某公司品質(zhì)制造質(zhì)量管理知識(shí)PPT課件

1、Slide 1D DI IMMC C GMSBuilt-In Quality制造制造質(zhì)質(zhì)量量不不斷斷改改進(jìn)進(jìn)員員工工參與參與標(biāo)標(biāo)準(zhǔn)化準(zhǔn)化縮縮短制造周期短制造周期制造制造質(zhì)質(zhì)量量Slide 2D DI IMMC C GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT

2、TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel Vehi

3、cleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVisionShop FloorManagementManufacturi

4、ngProcess Validation制造工制造工藝認(rèn)證藝認(rèn)證In-ProcessControl &Verification工工藝藝控制控制與與確確認(rèn)認(rèn)QualitySystemManagement質(zhì)質(zhì)量體系管理量體系管理QualityFeedback/Feed-forward質(zhì)質(zhì)量反量反饋饋/前前饋饋ProductQualityStandards產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量標(biāo)標(biāo)準(zhǔn)準(zhǔn)Built-In Quality制造制造質(zhì)質(zhì)量量Slide 3D DI IMMC C GMSBuilt-In-Quality制造制造質(zhì)質(zhì)量量uWhat Is Quality?u 什什么么是是質(zhì)質(zhì)量？量？uGroup

5、Discussionu 小小組討論組討論Slide 4D DI IMMC C GMSDefinitions 定定義義Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm質(zhì)質(zhì)量是客量是客戶戶感感覺覺能能夠夠接受接受并滿并滿足足其其熱熱忱的忱的東東西西Slide 5D DI IMMC C GMSMad Cow 瘋瘋牛牛(Diseased Meat 病牛肉病牛肉)Poor Quality Means Lost Sales質(zhì)質(zhì)量差意味著失去客量差意味著失去客戶戶Firestone燧石燧

6、石(Unintended Accidents)意外事故意外事故uninstalled shift lock漏裝移位漏裝移位鎖鎖定定(Sudden Acceleration)突然加速突然加速Slide 6D DI IMMC C GMS3452121671331501471542322111762222042191922031751562512622671999200020012001 2Q2002 1QIndustryAverageDaewooHyundaiKiaPP100: Not Reported Due To Insufficient Sample 樣樣品不足不品不足不匯報(bào)匯報(bào)( ) J.

7、D. Power IQS Trend By BrandSlide 7D DI IMMC C GMS647669624.85056688073656.35466677871647.75361NCSIDaewooHyundaiKia NCSI By Makers - 2002 2002 NCSI CustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints客戶期望值感知質(zhì)量感知價(jià)值客戶埋怨客戶忠誠客戶保持力Slide 8D DI IMMC C GMSSlide

8、 9D DI IMMC C GMS : : 1122334455667788991010Voice of Customer 客客戶戶意意見見Slide 10D DI IMMC C GMSVoice of Customer客客戶戶意意見見 1. 停車方便 (Convenience of parking)2. 外觀式樣 (Exterior styling)3. 內(nèi)部空間(Interior roominess)4. 節(jié)能 (Fuel economy)5. 安全(Safety)1.外觀式樣 (Exterior styling)2.內(nèi)部空間(Interior roominess)3. 噪音與靜音 (No

9、ise 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. 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 s

10、tyling)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. 檢查發(fā)動(dòng)機(jī)點(diǎn)火 (Check Engine light)5. 法人形象 (Corporate Image) 1. 節(jié)能 (Fuel economy)2. 制動(dòng)性能 (Brake performance) 3. 喇叭性能 (Speaker

11、 performance)4. 內(nèi)飾品質(zhì) (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. 法人形象 (Corporate Image) 5. 級(jí)別 (Gradablity)Slide 11D DI IMMC C GMSBuilt-in-Quality制造制造質(zhì)質(zhì)量量What is Built-In-Quality? 什什么么是制造是制造質(zhì)質(zhì)量？量？Group Discussion

