通用汽車公司如何制造品質(zhì)

Built-InQuality

制造質(zhì)量GMS不斷改進員工參與標(biāo)準(zhǔn)化縮短制造周期制造質(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

Storage

FixedPeriod

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(biāo)準(zhǔn)Built-InQuality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PP100:NotReportedDueToInsufficientSample樣品不足不匯報()J.D.PowerIQSTrendByBrand

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VoiceofCustomer

客戶意見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(zhuǎn)換

(M/TShift)1.節(jié)能(Fueleconomy)2.OSRVM手工控制(ManualOSRVM

control)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)Built-in-Quality制造質(zhì)量WhatisBuilt-In-Quality?什么是制造質(zhì)質(zhì)量？GroupDiscussion小組討論WhatisBuilt-InQuality?什么是制造質(zhì)質(zhì)量？Definition定義Methodbywhichqualityisbuiltintothemanufacturingprocess,sothatdefectsareprevented,detected,andcountermeasuresareimplementedtopreventreoccurrence.指質(zhì)量在生產(chǎn)產(chǎn)過程中產(chǎn)生生，因此可以以預(yù)防、發(fā)現(xiàn)現(xiàn)缺陷，以及采取措措施防止缺陷再發(fā)生的方法法。Purpose意圖Ensuresdefectsarenotpassedtothecustomer.確保不傳遞缺缺陷。Designers設(shè)計師Suppliers供應(yīng)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Assembly總裝Supplier供應(yīng)商Paint涂裝Body車身TheCustomerChain...ProductionPerspective客戶鏈…公司遠景EachProcessHasatLeastOne““Customer”andOne“Supplier”每個階段至少少有一個客戶戶和一個供應(yīng)應(yīng)商Built-In-Quality制造質(zhì)量Donot不要Accept接受Build制造Ship傳遞aDefect!缺陷SolveProblemsThroughTeamwork!團隊合作解決決問題！Built-In-QualityMotto制造質(zhì)量口號號SatisfyYourCustomer…滿足你的客戶戶QualityThroughTeamwork––KnowYourCustomer!Whatwaterleaks?Idon’’tseeanywaterleaks什么漏雨？我我沒發(fā)現(xiàn)漏雨雨。Thiscarwasn’tmadeonmyshiftTheproblemisPressShop.Theflangeistoolong.問題出自沖壓壓，邊緣過長Iwon’’trunanytrialuntilIhaveanassemblymethodfromIndustrialEngineeringandthemanpower.Theproblemisthatthepiecesarebadfromthesupplier.問題在于供應(yīng)應(yīng)商的材料不不好。Itisnotfrommyarea,maybeit’sthesealer這輛車不是我我輪班造的。。在沒有工業(yè)工工程裝配方法法及人力的情情況下，我不不做任何試驗驗。這不是我負責(zé)責(zé)的地方，也也許是粘膠負責(zé)Don’trunawayfromtheproblem!不要逃避問題題!LivinguptotheMotto...符合口號...-WhatIsaDefect?什么是缺陷？？GroupDiscussion小組討論Defect缺陷Adefectisaproductthatdoesnotmeettheestablishedqualitystandard.缺陷是不合已定標(biāo)準(zhǔn)的產(chǎn)品品。Measurementofaqualitycharacteristic質(zhì)量性能測量量Vehicle#車輛號UpperSpecificationLimit規(guī)格上限LowerSpecificationLimit規(guī)格下限QualityStandard質(zhì)量標(biāo)準(zhǔn)Defect缺陷Defect缺陷xxWhyaredefectsundesirable?為什么缺陷不不受歡迎？Defectsmayalsoresultin…缺陷還可能導(dǎo)導(dǎo)致Highwarrantycosts過高保修成本Lostcustomersale失去客戶DefectsRequireCorrection=CorrectionisWaste缺陷需要糾正正—糾正就是浪費費QUALITYISEVERYONE’’S

RESPONSIBILITY質(zhì)量是每個人人的職責(zé)Design,Engineering,Production,Quality,SupportDepartmentsandSuppliers.設(shè)計，工程，，生產(chǎn)，質(zhì)量量，相關(guān)部門門及供應(yīng)商OURBestResources:我們最好的資資源:→PEOPLE員工OURGoal:我們的目標(biāo)：：→EveryoneisaQualityInspector人人都是質(zhì)檢檢員→EveryoneisaProblemSolver人人都是問題題解決者WHOISRESPONSIBLEFORQUALITY?誰對質(zhì)量負責(zé)責(zé)？WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?WHOISRESPONSIBLEFORQUALITY?ME!!!我！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

