制造質(zhì)量培訓(xùn)課件(共69頁(yè)).ppt

1、GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 1 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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 2 GMSManufacturingProcess ValidationProductQualityStandardsQu

2、alitySystemManagementIn-ProcessControl &VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooli

3、ng and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHea

4、lth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVisionShop FloorManagementManufacturingProcess 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ProductQu

5、alityStandards產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量標(biāo)標(biāo)準(zhǔn)準(zhǔn)Built-In Quality制造質(zhì)量制造質(zhì)量GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 3 GMSBuilt-In-Quality制造制造質(zhì)質(zhì)量量uWhat Is Quality? 什什么么是是質(zhì)質(zhì)量？量？uGroup Discussion 小小組討論組討論GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Sli

6、de 4 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(jué)覺(jué)能能夠夠接受接受并滿并滿足其足其熱熱忱的忱的東東西西GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 5 GMSMad Cow 瘋瘋牛牛(Diseased Meat 病牛肉病牛肉)Poor Quality Means Lost Sale

7、s質(zhì)質(zhì)量差意味著失去客量差意味著失去客戶戶Firestone燧石燧石(Unintended Accidents)意外意外事故事故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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 6 GMS3452121671331501471542322111762222042191922031751562512622671999200020012001 2Q2002

8、1QIndustryAverageDaewooHyundaiKiaPP100: Not Reported Due To Insufficient Sample 樣品不足不匯報(bào)樣品不足不匯報(bào)( ) J.D. Power IQS Trend By BrandGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 7 GMS647669624.85056688073656.35466677871647.75361NCSIDaewooHyundaiKiau NCSI By Makers -

9、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(chéng)客戶保持力GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 8 GMSGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 20

10、03.03.12Slide 9 GMS : : 1122334455667788991010Voice of Customer 客客戶戶意意見(jiàn)見(jiàn)GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 10 GMSVoice of Customer客客戶戶意意見(jiàn)見(jiàn) 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(S

11、afety)1.外觀式樣 (Exterior styling)2.內(nèi)部空間(Interior roominess)3. 噪音與靜音 (Noise 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 a

12、nd quietness)3. 內(nèi)部空間(Interior roominess)4. 坐騎(Ride)5.外觀式樣 (Exterior styling)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 Im

13、age) 1. 節(jié)能 (Fuel economy)2. 制動(dòng)性能 (Brake performance) 3. 喇叭性能 (Speaker 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)GMS OrientationBuilt-in quality GMDA

14、T/DIMC ConfidentialVersion Date 2003.03.12Slide 11 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 小小組討論組討論GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 12 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 b

15、y 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(guò)產(chǎn)過(guò)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)缺陷缺陷，以及采取措施防止，以及采取措施防止缺陷缺陷再再發(fā)發(fā)生的方法。生的方法。Purpose 意意圖圖 Ensures defects are not passed to the customer.

16、確保不確保不傳遞傳遞缺陷。缺陷。GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 13 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(gòu)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制造質(zhì)量制造質(zhì)量GMS OrientationBuilt-in quali

17、ty GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 14 GMSAssembly總裝Supplier供應(yīng)商Paint涂裝Body車身The Customer Chain. . . Production Perspective客戶鏈客戶鏈 公司遠(yuǎn)景公司遠(yuǎn)景Each Process Has at Least One “Customer” and One “Supplier”每個(gè)階段至少有一個(gè)客戶和一個(gè)供應(yīng)商每個(gè)階段至少有一個(gè)客戶和一個(gè)供應(yīng)商Built-In-Quality制造質(zhì)量制造質(zhì)量GMS OrientationBuilt-in qua

18、lity GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 15 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Solve Problems Through Teamwork!團(tuán)隊(duì)團(tuán)隊(duì)合作解合作解決問(wèn)題決問(wèn)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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 200

19、3.03.12Slide 16 GMSQuality Through Teamwork Know Your Customer!What water leaks?I dont see any water leaks什么漏雨？我沒(méi)發(fā)現(xiàn)漏雨。This car wasnt made on my shiftThe problem is Press Shop. The flange is too long.問(wèn)題出自沖壓，邊緣過(guò)長(zhǎng)I wont run any trial until I have an assembly method from Industrial Engineering and the m