12、 小小組討論組討論Slide 12D DI IMMC C GMSWhat is Built-In Quality?什什么么是制造是制造質(zhì)質(zhì)量？量？Definition 定定義義Method by which quality is built into the manufacturing process, so that defects are prevented, detected, and countermeasures are implemented to prevent reoccurrence.指指質(zhì)質(zhì)量在生量在生產(chǎn)過產(chǎn)過程中程中產(chǎn)產(chǎn)生，因此可以生，因此可以預(yù)預(yù)防、防、發(fā)現(xiàn)發(fā)現(xiàn)缺缺陷，

13、以及采取措施防止缺陷再陷，以及采取措施防止缺陷再發(fā)發(fā)生的方法。生的方法。Purpose 意意圖圖 Ensures defects are not passed to the customer.確保不確保不傳遞傳遞缺陷。缺陷。Slide 13D DI IMMC C GMSDesigners設(shè)計(jì)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The Customer Chain. . . Company Perspective客客戶鏈戶鏈 公司公司遠(yuǎn)遠(yuǎn)景景Built-In-Quality制造制造質(zhì)質(zhì)量量

14、Slide 14D DI IMMC C GMSAssembly總裝Supplier供應(yīng)商Paint涂裝Body車身The Customer Chain. . . Production Perspective客客戶鏈戶鏈 公司公司遠(yuǎn)遠(yuǎn)景景Each Process Has at Least One “Customer” and One “Supplier”每每個(gè)階個(gè)階段至少有一段至少有一個(gè)個(gè)客客戶戶和一和一個(gè)個(gè)供供應(yīng)應(yīng)商商Built-In-Quality制造制造質(zhì)質(zhì)量量Slide 15D DI IMMC C GMSDo not不要不要Accept接受接受Build制造制造Ship傳遞傳遞a Def

15、ect!缺陷缺陷Solve Problems Through Teamwork!團(tuán)隊(duì)團(tuán)隊(duì)合作解合作解決問題決問題！Built-In-Quality Motto制造制造質(zhì)質(zhì)量口量口號(hào)號(hào)Satisfy Your Customer滿滿足足你你的客的客戶戶Slide 16D DI IMMC C GMSQuality 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 Sh

16、op. The flange is too long.問題出自沖壓，邊緣過長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. 問題在于供應(yīng)商的材料不好。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，我不做任何試驗(yàn)。這不是我負(fù)責(zé)的地方，也

17、許是粘膠負(fù)責(zé)Dont run away from the problem!不要逃避不要逃避問題問題!Slide 17D DI IMMC C GMSLiving up to the Motto. . . 符合口符合口號(hào)號(hào). . . - What Is a Defect? 什什么么是缺陷？是缺陷？Group Discussion 小小組討論組討論 Defect 缺陷缺陷Slide 18D DI IMMC C GMSA defect is a product that does not meet the established quality standard.缺陷是不合已定缺陷是不合已定標(biāo)標(biāo)準(zhǔn)的準(zhǔn)

18、的產(chǎn)產(chǎn)品。品。Measurement of a quality characteristic質(zhì)質(zhì)量性能量性能測測量量Vehicle #車輛車輛 號(hào)號(hào)Upper Specification Limit規(guī)規(guī)格上限格上限Lower Specification Limit規(guī)規(guī)格下限格下限Quality Standard質(zhì)質(zhì)量量標(biāo)標(biāo)準(zhǔn)準(zhǔn)Defect 缺陷缺陷Defect 缺陷缺陷xxSlide 19D DI IMMC C GMSWhy are defects undesirable?為為什什么么缺陷不受缺陷不受歡歡迎？迎？lDefects may also result in l 缺陷還可能導(dǎo)致l Hi

19、gh warranty costs 過高保修成本l Lost customer sale 失去客戶Defects Require Correction = Correction is Waste 缺陷需要缺陷需要糾糾正正糾糾正就是浪正就是浪費(fèi)費(fèi)Slide 20D DI IMMC C GMS QUALITY IS EVERYONE S RESPONSIBILITY質(zhì)質(zhì)量是每量是每個(gè)個(gè)人的人的職責(zé)職責(zé) Design, Engineering, Production, Quality, Support Departments and Suppliers. 設(shè)計(jì)，工程，生產(chǎn)，質(zhì)量，相關(guān)部門及供應(yīng)商 O

