(fù)性（第一階段）Oncemadetheholestherepeatabilityprocessonweldingfixturesclampingisinitiated(phaseI).IftheClampingdoesnotabletoproviderepeatabilitytheweldingfixturehastobeadjustedor/andre-definenewholespositions.Thepreviousstepredone.一旦打孔了，焊接夾具鉗位的重復(fù)性程序就啟動(dòng)了（第一階段）。如果鉗位不能提供重復(fù)性，必須調(diào)整焊接夾具或者重新確定孔位。然后重復(fù)前面的步驟。2.2.1–PerformClampingProcess;

執(zhí)行夾緊步驟Repeat10timesthefollowingsequence;重復(fù)10次以下序列；a)removepiecesandrelocatethem;移動(dòng)并重新安置零件；b)clampthefixture;夾緊夾具；c)measurethediameteroftheholesandregister(appendixB).測(cè)量孔的直徑并記錄下來(lái)（附件B）。

需要測(cè)量的孔見(jiàn)附件B2.2RepeatabilityofWeldingF16FortheValidationProcessisrecommendedtovalidatewitheveryholesdiameterminorthan0.5mm.Conditionalacceptshouldbeavoidedtonotimpactthenextphasesoftheprocess.建議的驗(yàn)證程序檢驗(yàn)每個(gè)孔的直徑小于0.5mm。有條件的接受應(yīng)避免影響程序的下一階段。焊接夾具鉗位的重復(fù)性（第一階段）評(píng)價(jià)夾緊步驟；驗(yàn)證程序的標(biāo)準(zhǔn)（一、二、三階段）接受：直徑變化：小于0.5mm有條件的接受：直徑變化：0.5到1.0mm拒絕：直徑變化：大于1.0mmFortheValidationProcessis172.3Repeatabilitywith“cold”welding;冷焊的重復(fù)性Thisstepwillensurewhatevervariationbetweenweldingfixturesandweldingprocess(phaseII)doesnotoccur.這一步驟確保焊接夾具和焊接程序間是否存在變化（第二階段）。2.3.1ApplyColdwelding;應(yīng)用冷焊-Repeat5timesthefollowingsequence:重復(fù)5次以下序列：a)removepiecesandrelocatethem;移動(dòng)并重新安置零件；b)Applycoldwelding(withpressureandwithoutcurrent);應(yīng)用冷焊（用壓力不用電流）c)measurethediameteroftheholesandregister(appendixB)測(cè)量孔的直徑并記錄（附件B）2.3.2AssessColdweldingprocess;評(píng)價(jià)冷焊工藝；IfcoldweldingprocessisacceptableunderValidationcriteriamovefornextphase.Ifnot,understandweldingfixturevariationandeliminateit.Thenstartthevalidationprocessagain(phaseI).如果在驗(yàn)證標(biāo)準(zhǔn)下冷焊工藝是可接受的就進(jìn)行下一階段。如果不可接受，了解焊接夾具變化并且消除。然后再次開(kāi)始驗(yàn)證程序（第一階段）。焊鉗冷點(diǎn)焊見(jiàn)附件B2.3Repeatabilitywith“cold”w182.4Studyinweldedsubassemblies;研究焊接組件ThisisthelaststepofTOMOANAValidationwithweldedsubassemblies(phaseIII).這是焊接組件TOMOANA驗(yàn)證的最后一步。2.4.1Welding;焊接Repeatoncethefollowingsequence:重復(fù)一次以下序列：removepiecesandrelocatethem;移動(dòng)并切重新安置零件；b)clampingtheweldingfixtures;夾緊焊接夾具；c)weldtheparts;焊接零件；d)measurethediameteroftheholesandregister(appendixB).測(cè)量孔的直徑并做記錄（附件B）。

2.4.2AssessWeldingProcess;IfweldingprocessisacceptableunderValidationcriteriathephaseisoverandthedocumentscanbearchived.Ifnot,understandweldingfixturevariationandeliminateit.Thenstartthevalidationprocessagain(phaseI).如果焊接工藝在驗(yàn)證標(biāo)準(zhǔn)下是可以接受的，此階段結(jié)束并且文件可以歸檔。如果不是，了解焊接夾具變化并消除。然后再次開(kāi)始驗(yàn)證程序（第一階段）。焊鉗點(diǎn)焊見(jiàn)附件B2.4Studyinweldedsubassembl192-ValidationProcess;驗(yàn)證程序2.5-Re-Validationprocess;再驗(yàn)證程序TheTOMOANAprocessmustbere-validatedalwaysthat:

