general motors globális gyártási rendszer si rendszerkardos/opel2008/2008.03.19/gmpth-sze_biq_mar...

General Motors Powertrain

–

Magyarország Kft.

Dátum: 2008. március

19.

Előadó:

Kovács János

Minőségügyi Igazgató

General MotorsGeneral Motors GlobGlobáális Gylis Gyáártrtáási Rendszersi Rendszer General Motors Global Manufacturing SystemGeneral Motors Global Manufacturing System

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Globális Gyártási RendszerGeneral Motors-Global Manufacturing System

3

Built

In

Quality

–

Beépített Minőség

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Cél:

Minőségügyi alapelvek alkalmazásának

bemutatása a GM Globális Gyártási Rendszer ismertetésén keresztül

Első

előadás témái:

A vevő fogalma, vevői elégedettség

Termékminőségi követelmények

Termelési folyamat jóváhagyás

Második előadás témái:

Folyamatközi ellenőrzés és folyamat igazolás

Minőség visszajelzés - előrejelzés rendszere

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.

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Car Plant

Supplier

Eng. AssemblyLine

Machining Line

Costumer

The costumer chain

There are at least One “Customer”

and One “Supplier”

in Each ProcessYou can find costumer-supplier relationship between workstations, departments, productive and

non-productive areas as well.

Supplier

Costumer

Costumer

COSTUMERSupplier

Supplier

Supplier

Costumer

A vevő


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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

A vevő


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Product Quality Standards (PQS)

Purpose

•

To provide cross functional groups with criteria for product evaluation

Definition

•

Measurable requirements for product characteristics, which when satisfied, ensure our products meet internal/external customer requirements.

Termékminőségi Követelmények (Product Quality Standards)

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Benefits

Communicates standards to upstream suppliers

Supports the Team Member in developing and using

standardized work

Supports the Team Member to make a clear judgment of

product quality

Avoids shipping sub-standard products to the customer

(internal and external)

Supports other GMS Principles or Operating Guidelines


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Development Process

•Customer Input (VOC data)

•Engineering Requirements

•Design Requirements

•Processing Requirements

•Standard Format which is

user friendly on shop floor

•Contains validated standards

•Approval signatures (Eng and Mfg.)

•Maintained in central database


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Types of Product Quality StandardsCompleted Vehicle Inspection Standards (CVIS)

At a minimum defines item to be inspected on the vehicle and the criteria for acceptability

In-Process Product Quality StandardsIn-process (upstream) inspection standards are used to

achieve completed vehicle inspection standards when required

Parts and Subassembly Inspection StandardsUsed for confirming quality of supplied parts or assemblies when required

Shipping StandardsUsed to ensure “obvious discrepancies” to the customer are identified at CARE and contained.


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Types of Product Quality Standards (cont.)

Powertrain Product Quality StandardsUsed for confirming quality of all Powertrain supplied components and assemblies.

Temporary Product Quality StandardsUsed 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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Incorporation into Standardized Work

Production Operation

Inspection Operation

output

output

PFMEA

and

Process

Control

Plans Input

Reference PCP xx-xxx


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Standardized InspectionManufacturing

The Product Quality Standard „Must”

PQSVoice of customer

feedback to PQS

Customer

•

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


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The Product Quality Standard

Build IssuesPTR/Validation Builds

Evaluate Product and process capability to meet quality standard (PQS)

Implement Countermeasures

Plan

Check

DoAct

Build issues are entered into the Problem Solving Process and assigned to appropriate owners:• Engineering• Production• Suppliers

Review PQS with Team Leaders to ensure standards are clear & understood

Plan

Check

DoAct

Feedback


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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.

•

At each step of the Manufacturing and Inspection Processes Quality expectations must be clearly understood by all Team Members.

•

Standards are not tighter than those applied in upstream processes.

•

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).

•

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.


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Manufacturing Process Validation

Purpose

•

The method by which processes are prepared and

validated before starting full volume production

Definition

•

To ensure that each manufacturing process is capable of

meeting defined product quality standards, while

achieving schedule

Termelési folyamat jóváhagyása (Manufacturing Process Validation)

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The GMS element “Manufacturing ProcessValidation”

serves

as

the foundation for the

BIQ motto:

Requirements to meet quality expectations are designed intoeach process and validated to ensure defects are not built orshipped to the next process or customer.


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Benefits of a Validated Process

•

Design quality into the product and process

Design the product such that it is physically impossible toproduce 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 teammember 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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Benefits of a Validated Process

-

continued

•

Processes are confirmed based on process

capability --

variation in Man, Machine, Methods,

Materials and

Environment do not disrupt

production and quality

•

Early identification of non capable processes

provides opportunity for resolution

•

Impact of production losses is reduced

•

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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Validate The Manufacturing System


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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 Identify ImplementCountermeasures

Identify ImplementCountermeasures

Process &

Capability

Validated

Global Launch ProcessValidate Under Production Conditions

DFMEA

KCDS

Engineering Ready for SOVP

OK

Build Event Build Event Build Event

X


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Manufacturing Planning and Validation: Integrating the Team

•

Team Members have early involvement in various activities of product & process development and validation

•

Product evaluation starting with Design Reviews and during pre-

production 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

•

Process is validated under well-defined conditions (usually Run @ Rate production condition)


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Risk Analysis


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Process ControlsProcess controls are developed to drive daily checks that are conducted

at the team level to control variation within the process.

Processes are identified through a risk analysis method

Determine the appropriate tool/method to use for each process

Document results and follow up with corrective actions

Control process output variation within quality standard limits


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Process Controls


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Validate The Manufacturing System


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Operational Readiness Process


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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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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?)

A vevő


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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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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

general motors globális gyártási rendszer si rendszerkardos/opel2008/2008.03.19/gmpth-sze_biq_mar...

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