20、UR Best Resources: 我們最好的資源: PEOPLE 員工 OUR Goal : 我們的目標(biāo)： Everyone is a Quality Inspector 人人都是質(zhì)檢員 Everyone is a Problem Solver 人人都是問題解決者Slide 21D DI IMMC C GMSWHO IS RESPONSIBLE FOR QUALITY? 誰對(duì)質(zhì)誰對(duì)質(zhì)量量負(fù)責(zé)負(fù)責(zé)？Slide 22D DI IMMC C GMSME!我！我！Slide 23D DI IMMC C GMSHealth andSafety PriorityQualified PeopleTeam

21、 ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturingProcess ValidationIn-ProcessControl & VerificationQualitySystemManagementScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementValuesVision/MissionShop FloorManagementInternal Pu

22、ll /DeliveryAndonConceptProblemSolvingSimpleProcessFlowProduct Quality StandardsStandardizedWorkSmall LotPackagingTemporaryMaterialStorageQualityFeedback/Feed-forwardVisualManagementManagementby TAKT TimeWork-placeOrganizationEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLe

23、an Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenance Fixed Period Ordering System/ Order PartsProductQualityStandards產(chǎn)品質(zhì)量標(biāo)準(zhǔn)產(chǎn)品質(zhì)量標(biāo)準(zhǔn)Slide 24D DI IMMC C GMSReflect voice of the customer反映反映顧顧客的心客的心聲聲Simple, clear & support user簡單簡單、清清晰，晰，有利操作者有利操作者C

24、learly Measurable at point of use在使用上可明確在使用上可明確測測量量In users Std. Work & posted visual在操作者的在操作者的標(biāo)標(biāo)準(zhǔn)化準(zhǔn)化工作或工作或張貼張貼出出來來Standards Must Support the Operator, too Not only the Engineer!標(biāo)標(biāo)準(zhǔn)不準(zhǔn)不僅僅有益于有益于設(shè)計(jì)設(shè)計(jì)者，者，也有益于操作工人也有益于操作工人Slide 25D DI IMMC C GMSNot tighter than those applied at the previous process 不要

25、比前道工序的更不要比前道工序的更嚴(yán)嚴(yán)格格Final Inspection Standard:Gap +/- 1mmFINAL INSPECTIONBODY SHOPBody ShopStandard:Gap +/- 2mmSlide 26D DI IMMC C GMSUse master parts and boundary samples as required to make visual標(biāo)標(biāo)準(zhǔn)件準(zhǔn)件與邊與邊界界樣樣件需要目件需要目視視化化Boundary Samples should visually indicate OK Not OK condition to help operat

26、ors make quick, good decisions邊界樣件應(yīng)該標(biāo)明好或不好，以便操作人員迅速且更好地下決定。Visually “describing” the defect is Not a Boundary Sample! 目目視視化化標(biāo)標(biāo)明缺陷不是明缺陷不是邊邊界界樣樣件！件！Crater more than this size is not acceptable不接受焊口大于此尺寸Example of a Boundary Sample邊界樣品的范例邊界樣品的范例Slide 27D DI IMMC C GMSI wouldnt buy this!Doesnt look good

27、 to me!My opinion isThis does not meet the standard.Talk in terms of The Standard, not opinions! 以以標(biāo)標(biāo)準(zhǔn)準(zhǔn)為為基點(diǎn)，而非基點(diǎn)，而非觀觀點(diǎn)！點(diǎn)！Slide 28D DI IMMC C GMSManufacturingProcess ValidationQualitySystemManagementProduct Quality StandardsQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT

28、 TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel Veh

29、icleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn

30、-ProcessControl&VerificationManufacturingProcess Validation制造工序認(rèn)證制造工序認(rèn)證Slide 29D DI IMMC C GMSWhat is a process?什什么么是工序？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.工序是集中相工序是集中相關(guān)關(guān)的的資資源源進(jìn)進(jìn)行一系列活行一系列活動(dòng)動(dòng)，把投入，把投入轉(zhuǎn)換轉(zhuǎn)換成成輸輸出！出！Env