TOMOANA程序必須再次驗(yàn)證：-Changethestandardpartsfor:改變標(biāo)準(zhǔn)件為：-Productchanges;產(chǎn)品改變-Weldingfixtureintervention/change;焊接夾具介入/改變-Anytransferweldfixtures:焊接夾具轉(zhuǎn)移：-Movementbetweenareas;區(qū)域之間移動(dòng)-PlanttoPlant公廠之間移動(dòng)Whenthestandardpartsarechangeddue:當(dāng)更改標(biāo)準(zhǔn)件由于：-Prematureabrasionoftheholes;孔的前期磨損-Damaged;損壞-Corrosionpoints;銹蝕點(diǎn)Thereisnoneedtore-validatedtheTOMOANA,onlychangetheparts.沒(méi)有必要再驗(yàn)證TOMOANA，只是改變零件即可。2-ValidationProcess;驗(yàn)證程序203-Dailycontrol:日常管理ProductionteamisaccountableforexecutetheTOMOANAdailycontrolandmaintainStandardPartincapablecondition.

生產(chǎn)小組在允許條件下負(fù)責(zé)允許TOMOANA日常管理并威脅標(biāo)準(zhǔn)件。3.1.StandardPart;標(biāo)準(zhǔn)件AfterTOMOANAprocessapprovedanewsubassemblypartshallbecreatedandavailableasStandardPart.

在TOMOANA程序通過(guò)后，應(yīng)造新的組件并且可以作為標(biāo)準(zhǔn)件使用。StandardParthastofollowthecharacteristicsbelow:

標(biāo)準(zhǔn)件必須符合以下特點(diǎn)：□keepthesamefigureastheholesandpositionsthatusedduringthevalidationprocess(step2offlow);

保證在驗(yàn)證程序中使用的孔和位置一致（步驟2的流程）；

□RecommendedtosubmitinElpoProcess;IfthedecisionissubmitinElpothepartshavetobeprocessedpriortoholesperforated.IfthedecisionisnotElpo

processthepartshavetobeappliedwithprotectiveoilinordertoavoidprematurecorrosion;

建議在電泳工藝中提交；如果在電泳過(guò)程中提交決定，在打孔之前必須加工零件。如果不在電泳過(guò)程中做決定，在零件上必須涂上防護(hù)油以避免前期銹蝕。3-Dailycontrol:日常管理213.1.StandardPart;(continuation)標(biāo)準(zhǔn)件（繼續(xù)部分）□Allthemeasurablepointsidentified;確定所有測(cè)量點(diǎn)□Partidentification;確認(rèn)零件□allocateinproperlyarea;在適當(dāng)區(qū)域分配□validatedate&exchangepartdefinition(without:damages,corrosionpoints,prematureabrasionoftheholes).

檢驗(yàn)日期&交換零件明確（沒(méi)有：損壞、銹蝕點(diǎn)、孔的前期磨損）見(jiàn)附件E3.1.StandardPart;(continua223-Dailycontrol:日常管理3.2Execution;執(zhí)行TheTOMOANAmustbeexecuteinbeginningoftheeachshift.

TOMOANA必須在每輪開(kāi)始執(zhí)行。ToinitiatetheTOMOANAthestandardpartsmustbeaccording,withnodamagesandtheholesmustnotbewiderorclosed.OtherwisecalltheTeamLeaderandwaitforhisdecision.

啟動(dòng)TOMOANA時(shí)，標(biāo)準(zhǔn)件必須符合要求，沒(méi)有損壞，孔不能過(guò)大或者關(guān)閉。否則通知小組領(lǐng)導(dǎo)等待他的決定。TheTomoanadailycontrolconsistinallocatethestandardpartsintheweldingfixtureandclosetheclampsandthenmeasuretheholesspecified.(phaseIofvalidationprocess)

TOMOANA日常管理包括在焊接夾具中分配標(biāo)準(zhǔn)件，關(guān)閉夾鉗然后測(cè)量具體的孔（驗(yàn)證程序的第一階段）。Theweldingfixturewillbeevaluateundercriteriabelowtobereleaseforproduction

焊接夾具將按照下面生產(chǎn)中發(fā)放的標(biāo)準(zhǔn)來(lái)評(píng)估。IftheresultisOK,recorditonTOMOANAregisterandreleasetheproduction.OntheotherhandiftheresultisNOK,recorditandinitiatethereactionplanaccordingtoAlarm&Escalationprocess.