20、anpower.The problem is that the pieces are bad from the supplier. 問(wèn)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(méi)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，也許是粘膠負(fù)責(zé)Dont run away from the problem!不要逃避不要逃避問(wèn)題問(wèn)題!GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12

21、Slide 17 GMSLiving up to the Motto. . . 符合符合口號(hào)口號(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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 18 GMSA defect is a product that does not meet the established quality standard.缺陷是不合缺陷是不合已

22、已定定標(biāo)標(biāo)準(zhǔn)的準(zhǔn)的產(chǎn)產(chǎn)品。品。Measurement of a quality characteristic質(zhì)質(zhì)量性能量性能測(cè)測(cè)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xxGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 19 GMSWhy are defect

23、s undesirable?為什么缺陷不受歡迎？為什么缺陷不受歡迎？lDefects may also result in 缺陷還可能導(dǎo)致L High warranty costs 過(guò)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)GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 20 GMS QUALITY IS EVE

24、RYONES 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OUR Best Resources:我們最好的資源: PEOPLE 員員工工OUR Goal :我們的目標(biāo)： Everyone is a Quality Inspector 人人都是人人都是質(zhì)檢員質(zhì)檢員 Everyone is a Problem Solver 人人都是人人都是問(wèn)題問(wèn)題解解決決者者GMS Orientati

25、onBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 21 GMSWHO IS RESPONSIBLE FOR QUALITY? 誰(shuí)對(duì)質(zhì)量負(fù)責(zé)？誰(shuí)對(duì)質(zhì)量負(fù)責(zé)？GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 22 GMSME!我！我！GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Sl

26、ide 23 GMSHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturingProcess ValidationIn-ProcessControl & VerificationQualitySystemManagementScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManage

27、mentValuesVision/MissionShop FloorManagementInternal Pull /DeliveryAndonConceptProblemSolvingSimpleProcessFlowProduct Quality StandardsStandardizedWorkSmall LotPackagingTemporaryMaterialStorageQualityFeedback/Feed-forwardVisualManagementManagementby TAKT TimeWork-placeOrganizationEarly Mfg. and Desi

28、gnIntegration (DFM / DFA)ContinuousImprovementProcessLean 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)GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Da

29、te 2003.03.12Slide 24 GMSReflect voice of the customer反映顧客的心聲反映顧客的心聲Simple, clear & support user簡(jiǎn)單、清晰，簡(jiǎn)單、清晰，有利操作者有利操作者Clearly Measurable at point of use在使用上可明確測(cè)量在使用上可明確測(cè)量In users Std. Work & posted visual在操作者的標(biāo)準(zhǔn)化在操作者的標(biāo)準(zhǔn)化工作或張貼出來(lái)工作或張貼出來(lái)Standards Must Support the Operator, too Not only the Engi

30、neer!標(biāo)準(zhǔn)不僅有益于設(shè)計(jì)者，標(biāo)準(zhǔn)不僅有益于設(shè)計(jì)者，也有益于操作工人也有益于操作工人GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 25 GMSNot tighter than those applied at the previous process 不要比前道工序的更嚴(yán)格不要比前道工序的更嚴(yán)格Final Inspection Standard:Gap +/- 1mmFINAL INSPECTIONBODY SHOPBody ShopStandard:Gap +/- 2m

31、mGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 26 GMSUse master parts and boundary samples as required to make visual標(biāo)準(zhǔn)件與邊界樣件需要目視化標(biāo)準(zhǔn)件與邊界樣件需要目視化Boundary Samples should visually indicate OK Not OK condition to help operators make quick, good decisions邊界樣件應(yīng)該標(biāo)明好或不好，

32、以便操作人員迅速且更好地下決定。Visually “describing” the defect is Not a Boundary Sample! 目視化標(biāo)明缺陷不是邊界樣件！目視化標(biāo)明缺陷不是邊界樣件！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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 27 GMSI wouldnt b

