某公司品质制造质量管理知识.ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,路漫漫其修远兮,吾将上下而求索,07 六月 2025,某公司品质制造质量管理知识,ManufacturingProcess Validation,ProductQualityStandards,QualitySystemManagement,In-ProcessControl&,Verification,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,AndonConcept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision,Shop FloorManagement,ManufacturingProcess Validation,制造工艺认证,In-Process,Control&,Verification,工艺控制与确认,QualitySystemManagement,质量体系管理,QualityFeedback/Feed-,forward,质量反馈/前馈,Product,Quality,Standards,产品质量标准,Built-In Quality,制造质量,Built-In-Quality制造质量,What Is Quality?,什么是质量？,Group Discussion,小组讨论,Definitions 定义,Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm,质量是客户感觉能够接受并满足其热忱的东西,Mad Cow 疯牛,(Diseased Meat 病牛肉),Poor Quality Means Lost Sales,质量差意味着失去客户,Firestone,燧石,(Unintended Accidents),意外事故,uninstalled shift lock,漏装移位锁定,(Sudden Acceleration),突然加速,PP100,:Not Reported Due To Insufficient Sample,样品不足不汇报,(),J.D.Power IQS Trend By Brand,NCSI By Makers-2002,2002 NCSI,Customer,Expectations,Perceived,Quality,Perceived,Value,Customer,Loyalty,Customer,Retention,Customer,Complaints,客户期望值,感知质量,感知价值,客户埋怨,客户忠诚,客户保持力,Voice of Customer 客户意见,Voice of Customer客户意见,1.停车方便(Convenience of parking),2.外观式样(Exterior styling),3.内部空间(Interior roominess),4.节能(Fuel economy),5.安全(Safety),1.外观式样(Exterior styling),2.内部空间(Interior roominess),3.噪音与静音(Noise and quietness),4.节能(Fuel economy),5.空调性能(Air conditioner performance),1.发动机性能(Engine Performance),2.发动机噪音(Engine Noise),3.外观式样(Exterior styling),4.噪音与静音(Noise and quietness),5.坐骑(Ride),L6,1.节能(Fuel economy),2.噪音与静音(Noise and quietness),3.内部空间(Interior roominess),4.坐骑(Ride),5.外观式样(Exterior styling),1节能(Fuel economy),2.空调(Air conditioner),3.噪音(Noise),4.发动机噪音(Engine Noise),5.M/T转换(M/T Shift),1.节能(Fuel economy),2.OSRVM手工控制(Manual OSRVM control),3.发动机噪音(Engine noise),4.检查发动机点火(Check Engine light),5.法人形象(Corporate Image),1.节能(Fuel economy),2.制动性能(Brake performance),3.喇叭性能(Speaker performance),4.内饰品质(Interior quality),5.喷涂质量差(Poor paint quality),1.3排坐椅相称(Seats comport:3rd line),2.节能(Fuel economy),3.发动机启动(Poor engine start),4.法人形象(Corporate Image),5.级别(Gradablity),Built-in-Quality制造质量,What is Built-In-Quality?,什么是制造质量？,Group Discussion,小组讨论,What is Built-In Quality?,什么是制造质量？,Definition 定义,Method by which quality is built into the manufacturing process,so that defects are prevented,detected,and countermeasures are implemented to prevent reoccurrence.,指质量在生产过程中产生，因此可以预防、发现缺陷，以及采取措施防止缺陷再发生的方法。,Purpose 意图,Ensures defects are not passed to the customer.,确保不传递缺陷。,Designers,设计师,Suppliers,供应商,Production,生产人员,Dealers,经销商,Buyers,采购员,Sales&Marketing,销售人员,The Customer Chain.Company Perspective,客户链 公司远景,Built-In-Quality制造质量,Assembly,总装,Supplier,供应商,Paint,涂装,Body,车身,The Customer Chain.Production Perspective,客户链 公司远景,Each Process Has at Least One“Customer”and One“Supplier”,每个阶段至少有一个客户和一个供应商,Built-In-Quality制造质量,Do not,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷,Solve Problems Through Teamwork!,团队合作解决问题！,Built-In-Quality Motto制造质量口号,Satisfy Your Customer,满足你的客户,Quality Through Teamwork Know Your Customer!,What water leaks?,I dont see any water leaks,什么漏雨？我没发现漏雨。