如果結(jié)果是合格的，將它記錄在TOMOANA登記簿上并且發(fā)放生產(chǎn)。另一方面如果結(jié)果是不合格的，將它記錄下來(lái)并且根據(jù)警報(bào)和升級(jí)程序啟動(dòng)反應(yīng)計(jì)劃。見(jiàn)附件C開(kāi)始標(biāo)準(zhǔn)件合格嗎？為焊接夾具分配標(biāo)準(zhǔn)件打電話給小組組長(zhǎng)，等待他的授權(quán)來(lái)開(kāi)始生產(chǎn)關(guān)閉焊接夾具夾鉗測(cè)量并登記每個(gè)指定的孔結(jié)果合格嗎？根據(jù)警告&升級(jí)流程啟動(dòng)反應(yīng)計(jì)劃準(zhǔn)備生產(chǎn)開(kāi)始3-Dailycontrol:日常管理If234-WeeklyMonitoring:QualityteamisaccountableforTOMOANAmonitoring.Itmeansperform

weeklythefollowingrequirements;

質(zhì)量小組負(fù)責(zé)TOMOANA監(jiān)督。這意味著每周按照以下要求執(zhí)行：1-mustensuredocumentationisinplace(STS/TIS);

必須確保文件到位（STS/TIS）；2-mustverifytheStandardPartintegrity:quality,identification;

必須檢驗(yàn)標(biāo)準(zhǔn)件的完整性：質(zhì)量、確認(rèn)；3-mustverifythegauge,pin;

必須檢驗(yàn)標(biāo)準(zhǔn)尺寸、識(shí)別碼；4-mustconfirmtheDailycontrolexecution:frequencyandcriteria;

必須確認(rèn)日常管理執(zhí)行：頻率和標(biāo)準(zhǔn)；5-mustensureanyprocessvariationrelatedtomeasurementshaveareactionplan;

必須確保任何與測(cè)量有關(guān)的程序變化有反應(yīng)計(jì)劃；6-mustrequestweldingfixtureadjustmentwhennecessary;

必須在必要時(shí)要求焊接夾具調(diào)整；Thereareothersrequirementsthatarerecommendedas:

還建議以下其他要求：7-couldverifytheTOMOANAareaandallocation;cleanup,organizedandsafety;

可以檢驗(yàn)TOMOANA區(qū)域和分配；清潔；組織和安全；8-couldchecktheTOMOANAboardifalldocumentationproposedisavailable;

如果所有提交的文件都是可用的，可以檢查TOMOANA看板；見(jiàn)附件D4-WeeklyMonitoring:見(jiàn)附件D245-Alarm&EscalationProcess:警告與升級(jí)程序ThereactionplanmustbeinitiatedbasedonAlarm&Escalationprocessdefinedwhennon-standardconditionoccurs.反應(yīng)計(jì)劃必須根據(jù)在不標(biāo)準(zhǔn)條件發(fā)生是確認(rèn)的警告和升級(jí)程序啟動(dòng)。?ThesubassemblyproductionmuststoponfirstNOKholeandcorrectiveactiondone.

組件生產(chǎn)必須在第一個(gè)不合格的孔時(shí)就停止，做校正工作。?Ifremain3consecutivedaysinAlarm1,theproductionshouldstopandcorrectiveactiondone;

如果警告1保持3個(gè)連續(xù)工作日，停止生產(chǎn)并做校正工作。5-Alarm&EscalationProcess:256-ProblemSolving：解決問(wèn)題TheProblemSolvingmustbeinitiatedalwaysthatunexpectedsituationoccursbasedoncriteriaestablishedonProcessValidationandAlarm&EscalationProcess.Recommendedisanalyzewholetheprocess,ifStandardPartisableforgeneratearealmeasurement(ifnottheStandardpartmustbechanged)oranadjustmentisrequiredonweldingfixturesbyMaintenanceareatoensuretherepeatabilityprocessontheweldedstructureandeliminateanyvariation.