Maintenance

FixedPeriod

Ordering

System/OrderPartsProductQualityStandards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)Reflectvoiceofthecustomer反映顧客的心心聲Simple,clear&supportuser簡單、清晰，，有利操作者ClearlyMeasurableatpointofuse在使用上可明明確測量KeyPointsofGoodQualityStandards:質(zhì)量標(biāo)準(zhǔn)的要要點：Inuser’sStd.Work&postedvisual在操作者的標(biāo)標(biāo)準(zhǔn)化工作或張貼出出來StandardsMustSupporttheOperator,too–NotonlytheEngineer!!!標(biāo)準(zhǔn)不僅有益益于設(shè)計者，，也有益于操作作工人Nottighterthanthoseappliedatthepreviousprocess不要比前道工工序的更嚴(yán)格格KeyPointsofGoodQualityStandards:質(zhì)量標(biāo)準(zhǔn)的要要點：FinalInspectionStandard:Gap+/-1mmFINALINSPECTIONBODYSHOPBodyShopStandard:Gap+/-2mmUsemasterpartsandboundarysamplesasrequiredtomakevisual標(biāo)準(zhǔn)件與邊界界樣件需要目目視化KeyPointsofGoodQualityStandards:質(zhì)量標(biāo)準(zhǔn)的要要點：BoundarySamplesshouldvisuallyindicateOK––NotOKconditiontohelpoperatorsmakequick,gooddecisions邊界樣件應(yīng)該該標(biāo)明好或不不好，以便操作人員迅速速且更好地下下決定。Visually“describing””thedefectisNotaBoundarySample!目視化標(biāo)明缺缺陷不是邊界界樣件！Cratermorethanthissizeisnotacceptable不接受焊口大于此尺寸ExampleofaBoundarySample邊界樣品的范例Createa“Standards-Based””Culture創(chuàng)造一個以標(biāo)標(biāo)準(zhǔn)為基點的的文化氛圍Iwouldn’tbuythis!Doesn’tlookgoodtome!Myopinionis…Thisdoesnotmeetthestandard..TalkintermsofTheStandard,notopinions!以標(biāo)準(zhǔn)為基點點，而非觀點點！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

Storage

FixedPeriod

Ordering

System/OrderPartsHealthandSafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&VerificationManufacturing

Process

Validation制造工序認證Whatisaprocess?什么是工序？？Inputs投入Outputs輸出Aprocessisasetofinter-relatedresourcesandactivitieswhichtransformsinputsintooutputs.工序是集中相相關(guān)的資源進進行一系列活活動，把投入入轉(zhuǎn)換成輸出出！Environment環(huán)境Process工序ManMachinesMethodMaterialsWherecanErrorsOccur?問題會出在哪哪？Defects缺陷Materials:材料Partsoutofstandard不符標(biāo)準(zhǔn)的零零件Wrongparts錯誤零件Poordesign設(shè)計不當(dāng)Method:方法Poorstd.Work不好的標(biāo)準(zhǔn)工工作LackofTraining缺乏培訓(xùn)Machine/Process:機器/工序NoTPM沒有TPMProcessnotcapable工序不好Improperspecification規(guī)格不當(dāng)Man:人力Notfollowstd.Work不遵循標(biāo)準(zhǔn)化化工作Distractions,Forgetfulness分心、遺忘LackofExperience缺乏經(jīng)驗ErrorsResultInValidatethemanufacturingprocesspriortoStartofProduction!在生產(chǎn)啟動前前認證制造工工藝！Donot切勿Accept

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制造Ship傳遞aDefect!缺陷！LivingUptotheMotto…達到口號“EliminatetheNeedforInspectiononaMassBasisbyBuildingQualityintotheProductintheFirstPlace”-Dr.DemingPFMEAWorkstationReadiness工位準(zhǔn)備ProcessControlPlan工藝控制計劃劃Error-proofingPlan防錯計劃ErrorProofingHierarchy防錯層次Prevention預(yù)防Detection