31、ironment環(huán)境Process 工序工序 Man MachinesMethod MaterialsSlide 30D DI IMMC C GMSWhere can Errors Occur?問題會(huì)出在哪？Defects缺陷缺陷Materials:材料材料Parts out of standard 不符標(biāo)準(zhǔn)的零件不符標(biāo)準(zhǔn)的零件Wrong parts錯(cuò)誤零件錯(cuò)誤零件Poor design 設(shè)計(jì)不當(dāng)設(shè)計(jì)不當(dāng) Method: 方法方法Poor std. Work 不好不好的標(biāo)準(zhǔn)工作的標(biāo)準(zhǔn)工作Lack of Training 缺乏缺乏培訓(xùn)培訓(xùn) Machine/Process: 機(jī)器機(jī)器/工序工序No

32、 TPM 沒有沒有TPMProcess not capable 工工序不好序不好Improper specification 規(guī)格不當(dāng)規(guī)格不當(dāng) Man:人力人力Not follow std. Work 不遵循不遵循標(biāo)準(zhǔn)化工作標(biāo)準(zhǔn)化工作Distractions, Forgetfulness 分心、遺忘分心、遺忘Lack of Experience 缺乏經(jīng)缺乏經(jīng)驗(yàn)驗(yàn)Errors Result InSlide 31D DI IMMC C GMSValidate the manufacturing process prior to Start of Production! 在生在生產(chǎn)啟產(chǎn)啟動(dòng)動(dòng)前前認(rèn)證

33、認(rèn)證制造工制造工藝藝！Do not切勿切勿Accept 接受接受Build 制造制造Ship 傳遞傳遞a Defect! 缺陷！缺陷！Living Up to the Motto達(dá)達(dá)到口到口號(hào)號(hào)“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place” - Dr. DemingPFMEAWorkstationReadiness工位準(zhǔn)備Process ControlPlan 工藝控制計(jì)劃Error-proofing Plan防錯(cuò)計(jì)劃Slide

34、 32D DI IMMC C GMSError Proofing Hierarchy 防錯(cuò)層次Prevention 預(yù)防預(yù)防Detection 檢測檢測None無無Product / Process Design Change 產(chǎn)品/工藝設(shè)計(jì)改變 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

35、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)Standardized Work 標(biāo)準(zhǔn)化工作Errors Cant Happen Small Improvement小改進(jìn)Significant Improvement 重大改進(jìn)Introduction to Error Proofing防錯(cuò)介紹Slide 33D DI IMMC C GMS0515100396OLHM510201501510124578101150515100396OLHM510201

36、50151045781011512Original:Best:Visual Control Example0515100396OLHM51020150151012457810115Better:Slide 34D DI IMMC C GMSABExample: Vehicle Identification車輛認(rèn)證車輛認(rèn)證 (Mutilation Cover Color)(蓋板蓋板顏顏色毀色毀損損)Visual Control ExampleSlide 35D DI IMMC C GMSVertical Plate垂直板Battery Post電池接頭Process Control Exampl

37、eSlide 36D DI IMMC C GMSXWork Piece 加工件Work Piece 加工件Fixture 夾具Fixture 夾具Process Control ExampleSlide 37D DI IMMC C GMSProduct Design Example (Before)OLDDESIGN老設(shè)計(jì)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Slide 38D DI IMMC C GMSNEWDESIGN新設(shè)計(jì)新設(shè)計(jì)Application of Lab

38、els on Cassette Decks.門板標(biāo)簽Can Only Be Installed Correctly!Product Design Example (After)Slide 39D DI IMMC C GMSLeft Hand Locator TabRight Hand Locator Tab Example - Product Error Proofing (One Way to Install Seat Belt)防防錯(cuò)樣錯(cuò)樣品品只有一只有一種種安全安全帶帶安裝方法安裝方法Product Design Example 產(chǎn)品設(shè)計(jì)范例Slide 40D DI IMMC C GMS