解決問(wèn)題必須在意外情況發(fā)生時(shí)，根據(jù)驗(yàn)證程序和警告&升級(jí)程序建立的標(biāo)準(zhǔn)下啟動(dòng)。建議分析整個(gè)流程，如果標(biāo)準(zhǔn)件可以真實(shí)測(cè)量（如果不是標(biāo)準(zhǔn)件必須更換）或者維修區(qū)域要求調(diào)整焊接夾具以確保焊裝結(jié)構(gòu)的重復(fù)性程序并且消除任何變化。

焊接設(shè)備6-ProblemSolving：解決問(wèn)題267-Effectiveness&Efficiency:效力與效率Effectiveness效力▲

Itconsistsinimplement100%ofthisOperatingToolinthePlant.

效力包括在工廠100%執(zhí)行這個(gè)操作工具。Efficiency:效率

▲ReachQualityMetricsrelatedto;達(dá)到質(zhì)量指標(biāo)關(guān)于：

?ABCQualityrateandFVS;有效車身控制質(zhì)量比率和整車運(yùn)輸；?95%@6Sigma;95%按照6Sigma；?DRR;拒絕交付報(bào)告；?GCA;全球客戶評(píng)審；7-Effectiveness&Efficiency27RASICchartRASIC表格R：責(zé)任A:驗(yàn)證S:支持I:信息TOMOANA計(jì)劃認(rèn)定（啟動(dòng)流程）TOMOANA計(jì)劃（目前流程）TOMOANA驗(yàn)證程序和日常管理培訓(xùn)TOMOANA驗(yàn)證流程再驗(yàn)證流程TOMOANA日常管理TOMOANA標(biāo)準(zhǔn)件TOMOANA周監(jiān)督解決問(wèn)題（調(diào)整焊接夾具）工藝車身車間質(zhì)量管理員質(zhì)量工程師維修RASICchartRASIC表格R：責(zé)任28RevisionLog校正記錄校正編號(hào)校正日期校正描述合同名稱/組織初始版本RevisionLog校正記錄校正編號(hào)校正日期校正描述合29附件A：打孔；鉆4.0mm的孔附件A：打孔；鉆4.0mm的孔30TOMOANA重復(fù)性研究驗(yàn)證流程單TOMOANA重復(fù)性研究驗(yàn)證流程單31附件C:TOMOANA日常管理單附件C:TOMOANA32附件D:附件D:33附件E：標(biāo)準(zhǔn)件說(shuō)明至少要包含以下內(nèi)容：零件號(hào)碼零件名稱操作驗(yàn)證日期附件E：標(biāo)準(zhǔn)件說(shuō)明至少要包含以下內(nèi)容：零件號(hào)碼零件名稱操作驗(yàn)34附件F:標(biāo)準(zhǔn)看板測(cè)量孔第一個(gè)研究項(xiàng)目第二個(gè)或更多研究項(xiàng)目日常管理說(shuō)明/任務(wù)說(shuō)明單附件F:標(biāo)準(zhǔn)看板測(cè)量孔第一個(gè)研究項(xiàng)目第二個(gè)或更多研究項(xiàng)目日常35附件G：TOMOANA圖示附件G：TOMOANA圖示36全員參與標(biāo)準(zhǔn)化作業(yè)持續(xù)改進(jìn)縮短制造周期造入質(zhì)量通用-全球制造系統(tǒng)Principle:BuiltInQuality

原則：造入質(zhì)量Element:14ManufacturingProcessValidation

元素：14個(gè)制造工藝驗(yàn)證GM-GMSOperatingTool

通用-全球制造系統(tǒng)操作工具14.5TOMOANA僅供通用內(nèi)部使用2010年8月全員參與標(biāo)準(zhǔn)化作業(yè)持續(xù)改進(jìn)縮短制造周期造入質(zhì)量通用-全球制造37CopyrightNotice版權(quán)聲明?August,2000GeneralMotorsCorporation(GM).2000年8月，通用汽車公司Allrightsreserved.版權(quán)所有Nopartofthismaterialmaybereproducedinanyformorbyanymethod(photocopy,microfilm,digital,etc.)withoutthewrittenpermissionofGeneralMotorsCorporation,educationalpurposesincluded.本資料中的任何部分在沒(méi)有通用汽車公司書面許可證的情況下不得以任何形式或任何方式（復(fù)印，縮微拍攝，數(shù)碼拍照等等）復(fù)制，包括教育用途。CopyrightNotice38Scope范圍Thisoperatingtooldefinesroles&responsibilitiesforTOMOANAactivitiesappliedtoallGMSouthAmericaandAfricanAssemblyPlants.本操作工具為應(yīng)用于所有通用南美和非洲的組裝工廠的TOMOANA活動(dòng)定義了角色和責(zé)任。Definition定義TOMOANAisamethodtoensuretheprocessrepeatabilityinweldingfixturesforweldedsubassembliesandreducedimensionalvariationinBody-in-whitebuildupprocess.TOMOANA是一種確認(rèn)焊接夾具工藝復(fù)現(xiàn)性和在白車身制造過(guò)程中減少尺寸變化的方法。Purpose目的▲