檢測HumanJudgment人為判斷None無Product/ProcessDesignChange產(chǎn)品/工藝設(shè)設(shè)計改變DFM/A&D/PFMEARobustDesigns&CapableProcesses機器設(shè)計及可可行工藝One-WayAssembly同一裝配ProcessControls工藝控制LocatingPins&Stops固定點及停點點Sensors&ProcessMonitors傳感器及工藝藝監(jiān)控Electro-MechanicalDevices電子機械儀器器ColorCoding顏色信號VisualControls直觀控制AndonSystems暗燈系統(tǒng)StandardizedWork標(biāo)準(zhǔn)化工作ErrorsCan’’tHappenSmallImprovement小改進SignificantImprovement重大改進IntroductiontoErrorProofing防錯介紹0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:VisualControlExampleHumanJudgment0515100396OLHM51020150151012457810115Better:ABExample:VehicleIdentification車輛認證(MutilationCoverColor)(蓋板顏色毀毀損)HumanJudgment人為判斷VisualControlExampleVerticalPlate垂直板BatteryPost電池接頭ProcessControlExampleDetection檢測XWorkPiece加工件WorkPieceFixture夾具Fixture夾具ProcessControlExamplePrevention預(yù)防ProductDesignExample(Before)REC<<>>>STOPPAUSEREC<<>>>STOPPAUSEOLDDESIGN老設(shè)計CanbeInstalledUpsideDown可以反安裝裝ApplicationofLabelsonCassetteDecks.門板標(biāo)簽Prevention預(yù)防REC<<>>>STOPPAUSENEWDESIGN新設(shè)計ApplicationofLabelsonCassetteDecks.門板標(biāo)簽CanOnlyBeInstalledCorrectly!ProductDesignExample(After)PreventionLeftHandLocatorTabRightHandLocatorTabExample--ProductErrorProofing(OneWaytoInstallSeatBelt)防錯樣品——只有一種種安全帶安安裝方法ProductDesignExample產(chǎn)品設(shè)計范范例PreventionSimpleEverydayExamples1)ErrorPrevention?????Automaticshut-off自動斷電ErrorProofingExerciseThinkofanexampleatworkorathomewhereerrorproofingcanpreventanundesirablethingfromhappening想想工作或或生活中使使用防錯措措施避免不不好事情發(fā)發(fā)生的例子子Discussasateamandreport––Take5minutes小組討論、、匯報—5分鐘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

Storage

FixedPeriod

Ordering

System/OrderPartsHealthand

SafetyPriorityQualifiedPeopleTeamConceptPeople

InvolvementOpen

Communication

ProcessValuesVision/MissionShopFloor

ManagementIn-ProcessControl&Verification工序控制與認證ProductQualityStandardsIn-ProcessControl&Verification–(3)Elements工序控制與與認證1.PreventionOutputs輸出Inputs投入NOK2.DetectionOKNextProcess下道工序Feedback反饋Donot不要Accept

