General Motors Globális Gyártási Rendszer General Motors Global Manufacturing System
General Motors Powertrain – Magyarország Kft. Dátum:
2008. március 19.
Előadó:
Kovács János Minőségügyi Igazgató
Globális Gyártási Rendszer General Motors-Global Manufacturing System
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Built In Quality – Beépített Minőség
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Cél: Minőségügyi alapelvek alkalmazásának bemutatása a GM Globális Gyártási Rendszer ismertetésén keresztül Első előadás témái: 9
A vevő fogalma, vevői elégedettség
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Termékminőségi követelmények
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Termelési folyamat jóváhagyás
Második előadás témái: 9
Folyamatközi ellenőrzés és folyamat igazolás
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Minőség visszajelzés - előrejelzés rendszere
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Minőségirányítási rendszer
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A vevő fogalma, vevői elégedettség(Definition of customer,
customer satisfaction)
The CUSTOMER is an organization or person that receives a product. Example: consumer, client, end-user, retailer, beneficiary and purchaser. NOTE: A customer can be internal or external to the organization. The SUPPLIER is an organization or person that provides a product. Example: Producer, distributor, retailer or vendor of a product, or provider of a service or information. NOTE: A supplier can be internal or external to the organization. 6
A vevő fogalma, vevői elégedettség(Definition of customer,
customer satisfaction)
The costumer chain
Supplier
Machining Line Eng. Assembly Line
Costumer Car Plant
There are at least One “Customer” and One “Supplier” in Each Process You can find costumer-supplier relationship between workstations, departments, productive and non-productive areas as well.
Supplier
¡
£
Supplier
Costumer
¥
Costumer
Supplier
Costumer
Supplier
COSTUMER
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A vevő fogalma, vevői elégedettség(Definition of customer,
customer satisfaction)
Customer satisfaction achievement
Customer satisfaction is achieved through three sub-elements: • Prevention: avoid defects or non-standards occurring • Detection: identify when defects or non-standards have occurred • Containment: assure defects or non-standards are not passed on 8
Termékminőségi Követelmények (Product Quality Standards)
Product Quality Standards (PQS) Purpose
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To provide cross functional groups with criteria for product evaluation
Definition
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Measurable requirements for product characteristics, which when satisfied, ensure our products meet internal/external customer requirements.
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Termékminőségi Követelmények (Product Quality Standards)
Benefits ¾ Communicates standards to upstream suppliers ¾ Supports the Team Member in developing and using standardized work ¾ Supports the Team Member to make a clear judgment of product quality ¾ Avoids shipping sub-standard products to the customer (internal and external) ¾ Supports other GMS Principles or Operating Guidelines
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Termékminőségi Követelmények (Product Quality Standards)
Development Process
•Customer Input (VOC data)
•Standard Format which is
•Engineering Requirements
user friendly on shop floor
•Design Requirements
•Contains validated standards
•Processing Requirements
•Approval signatures (Eng and Mfg.) •Maintained in central database
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Termékminőségi Követelmények (Product Quality Standards)
Types of Product Quality Standards ¾Completed Vehicle Inspection Standards (CVIS) At a minimum defines item to be inspected on the vehicle and the criteria for acceptability ¾In-Process Product Quality Standards In-process (upstream) inspection standards are used to achieve completed vehicle inspection standards when required ¾Parts and Subassembly Inspection Standards Used for confirming quality of supplied parts or assemblies when required ¾Shipping Standards Used to ensure “obvious discrepancies” to the customer are identified at CARE and contained. 12
Termékminőségi Követelmények (Product Quality Standards)
Types of Product Quality Standards (cont.) ¾Powertrain Product Quality Standards Used for confirming quality of all Powertrain supplied components and assemblies. ¾Temporary Product Quality Standards Used for interim standards (e.g. launch, temporary product or part issues) with a set start/stop time frame.
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Korai Gyártás és Tervezés Egységesítés (Early Manufacturing
and Design Integration (DFM/DFA))
DFM Impacts the Biggest Shadow Product Design more than any other factor, influences the cost of producing a product. Therefore, product design exerts a powerful influence on the ability of a manufacturing company to compete in quality and cost. If quality improvements and cost reductions are to take place, this is the place to focus.
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Korai Gyártás és Tervezés Egységesítés (Early Manufacturing
and Design Integration (DFM/DFA))
DFM Tools and Benefits
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Termékminőségi Követelmények (Product Quality Standards)
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Termékminőségi Követelmények (Product Quality Standards)
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Termékminőségi Követelmények (Product Quality Standards)
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Termékminőségi Követelmények (Product Quality Standards)
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Termékminőségi Követelmények (Product Quality Standards) Incorporation into Standardized Work EA PFMnd a ess c Pro ntrol o C lans P
Input
o
t u p ut
Production Operation
output
Reference PCP xx-xxx
Inspection Operation
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Termékminőségi Követelmények (Product Quality Standards)
The Product Quality Standard „Must”
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Support the true ‘voice of the customer’ PQS is a BUILD standard as well as INSPECTION standard Be easy to interpret as a ‘shop floor’ document
PQS Voice of customer feedback to PQS
Manufacturing
Standardized Inspection
Customer
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Termékminőségi Követelmények (Product Quality Standards)
The Product Quality Standard Plan Act
Review PQS with Team Leaders to ensure standards are Do clear & understood
Plan Do
Act Implement Countermeasures
Check PTR/Validation Builds Evaluate Product and process capability to meet quality standard (PQS)
Check
Build Issues Feedback
Build issues are entered into the Problem Solving Process and assigned to appropriate owners: • Engineering • Production • Suppliers
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Termékminőségi Követelmények (Product Quality Standards)
The Product Quality Standard – Summary •
Product Quality Standards are developed to clearly communicate a condition, dimension or value that must be achieved to satisfy customer, engineering, and regulatory requirements.