SupportGM-GMSprinciple:¨Built-in-Quality〃;

支持通用-全球制造系統(tǒng)原則：制造質(zhì)量；▲

SupportdeliverableexecutionasrequiredinMQRR(ManufacturingQualityReadinessReview);

支持根據(jù)MQRR（制造質(zhì)量準(zhǔn)備評(píng)審）要求的交付運(yùn)行；▲

Definethestandardizedprocessforvalidationandcontrolandverificationofstabilityforweldingfixture.

確定驗(yàn)證和控制標(biāo)準(zhǔn)化程序和焊接夾具穩(wěn)定性驗(yàn)證。Scope范圍39Responsibility責(zé)任TheManufacturingEngineering(DimensionalEngineering)istheprocessownerforimplementationofthisprocessduringtheLaunch.TheBodyShopManageristheprocessownerforexecutionofthisprocedureinregularproduction.工藝（尺寸工程師）是負(fù)責(zé)在產(chǎn)品啟動(dòng)過(guò)程中實(shí)施流程。車身車間經(jīng)理是在量產(chǎn)時(shí)運(yùn)行這個(gè)過(guò)程的負(fù)責(zé)人。IntroductionTOMOANAisatoolappliedtoensurethedimensionalrepeatabilityinweldedsubassembliesanditiseffectivepreventivetooltosupporttheQualityMotto;Donotaccept,buildandshipDefects.TOMOANA是適用于焊接總成部件時(shí)相關(guān)尺寸的確認(rèn)，是一種預(yù)防性的工具，它是有效來(lái)支持質(zhì)量格言的預(yù)防工具：絕不接受，制造，傳遞缺陷。ItisamethodologyappliedtoreducedimensionalvariationinBodyShopandcontinuouslyimprovetheDimensionalQualityofBIWandAssemblies(Arateand6Sigma).它是適用于在車身車間減少尺寸變化和持續(xù)改進(jìn)白車身和裝配的尺寸質(zhì)量的方法論（等級(jí)A和6Sigma）。DonotDefects絕不接受制造傳遞缺陷Responsibility責(zé)任Donot40Enablers要素?Standardparts;

標(biāo)準(zhǔn)件；?Weldingfixtures;

焊接夾具；?Measurementsystem(GaugePass-no-Pass);

測(cè)量系統(tǒng)（測(cè)量及格不及格）?StandardizeWork;

標(biāo)準(zhǔn)化工作；?Records(validationanddailyrecord);

記錄（確認(rèn)及日記錄）Enablers要素41TOMOANA:PDCAcycle6.ProblemSolving;7.Effectiveness&Efficiency.1.TOMOANAplanning;2.TOMOANAvalidation5.Alarm&Escalation;3.DailyControl(Productioncore)4.WeeklyMonitoring(Qualitycore)PDCA周期計(jì)劃驗(yàn)證問(wèn)題解決效力與效率報(bào)警升級(jí)日常管理（生產(chǎn)核心）周監(jiān)督（質(zhì)量核心）TOMOANA:PDCAcycle6.Problem421-Planning:Launchprocess計(jì)劃：流程啟動(dòng)TheTOMOANAmustbedevelopedforalltheintheBodyShopProcess.Geo-stationsmeansanysub-assembledpartsthatimpactthegeometryofthevehicleandstillcanbeapplicableforanysub-assembledpartthatiscausingdownstreamqualityissues(noise,waterintrusion,fits)orthatisknownascritical.