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傳遞aDefect!缺陷！LivingUptotheMotto…符合標(biāo)準(zhǔn)3.Containment包容1)StandardizedWork標(biāo)準(zhǔn)化工作作FollowandContinuouslyImproveStandardizedWork!!!遵守及不斷斷改進標(biāo)準(zhǔn)化化工作?。?！In-ProcessControl&Verification–1)PREVENTIONPreventionVehicleManifestManual2-DoorSunroof2)FocusonOperation集中精力生生產(chǎn)KeepYourConcentration&RespectStandardizedWorkofOthers!注意及尊重重他人的標(biāo)準(zhǔn)化工作作In-ProcessControl&Verification–1)PREVENTIONPrevention3)ErrorProofingPrevention&OperatorAids防錯預(yù)防與與操作者支支持TheBestProcessisOneThatCannotFail!最好工序就就是不會失失敗的！In-ProcessControl&Verification–1)PREVENTIONPreventionDAEWOO4)RegularChecksofSystems&Processes定時檢查系系統(tǒng)與工藝藝Std.WorkChecks!檢查標(biāo)準(zhǔn)化化工作In-ProcessControl&Verification–1)PREVENTIONPreventionCHECKCHECK???????CHECKProcessControlChecks!檢查查工工序序控控制制??！TPMChecks!檢查查TPMSafety/5SChecks!檢查查安安全全/5SSelf-Checks自檢檢IncludeQualityChecksinStandardizedWork!把質(zhì)質(zhì)檢檢作作為為標(biāo)標(biāo)準(zhǔn)準(zhǔn)化化工工作作的一一部部分分In-ProcessControl&Verification–2)DETECTIONDetectionCheckMethods:POINTTOUCHLISTENCOUNT2)ErrorProofingDetection檢測測防防錯錯UseVisualandAudioSignals!使用用視視覺覺、、聽覺覺信信號號??！In-ProcessControl&Verification–2)DETECDetectionStoptheLine,or停線線或或UseAlarms,or使用用警警報報或或CombinationofBoth,dependingonCriticality根據(jù)據(jù)危危險險程程度度兼兼用用兩兩種種方方法法3)In-ProcessVerification工序序認認證證Inspectorsarenotthereasapoliceman,theysupportproductionbyconfirmingtheprocess!檢察察員員不不充充當(dāng)當(dāng)警警察察角角色色，，而是是作作為為確確定定工工序序的的生生產(chǎn)產(chǎn)支支持持者者In-ProcessControl&Verification–2)DETECTIONDetectionVerificationStationsFinalLineC.A.R.E.3a)FocusonCriticalitems集中注意意重大問問題FrequencyofcheckstonotallowCriticaldefectstoleavetheshop!經(jīng)常檢查查，不讓讓重大缺缺陷走出車間間！In-ProcessControl&Verification–2)DETECTIONDetectionSafetyItems“Walk-Home”ItemsMajorCustomerDissatisfierS/CF/F4)DefectEscalation缺陷逐層層匯報Escalatedefectstoleadershipforsupportdependingonfrequencyandcriticality!根據(jù)缺陷陷出現(xiàn)頻頻率與嚴(yán)嚴(yán)重程度度逐層向領(lǐng)領(lǐng)導(dǎo)匯報報以尋求求支持?。n-ProcessControl&Verification–2)DETECTIONDetectionExample:TeamLeaderSectionLeaderGroupLeader2defects/1hour4defects/1hour1)UseAndon(taughtmorelater)使用暗燈燈Makeproblemsvisual&pullinsupport!問題直觀觀，拉線尋求求幫助??！In-ProcessControl&Verification–3)CONTAINMENTAlwaysRememberthePriorities:一定要牢牢記：1)Safety安全2)Quality質(zhì)量3)Responsiveness(Throughput)響應(yīng)Containment包容2)FollowContainmentProcess遵循包容容程序Extraordinaryactionstopreventdefectsfrombeingpassed!采取特別別行動防防止缺陷傳遞遞！In-ProcessControl&Verification–3)CONTAINMENTSomeexamples:1)Stoptheline停線2)100%checks100%檢查3)On-linerepair線上維修修4)Reworks返工5)Sorting整理Containment包容HowDoesourQualityMottorelatetoContainment?Donot不要Accept