33、uy this!Doesnt look good to me!My opinion isThis does not meet the standard.Talk in terms of The Standard, not opinions! 以標(biāo)準(zhǔn)為基點(diǎn)，而非觀點(diǎn)！以標(biāo)準(zhǔn)為基點(diǎn)，而非觀點(diǎn)！GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 28 GMSManufacturingProcess ValidationQualitySystemManagementProduct Qua

34、lity StandardsQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal

35、ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam

36、 ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl&VerificationManufacturingProcess Validation制造工序認(rèn)證制造工序認(rèn)證GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 29 GMSWhat is a process?什么是工序？什么是工序？Inputs投入Output

37、s輸出A process is a set of inter-related resources and activities which transforms inputs into outputs.工序是集中相關(guān)的資源進(jìn)行一系列活動(dòng)，把投入轉(zhuǎn)換成輸出！工序是集中相關(guān)的資源進(jìn)行一系列活動(dòng)，把投入轉(zhuǎn)換成輸出！Environment環(huán)境Process 工序工序 Man MachinesMethod MaterialsGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 30 GMSW

38、here can Errors Occur?問(wèn)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Wrong parts錯(cuò)誤零件Poor design 設(shè)計(jì)不當(dāng) Method: 方法方法Poor std. Work 不好的標(biāo)準(zhǔn)工作Lack of Training 缺乏培訓(xùn) Machine/Process: 機(jī)機(jī)器器/工序工序No TPM 沒(méi)有TPMProcess not capable 工序不好Improper specification 規(guī)格不當(dāng) Man:人力人力Not follow std. Work 不遵循標(biāo)準(zhǔn)化工作Di

39、stractions, Forgetfulness 分心、遺忘Lack of Experience 缺乏經(jīng)驗(yàn)Errors Result InGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 31 GMSValidate the manufacturing process prior to Start of Production! 在生產(chǎn)啟在生產(chǎn)啟動(dòng)前認(rèn)證制造工藝！動(dòng)前認(rèn)證制造工藝！Do not切勿切勿Accept 接受接受Build 制造制造Ship 傳遞傳遞a Defect!

40、 缺陷！缺陷！Living Up to the Motto達(dá)到口號(hào)達(dá)到口號(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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Da

41、te 2003.03.12Slide 32 GMSError Proofing Hierarchy 防錯(cuò)層次Prevention 預(yù)防預(yù)防Detection 檢測(cè)檢測(cè)None無(wú)無(wú)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 Moni

42、tors 傳感器及工藝監(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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.

43、03.12Slide 33 GMS0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:Visual Control Example0515100396OLHM51020150151012457810115Better:GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 34 GMSABExample: Vehicle Identification車輛認(rèn)證車輛

44、認(rèn)證 (Mutilation Cover Color)(蓋板顏色毀損蓋板顏色毀損)Visual Control ExampleGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 35 GMSVertical Plate垂直板Battery Post電池接頭Process Control ExampleGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 36 GMSX

45、Work Piece 加工件Work Piece 加工件Fixture 夾具Fixture 夾具Process Control ExampleGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 37 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GMS Orientatio

46、nBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 38 GMSNEWDESIGN新設(shè)計(jì)新設(shè)計(jì)Application of Labels on Cassette Decks.門板標(biāo)簽Can Only Be Installed Correctly!Product Design Example (After)GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 39 GMSLeft Hand Loc

47、ator TabRight Hand Locator Tab Example - Product Error Proofing (One Way to Install Seat Belt)防錯(cuò)樣品防錯(cuò)樣品只有一種安全帶安裝方法只有一種安全帶安裝方法Product Design Example 產(chǎn)品設(shè)計(jì)范例GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 40 GMSSimple Everyday Examples1) Error Prevention Automatic shu

48、t-off自動(dòng)斷電GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 41 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錯(cuò)措施避免不好事情發(fā)生的例子或生活中使用防錯(cuò)措施避免不好事情發(fā)生的例子 Discuss as a team