TOMOANA必須在車身車間程序中為所有GEO-STATIONS發(fā)展。Geo-stations意味著任何影響車輛幾何學(xué)的初級(jí)裝配零件并且仍然適用于引起質(zhì)量問(wèn)題（異響，水浸，匹配問(wèn)題）或者是危險(xiǎn)的初級(jí)裝配零件。DuringtheBodyShopReadinessthistoolshouldbeinitiatedtogetherwithIterativematchingactivities(53weekspriortoSORP)andachieve100%approvedbyEndofMVBns.

在車身車間準(zhǔn)備期間，此工具應(yīng)該和反復(fù)的匹配活動(dòng)一起啟動(dòng)（在SORP階段53周前）并且在MVBns結(jié)束時(shí)得到100%通過(guò)。TOMOANATimeline時(shí)間軸技術(shù)規(guī)格檢驗(yàn)感覺(jué)特性設(shè)計(jì)研究生產(chǎn)裝配文件下發(fā)100%通過(guò)第一圈1-Planning:Launchprocess計(jì)431-Planning:Currentprocess計(jì)劃：目前工藝TOMOANAisalsoappliedindimensionalcontinuousimprovementprocessforcurrentprograms.BasedontheGCA,VerificationStationandCMMfeedbacksTOMOANAcansupportamethodtoeliminatethevariabilityexistingonweldedsubassemblyfixtureaftertherootcausedanalyzed.TOMOANA也適用于目前項(xiàng)目的空間持續(xù)改進(jìn)程序。根據(jù)GCA、檢驗(yàn)站和CMM回饋，TOMOAMA可以在分析根本原因之后，支持消除存在于焊接部件夾具變異性的方式。偏差1-Planning:Currentprocess44TOMOANAPlanning計(jì)劃

TheTOMOANAmusthaveadeploymentplandeveloped,whichincludesfourkeyattributes(4Ms)toensuretheadequateexecutionlevelfromtheTOMOANAactivities:

TOMOANA必須發(fā)展部署計(jì)劃，包括4個(gè)保證TOMOANA行為適當(dāng)運(yùn)行水平的關(guān)鍵屬性：1.Man:

人員1.1Defineteamtoperformthevalidationprocess;

明確小組實(shí)施驗(yàn)證程序；Dimensionalexpertshouldleadorsupportteam;

空間專家應(yīng)該領(lǐng)導(dǎo)或支持小組；1.2DefinebywhomtheDailyControlwillbeconducted;

明確誰(shuí)來(lái)執(zhí)行日常管理；1.3Developtrainingforthedifferentlevelsofpeopleinvolvementanddeployit;

為各階層的參與人員開(kāi)展并部署培訓(xùn)；2.Material:材料2.1Definehowstandardpartswillbeavailable;

明確標(biāo)準(zhǔn)件如何可用；2.2Definewhereandhowthestandardpartswillbestorage,includewhoismakethesupports;

明確標(biāo)準(zhǔn)件應(yīng)該如何存放并存放在哪里，包括誰(shuí)來(lái)支持；2.3Definewhenthestandardpartsshouldbeexchanged(date);

明確何時(shí)交換標(biāo)準(zhǔn)件（日期）；3.Machine:機(jī)器3.1Definewhichweldingfixturewillbeimplementedandwhen;

明確適用哪個(gè)焊接夾具，何時(shí)適用；4.Method:

方案4.1Deploymeasurementprocessandpingagemustbeenoughforalltheareas;

部署測(cè)量程序，全部地區(qū)的定位銷板必須充足；4.2DevelopStandardizedWork(STS/TIS)andapplyJIT.

開(kāi)展標(biāo)準(zhǔn)化工作（STS/TIS）并且應(yīng)用JIT.TOMOANAPlanning計(jì)劃1.Man:人員451.TOMOANAPlanning計(jì)劃MeasurementSystem;測(cè)量系統(tǒng)Gaugesin3.0-3.5and4.0mmareappliedtomeasurethediametersofholespreviouslyidentified.3.0-3.5mm和4.0mm的測(cè)量?jī)x器應(yīng)用于以前確定的孔的直徑。測(cè)量?jī)x器測(cè)量系統(tǒng)1.TOMOANAPlanning計(jì)劃Measurem46驗(yàn)證流程：TOMOANA驗(yàn)證標(biāo)記并打4.0mm的孔打開(kāi)夾鉗，移動(dòng)零件，放下零件，關(guān)閉夾鉗測(cè)量孔的直徑并記錄每10個(gè)重復(fù)項(xiàng)目3和4結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？分析并做調(diào)整。回到項(xiàng)目1階段1階段2打開(kāi)夾鉗，移動(dòng)零件，放下零件，夾緊夾鉗測(cè)量孔的直徑并記錄每5個(gè)重復(fù)項(xiàng)目7和8結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？打開(kāi)夾鉗，移動(dòng)零件，放下零件，關(guān)閉夾鉗測(cè)量孔的直徑并記錄階段3結(jié)果是依據(jù)標(biāo)準(zhǔn)的嗎？結(jié)束驗(yàn)證。存檔文件驗(yàn)證流程：TOMOANA驗(yàn)證標(biāo)記并打4.0mm的孔打開(kāi)夾鉗，472-ValidationProcess;驗(yàn)證程序Theinitialvalidationprocessmustbeconductedinfourstepsasfollows:最初的驗(yàn)證程序必須按照以下四個(gè)步驟執(zhí)行：3.1Defineholepositionsandmaketheholes;