39、Simple Everyday Examples1) Error Prevention Automatic shut-off自動(dòng)斷電Slide 41D DI IMMC C GMSError Proofing Exercise Think of an example at work or at home where error proofing can prevent an undesirable thing from happening 想想工作想想工作或生活中使用防或生活中使用防錯(cuò)錯(cuò)措施避免不好事情措施避免不好事情發(fā)發(fā)生的例子生的例子 Discuss as a team and report

40、 Take 5 minutes 小小組討論組討論、匯報(bào)匯報(bào)5分分鐘鐘Slide 42D DI IMMC C GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DF

41、M / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall Lot

42、PackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl & Verification工序控制與認(rèn)證工序控制與認(rèn)證Product Quality StandardsSlide 43D DI IMM

43、C C GMS1. PreventionOutputs輸出Inputs投入NOK2. DetectionOKNext Process下道工序Feedback 反饋Do not不要不要Accept 接受接受Build 制造制造Ship 傳遞傳遞a Defect! 缺陷！缺陷！Living Up to the Motto符合符合標(biāo)標(biāo)準(zhǔn)準(zhǔn)3. Containment包容包容Slide 44D DI IMMC C GMS1) StandardizedWork 標(biāo)標(biāo)準(zhǔn)化工作準(zhǔn)化工作Follow and Continuously Improve Standardized Work!遵守及不遵守及不斷斷改改

44、進(jìn)標(biāo)進(jìn)標(biāo)準(zhǔn)化工作！準(zhǔn)化工作！In-Process Control & Verification 1) PREVENTIONPreventionVehicle ManifestManual 2-DoorSunroofSlide 45D DI IMMC C GMS2) Focus on Operation 集中精力生集中精力生產(chǎn)產(chǎn)Keep Your Concentration & Respect Standardized Work of Others!注意及尊重他人的注意及尊重他人的標(biāo)標(biāo)準(zhǔn)化工作準(zhǔn)化工作In-Process Control & Verification 1)

45、 PREVENTIONPreventionSlide 46D DI IMMC C GMS3) Error Proofing Prevention & Operator Aids 防防錯(cuò)預(yù)錯(cuò)預(yù)防防與與操作者支持操作者支持The Best Process is One That Cannot Fail!最好工序就是不最好工序就是不會(huì)會(huì)失失敗敗的！的！In-Process Control & Verification 1) PREVENTIONPreventionDAEWOOSlide 47D DI IMMC C GMS4) Regular Checks of Systems &am

46、p; Processes定定時(shí)檢查時(shí)檢查系系統(tǒng)與統(tǒng)與工工藝藝Std. WorkChecks!檢查標(biāo)檢查標(biāo)準(zhǔn)化工作準(zhǔn)化工作In-Process Control & Verification 1) PREVENTIONPreventionCHECKCHECK?CHECKProcess Control Checks!檢查檢查工序控制！工序控制！TPM Checks!檢查檢查TPMSafety/5SChecks!檢查檢查安全安全/5SSlide 48D DI IMMC C GMSSelf-Checks自自檢檢Include Quality Checksin Standardized Work!

47、把把質(zhì)檢質(zhì)檢作作為標(biāo)為標(biāo)準(zhǔn)化工作準(zhǔn)化工作的一部分的一部分DetectionCheck Methods:POINTTOUCHLISTENCOUNTSlide 49D DI IMMC C GMS2) Error ProofingDetection 檢測檢測防防錯(cuò)錯(cuò)Use Visual and Audio Signals!使用使用視覺視覺、聽聽覺覺信信號(hào)號(hào)！DetectionStop the Line, or停停線線或或Use Alarms, or使用警使用警報(bào)報(bào)或或Combination of Both, depending on Criticality 根據(jù)根據(jù)危危險(xiǎn)險(xiǎn)程度兼用程度兼用兩種兩種方

48、法方法Slide 50D DI IMMC C GMS3) In-ProcessVerification 工序工序認(rèn)證認(rèn)證Inspectors are not there as a policeman, theysupport production byconfirming the process!檢檢察察員員不充不充當(dāng)當(dāng)警察角色，警察角色，而是作而是作為為確定工序的生確定工序的生產(chǎn)產(chǎn)支持者支持者DetectionVerification Stations Final LineC.A.R.E.Slide 51D DI IMMC C GMS3a) Focus onCritical items 集中