49、and report Take 5 minutes 小組討論、匯報(bào)小組討論、匯報(bào)5分鐘分鐘GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 42 GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-p

50、laceOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder S

51、chedulesSupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessCon

52、trol & Verification工序控制與認(rèn)證工序控制與認(rèn)證Product Quality StandardsGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 43 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 M

53、otto符合標(biāo)準(zhǔn)符合標(biāo)準(zhǔn)3. Containment包容包容GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 44 GMS1) StandardizedWork 標(biāo)準(zhǔn)化工作標(biāo)準(zhǔn)化工作Follow and Continuously Improve Standardized Work!遵守及不斷遵守及不斷改進(jìn)標(biāo)準(zhǔn)化工作！改進(jìn)標(biāo)準(zhǔn)化工作！In-Process Control & VerificationPreventionVehicle ManifestManual 2-Do

54、orSunroofGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 45 GMS2) Focus on Operation 集中精力生產(chǎn)集中精力生產(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)準(zhǔn)化工作標(biāo)準(zhǔn)化工作In-Process Control & VerificationPreventionGMS OrientationBuilt-in qual

55、ity GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 46 GMS3) Error Proofing Prevention & Operator Aids 防錯(cuò)預(yù)防與操作者支持防錯(cuò)預(yù)防與操作者支持The Best Process is One That Cannot Fail!最好工序就是不會(huì)失敗的！最好工序就是不會(huì)失敗的！In-Process Control & VerificationPreventionDAEWOOGMS OrientationBuilt-in quality GMDAT/DIMC Confiden

56、tialVersion Date 2003.03.12Slide 47 GMS4) Regular Checks of Systems & Processes定時(shí)檢查系統(tǒng)與工藝定時(shí)檢查系統(tǒng)與工藝Std. WorkChecks!檢查標(biāo)準(zhǔn)化工作檢查標(biāo)準(zhǔn)化工作In-Process Control & VerificationPreventionCHECKCHECK?CHECKProcess Control Checks!檢查工序控制！檢查工序控制！TPM Checks!檢查檢查TPMSafety/5SChecks!檢查安全檢查安全/5SGMS OrientationBuilt-in

57、quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 48 GMSSelf-Checks自檢自檢Include Quality Checksin Standardized Work!把質(zhì)檢作為標(biāo)準(zhǔn)化工作把質(zhì)檢作為標(biāo)準(zhǔn)化工作的一部分的一部分DetectionCheck Methods:POINTTOUCHLISTENCOUNTGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 49 GMS2) Error Proof

58、ingDetection 檢測(cè)防錯(cuò)檢測(cè)防錯(cuò)Use Visual and Audio Signals!使用視覺(jué)、使用視覺(jué)、聽(tīng)覺(jué)信號(hào)！聽(tīng)覺(jué)信號(hào)！DetectionStop the Line, or停線或停線或Use Alarms, or使用警報(bào)或使用警報(bào)或Combination of Both, depending on Criticality 根根據(jù)危險(xiǎn)程度兼用據(jù)危險(xiǎn)程度兼用兩種方法兩種方法GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 50 GMS3) In-ProcessV

59、erification 工序認(rèn)證工序認(rèn)證Inspectors are not there as a policeman, theysupport production byconfirming the process!檢察員不充當(dāng)警察角色，檢察員不充當(dāng)警察角色，而是作為確定工序的生產(chǎn)支持者而是作為確定工序的生產(chǎn)支持者DetectionVerification Stations Final LineC.A.R.E.GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 51 GMS3a

60、) Focus onCritical items 集中注意重大問(wèn)題集中注意重大問(wèn)題Frequency of checks to not allow Critical defects to leave the shop!經(jīng)常檢查，不讓重大缺陷經(jīng)常檢查，不讓重大缺陷走出車間！走出車間！DetectionSafety Items“Walk-Home” ItemsMajor Customer DissatisfierS/CF/FGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 52 GMS4) Defect Escalation缺陷逐層匯報(bào)缺陷逐層匯報(bào)Escalate defects to leadership for sup