確定孔位并打孔；3.2Repeatabilityoftheweldingfixtureclamping;

焊接夾具鉗位重復(fù)定位；3.3Repeatabilitywith“cold”welding;

用冷焊重復(fù)定位；3.4Studyinweldedsubstructure;

研究焊接底層結(jié)構(gòu)；Duringthevalidationprocessisimportanttomention;驗(yàn)證程序的重點(diǎn)：?Thesamesubassemblypartswillbeusedforallphase(I,IIandIII);

相同組件應(yīng)該應(yīng)用于各個(gè)階段（I,II和

III）?Afterrunsprocessvalidationtheweldedsubassembliesshallbedisposalforscraporifnodamagewasdone,canbeusedasnormalproductionparts,aslongproductengineeringapproves.

運(yùn)行驗(yàn)證程序之后，焊接組件應(yīng)該處理廢料，或者如果沒(méi)有損壞，可以作為正常生產(chǎn)零件使用，只要產(chǎn)品工程批準(zhǔn)。2-ValidationProcess;驗(yàn)證程序482-ValidationProcess;驗(yàn)證程序3.1Defineholepositionsandmaketheholes;

確定孔位并打孔；It’s

thefirststepfortheTomoanavalidation.EnsurethatweldingfixtureisOKandthereisnotpotentialvariationrelatedtofixtures.Makesurethatallholesdefinedareabletoidentifyanyvariationonsubassemblyprocessand:這是Tomoana驗(yàn)證的第一步。確保焊接夾具沒(méi)問(wèn)題，并且沒(méi)有涉及到夾具的潛在變化。確保所有確定的孔都能夠在分部裝配過(guò)程中鑒定任何變化并且：?analyzeallthevariationtobestudied(x,yandzaxles)betweentwoormoreparts;

分析全部要研究的兩個(gè)或多個(gè)零件之間的變化（x,y和z軸）；?defineaminimumoftwopointsthatguaranteethisvariation;

確定最小的保證這個(gè)變化的兩點(diǎn)；?definethelocationoftheperforationconsidering:

確定穿孔位置時(shí)考慮到：?mustnotcoincidewithweldingspotposition;

一定不要和焊點(diǎn)位置一致；?mustbeaccessibleformeasuringontheweldingfixture;

一定在焊接夾具上能夠測(cè)量；?eliminatetheburrsontheholes;

去除孔邊的毛刺；?identifytheholeswithnumbers;

確定孔的編號(hào)；見(jiàn)附件A2-ValidationProcess;驗(yàn)證程序3.149確定孔位并打孔（繼續(xù)部分）例如：基準(zhǔn)面注意孔的質(zhì)量！穿孔直徑：4mm確定孔位并打孔（繼續(xù)部分）例如：基準(zhǔn)面注意孔的質(zhì)量！穿孔直徑50確定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外部部件聯(lián)合區(qū)域右邊左邊確定零件上的部件聯(lián)合區(qū)域以確保適當(dāng)?shù)拇┛状_定孔位和打孔；（繼續(xù)部分）確保零件之間的正確匹配內(nèi)部和外部512.2RepeatabilityofWeldingFixturesClamping(phaseI)

焊接夾具鉗位的重復(fù)性（第一階段）Oncemadetheholestherepeatabilityprocessonweldingfixturesclampingisinitiated(phaseI).IftheClampingdoesnotabletoproviderepeatabilitytheweldingfixturehastobeadjustedor/andre-definenewholesposition