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At each step of the Manufacturing and Inspection Processes Quality expectations must be clearly understood by all Team Members.
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Standards are not tighter than those applied in upstream processes.
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A formal change process needs to be followed to initiate and implement any changes to a Quality Standard. This procedure should ensure that all the affected parties have a common set of standards.
Standards provide shop floor documentation supporting standardization and built-in quality – used in conjunction with standardized work (Standard Operation Sheet-SOS & Job Element Sheet-JES).
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Manufacturing Process Validation Purpose
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The method by which processes are prepared and validated before starting full volume production
Definition
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To ensure that each manufacturing process is capable of meeting defined product quality standards, while achieving schedule
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
The GMS element “Manufacturing Process Validation” serves as the foundation for the BIQ motto:
Requirements to meet quality expectations are designed into each process and validated to ensure defects are not built or shipped to the next process or customer.
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Benefits of a Validated Process
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Design quality into the product and process
Design the product such that it is physically impossible to produce the defect
Design the process such that it prevents or detects an error and stops for intervention
Validate the process
Validate under production conditions
Operational readiness ensures process is ready for team member and that team member is ready for the process
Deliver a process which at the Start Of Production will produce products in station that meet or exceed customer expectations
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Benefits of a Validated Process - continued
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Processes are confirmed based on process capability -variation in Man, Machine, Methods, Materials and Environment do not disrupt production and quality
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Early identification of non capable processes provides opportunity for resolution
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Impact of production losses is reduced
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Smooth start-up supporting quality glide path and launch curves Customers’ requirements are met by following the principles of ‘Plan-Do-Check-Act’
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Validate The Manufacturing System
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Process Overview Provide a manufacturing process that exceeds customer expectations through:
• Up front application of lessons learned and error proofing • Validation of the manufacturing processes and procedures • Operational Readiness that supports the Team Member Product & Process
Global Launch Process Validate Under Production Conditions Identify Implement
Countermeasures
DFMEA KCDS
Identify Implement
Process & Capability Validated
Countermeasures
X OK
Engineering
Build Event
Build Event
Build Event
Ready for SOVP
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Manufacturing Process Validation Manufacturing Planning and Validation: Integrating the Team
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Team Members have early involvement in various activities of product & process development and validation • Product evaluation starting with Design Reviews and during preproduction builds • Risk analysis and process planning • Tool and Equipment design, construction, and tryout • Standardized work development and problem solving • Total Maintenance System planning (TMS) • Workstations planning and implementation using Operational Readiness
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Process is validated under well-defined conditions (usually Run @ Rate production condition)
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Manufacturing Process Validation Risk Analysis
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Process Controls Process controls are developed to drive daily checks that are conducted at the team level to control variation within the process. ¾Processes are identified through a risk analysis method ¾Determine the appropriate tool/method to use for each process ¾Document results and follow up with corrective actions ¾Control process output variation within quality standard limits
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Process Controls
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Validate The Manufacturing System
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Operational Readiness Process
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Summary Manufacturing Process Validation promotes advanced planning, preparation, and confirmation that a production process is ready at Start of Production.
• • • • • •
Integrates Production Teams into Manufacturing planning process: • Provides strong links with the Global Vehicle Development Process, including product evaluation with Design Reviews • Includes Production Teams into Manufacturing planning process Includes structured risk assessment (e.g. PFMEA) in product and process design Incorporates prevention-focused error proofing in the design process Process controls are developed and capability confirmed; design and manufacturing processes validated under production conditions Operational readiness prepares and confirms the shop floor processes Changes in the manufacturing process are validated
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A vevő fogalma, vevői elégedettség(Definition of customer,
customer satisfaction)
Ellenőrző kérdések: 1. Mi a vevő és a beszállító fogalma? (What is the definition of the customer and the supplier?) 2. Sorold fel egy lehetséges vevői lánc elemeit, az autó előállítása folyamán. (List a possible customer chain elements during manufacturing of cars.) 3. Miért fontos a vevői elégedettség kivívása? (Why so important is the costumer satisfaction?) 4. Milyen módszerekkel biztosítható a vevői elégedettség a gyártás során? (What methods can you achieve the costumer satisfaction with during manufacturing?)
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Termékminőségi Követelmények (Product Quality Standards)
Ellenőrző kérdések: 1. Mi a meghatározása a termék minőségi normáknak? (What is the definition of the Product Quality Standards?) 2. Mit kell tudnia a termékminőségi normáknak, előírásoknak(3 dolog)? (What must know the Product Quality Standards?) 3. Milyen részei vannak egy munkaelem lapnak? (What elements does the Job Element Sheet have?) 4. Sorold fel a termék minőség normák típusait. (Specify the type of the Product Quality Standards.)
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Termelési folyamat jóváhagyása (Manufacturing Process Validation)
Ellenőrző kérdések: 1. Mi a célja a termelési folyamat jóváhagyásának? (What is the purpose of the Manufacturing Process Validation?) 2. Mik az előnyei a termelési folyamat jóváhagyásának? (What is the benefits of the Manufacturing Process Validation?) 3. Milyen tevékenységek vannak a folyamat jóváhagyása során? (What kind of activities are there during process verification?) 4. Mit jelentenek az alábbi kifejezések, és mi célt szolgálnak? (What do these expression mean?) DFMEA, PFMEA, SPC, Control Plan, Error Proofing, 100% inspection, Sampling, Capability Study, Reaction Plan
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Köszönöm a figyelmet! Thank you for your attention!
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Words and expressions
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