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傳遞aDefect!缺陷！Itmeansempoweredleadersmakejudgmentshowtocontrolqualitywhiletryingtokeepthelinerunning!!意味著領(lǐng)領(lǐng)導(dǎo)有權(quán)權(quán)作出決決定：在在盡量不不停線的的情況下下，怎樣控制制好質(zhì)量量！Doesthismeanwestopthelineeverytimewehaveaproblem?這是不是是意味著著一有問問題就停停線呢？？HowDoesourQualityMottorelatetoContainment?Sometimesthebestdecisionmaybetoletadefectpasstothenextprocess,but…有時最好好的辦法法是讓差差錯轉(zhuǎn)到到下工序序，但是是……ItisaconsciousdecisionmadebytheappropriatelevelActionmustbecommunicatedtonext““customer””DefectmustbeclearlyidentifiedonvehicleContainmentmustbeinplacetopreventfurtherdefectsExamplesofSomeAndonGuidelines:暗燈使使用的的指導(dǎo)導(dǎo)方針針1)Willtheproblemaffectthenextprocess?問題會會不會會影響響下道道工序序？2)CanIeffectivelyrepairthedefectoutofstation?能不能能在工工位外外有效效解決決問題題？3)Whatisthestatusofmydecouplers?自己的的切斷斷器是是什么么狀態(tài)態(tài)？4)Others…其他………AndonDiscussion––HoodsSituation:AttheBodyShopend-of-lineQualitystationitisdiscoveredthatthereisaproblemwithcrackedhoods.AfterworkingthelinebackweDiscussion:YouarethePlantQualityManager––whatisyourdecision?Discussasagroup!Background:Inthiscase,thedecisionisisshutdownthelinefor(6)hoursandwaitforpartsorrunthelineandmakeacontainmentplan.SincethedecouplerbetweenBodyanPotentialDecision:Inthiscase,QualitycanstillbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethehoodsdonotaffectthenextprocess.TheCostofstoppingthelinewillnotresultinbetterQualityorResponsiveness.Thus,agooddecisionwouldprobablybetorunthelineandmakeacontainmentplan:Allcarswithbadhoodstobespeciallyidentified.ProductionandQualityinPaintandGAnotifiedofthesituation,knowthevehiclenumbersandidentificationmethod.100%checkatHoodInstalloperationuntilprocesscapabilityisassured.PaintandFinalProcessnotifiedthatnewhoodstobepaintedinPaintandwillbeswappedinFinalProcessareaandhavetimetomakeaplanhowtoaccommodatethat.AndonDiscussion-HoodsSituation:AttheCockpitLoadstationinGAitisdiscoveredthatthereisaproblemwithoneoftheelectricalharnesseswithinthecockpit.Thecockpitsarebuiltasamodulebyanoutsidesupplier.Afterworkingthelinebackweknowthatseveralcockpitsinthesystemhavethecondition.TheoperatorsatCockpitLoadhavepulledtheAndonandtheescalationprocesshaspulledintheTrimLineSectionLeader,whoconsultswiththeChassisLineSectionLeader.Considerationsare:1)ThedecouplerbetweenTrimandChassisabouthalffull,2)Theelectricalharnesswillaffectthenextassemblyprocess,3)Repairingtheharnesseson-linewilltakeapproximatelyonehour,and4)RepairingtheCockpitlaterintheprocessisdifficultandverytimeconsuming.Discussion:YouaretheTrimSectionLeader––whatisyourdecision?Discussasagroup!AndonDiscussion-CockpitsBackground:Inthiscase,thedecisionisisshutdownthelinefor(1)hourandrepairtheharnessespriortoCockpitLoadorrunthelineandrepairthecockpitsout-of-station.SincethedecouplerbetweenTrimandChassisisabouthalffull,thismeansthatChassiscancontinuerunningforashortwhileandtheneventuallyshutdown.PotentialDecision:Inthiscase,QualitycannotbeachievedwhilemaintainingourResponsivenesstargetsmostlybecausethebadcockpitsaffectthenextprocessandareextremelydifficulttorepairlater.TheCostofstoppingthelineismoredesirablethanthecostofrepairingthemlaterandthepotentialtocreatemoredefects.Inthiscase,thedecouplerstatusdoesnotreallyimpactthefinaldecisiontoomuch.Thus,agooddecisionwouldprobablybetostopthelineandfixtheharnessespriortoCockpitInstall.TheTrimLineSectionLeaderwillinformtheGAAreaManagerofthisdecisionandtheimpactonourResponsivenesstarget.AndonDiscussion-CockpitsManufacturing

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Feedforward質(zhì)量反饋與前饋ProductQualityStandardsIn-ProcessControl&Verification“Customer””客戶QualityInformationFeedback/Feedforward質(zhì)量反饋與與前饋“Suppliers”供應(yīng)商You你ProcessAProcessBProcessCbackDefectflowingfromAtoB缺陷從A流到BStatusonProblemResolution問題解決狀狀態(tài)forwardEscapeddefectflowingtoProcessC避免缺陷流流到CTemporaryprocessbeingusedinProcessB過程B的暫時方案案Process/productchangewithtime工藝/產(chǎn)品品隨時間改改變StatusonProblemResolution問題解決狀狀態(tài)MotivationforTimelyFeedback及時反饋的的動機Immediate1Day1YearHighMediumLow1s100s1000sTimetoDiscoverDefect發(fā)現(xiàn)缺陷的的時間AbilitytoDiscoverRootCause發(fā)現(xiàn)根源的的能力NumberofDefectiveVehiclesBuilt已經(jīng)生產(chǎn)的的缺陷產(chǎn)品品Example--DailyReportingMetrics(DirectRun)每天匯報制制度DefinitionPercentageofvehiclesthatmadeitthroughtotheEnd-of-Lineinspectionprocesseswithnodefects.Thisisacommon,globalmetricthatiscomputeddailybyallAssemblyPlants.下線檢查合合格的車FinalInspection(End-of-Line)下線檢測測DynamicVehicleTestorequivalent動態(tài)測試試Other100%Inspections**其他10%檢測測(i.e.U/BCheck)TotalDirectRun=(92%*98%*96%*99%)=86%vehicleswithnodefectRepairCARELine#offirsttimevehicleswithatleastonedefect至少有一一個缺陷陷的第一一次認證證80204010%FirstTimeQuality一次質(zhì)量量認證百百分比92%98%96%99%Totalfirsttimevehiclesthroughthestationonagivenday在特定時時間工位位的第一一次認證證1000100010001000RepairRepairRepair**100%WaterTestand100%SqueakandRattleTestresultsarenotcurrently(3/2000)includedinDirectRun**100%的漏雨測測試與異異響測試試并不包包含在DirectRunManufacturing

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