49、注意重大集中注意重大問題問題Frequency of checks to not allow Critical defects to leave the shop!經(jīng)經(jīng)常常檢查檢查，不，不讓讓重大缺陷重大缺陷走出走出車間車間！DetectionSafety Items“Walk-Home” ItemsMajor Customer DissatisfierS/CF/FSlide 52D DI IMMC C GMS4) Defect Escalation缺陷逐缺陷逐層匯報(bào)層匯報(bào)Escalate defects to leadership for support depending on frequ

50、ency and criticality!根據(jù)缺陷出根據(jù)缺陷出現(xiàn)頻現(xiàn)頻率率與嚴(yán)與嚴(yán)重程度重程度逐逐層層向向領(lǐng)導(dǎo)匯報(bào)領(lǐng)導(dǎo)匯報(bào)以以尋尋求支持！求支持！DetectionExample:Team LeaderSection LeaderGroup Leader2 defects/ 1 hour4 defects/ 1 hourSlide 53D DI IMMC C GMS1) Use Andon (taught morelater) 使用暗燈使用暗燈Make problems visual & pull in support!問題問題直直觀觀，拉拉線尋線尋求求幫幫助！助！Always Rem

51、ember the Priorities:一定一定要牢要牢記記：1) Safety安全安全2) Quality質(zhì)質(zhì)量量3) Responsiveness (Throughput)響應(yīng)響應(yīng)Containment包容包容Slide 54D DI IMMC C GMS2) Follow Containment Process 遵循包容程序遵循包容程序Extraordinary actionsto prevent defects frombeing passed!采取特采取特別別行行動(dòng)動(dòng)防止防止缺陷缺陷傳遞傳遞！Some examples:1) Stop the line停停線線2) 100% che

52、cks100%檢查檢查3) On-line repair 線線上上維維修修4) Reworks返工返工5) Sorting 整理整理Containment包容包容Slide 55D DI IMMC C GMSDo not不要不要Accept 接受接受Build 制造制造Ship 傳遞傳遞a Defect! 缺陷！缺陷！It means empowered leaders make judgments how to control quality while trying to keep the line running!意味著意味著領(lǐng)導(dǎo)領(lǐng)導(dǎo)有有權(quán)權(quán)作出作出決決定：在定：在盡盡量不停量不停線線的

53、情的情況況下，下，怎樣怎樣控制好控制好質(zhì)質(zhì)量！量！Does this mean we stop the line every time we have a problem?這這是不是意味著一有是不是意味著一有問題問題就停就停線線呢？呢？Slide 56D DI IMMC C GMSSometimes the best decision may be to let a defect pass to the next process, but有有時(shí)時(shí)最好的最好的辦辦法是法是讓讓差差錯(cuò)轉(zhuǎn)錯(cuò)轉(zhuǎn)到下工序，但是到下工序，但是It is a conscious decision made by the ap

54、propriate level Action must be communicated to next “customer”Defect must be clearly identified on vehicleContainment must be in place to prevent further defects Examples of Some Andon Guidelines: 暗燈使用的指暗燈使用的指導(dǎo)導(dǎo)方方針針1) Will the problem affect the next process? 問題會(huì)問題會(huì)不不會(huì)會(huì)影影響響下道工序？下道工序？2) Can I effecti

55、vely repair the defect out of station? 能能不能在工位外有效解不能在工位外有效解決問題決問題？3) What is the status of my decouplers? 自己的切自己的切斷斷器器是什是什么狀態(tài)么狀態(tài)？4) Others 其他其他Slide 57D DI IMMC C GMSAndon Discussion Hoods Situation: At the Body Shop end-of-line Quality station it is discovered that there is a problem with cracked h

56、oods. After working the line 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 su

57、ppler says new hoods will 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

58、 any of the subsequent processes, 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! Slide 58D DI IMMC C GMSBackground: In this case, the decision is is shut down the line for (6) hours and wait for par

59、ts or run the line and make a containment 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

60、 hoods do not affect the next process. 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 vehicle numbers and identification met