,This car wasnt made on my shift,The problem is Press Shop.The flange is too long.,问题出自冲压，边缘过长,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.问题在于供应商的材料不好。,It is not from my area,maybe its the sealer,这辆车不是我轮班造的。,在没有工业工程装配方法及人力的情况下，我不做任何试验。,这不是我负责的地方，也许是粘胶负责,Dont run away from the problem!不要逃避问题!,Living up to the Motto.,符合口号.,-What Is a Defect?,什么是缺陷？,Group Discussion,小组讨论,Defect 缺陷,A defect is a product that does not meet the established quality standard.,缺陷是不合已定标准的产品。,Measurement of a quality characteristic,质量性能测量,Vehicle#,车辆 号,Upper Specification Limit,规格上限,Lower Specification Limit,规格下限,Quality Standard,质量标准,Defect 缺陷,Defect 缺陷,x,x,Why are defects undesirable?,为什么缺陷不受欢迎？,Defects may also result in,缺陷还可能导致,High warranty costs 过高保修成本,Lost customer sale 失去客户,Defects Require Correction=Correction is Waste,缺陷需要纠正纠正就是浪费,QUALITY IS EVERYONES RESPONSIBILITY质量是每个人的职责,Design,Engineering,Production,Quality,Support Departments and Suppliers.,设计，工程，生产，质量，相关部门及供应商,OUR Best Resources:,我们最好的资源:,PEOPLE 员工,OUR Goal:,我们的目标：,Everyone is a Quality Inspector 人人都是质检员,Everyone is a Problem Solver 人人都是问题解决者,WHO IS RESPONSIBLE FOR QUALITY?谁对质量负责？,WHO IS RESPONSIBLE FOR QUALITY?,WHO IS RESPONSIBLE FOR QUALITY?,WHO IS RESPONSIBLE FOR QUALITY?,ME!,我！,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,ControlledExternal,Transportation,ManufacturingProcess Validation,In-Process,Control&,Verification,QualitySystemManagement,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Values,Vision/,Mission,Shop FloorManagement,Internal,Pull/,Delivery,AndonConcept,ProblemSolving,SimpleProcessFlow,Product,Quality,Standards,StandardizedWork,Small LotPackaging,TemporaryMaterialStorage,QualityFeedback/Feed-,forward,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,Fixed Period Ordering System/,Order Parts,Product,Quality,Standards,产品质量标准,Reflect voice,of the customer,反映顾客的心声,Simple,clear,&support user,简单、清晰，,有利操作者,Clearly Measurable,at point of use,在使用上可明确测量,Key Points of Good Quality Standards:质量标准的要点：,In users Std.Work,&posted visual,在操作者的标准化,工作或张贴出来,Standards Must,Support the Operator,too,Not only the Engineer!,标准不仅有益于设计者，,也有益于操作工人,Not tighter than,those applied at the,previous process,不要比前道工序的更严格,Key Points of Good Quality Standards:质量标准的要点：,Final Inspection,Standard:,Gap+/-1mm,FINAL INSPECTION,BODY SHOP,Body Shop,Standard:,Gap+/-2mm,Use master parts and,boundary samples as,required to make visual,标准件与边界样件需要目视化,Key Points of Good Quality Standards:质量标准的要点：,Boundary Samples should,visually indicate OK Not OK,condition to help operators,make quick,good decisions,边界样件应该标明好或不好，以便,操作人员迅速且更好地下决定。,Visually“describing”the defect,is Not a Boundary Sample!,目视化标明缺陷不是边界样件！,Crater more than this size is not acceptable,不接受焊口大于此尺寸,Example of a Boundary Sample,边界样品的范例,Create a“Standards-Based”Culture创造一个以标准为基点的文化氛围,I wouldnt buy this!,Doesnt look good to me!,My opinion is,This does not meet the standard.,Talk in terms of The Standard,not opinions!,以标准为基点，而非观点！,ManufacturingProcess Validation,QualitySystemManagement,Product Quality Standards,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,AndonConcept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision/,Mission,Shop FloorManagement,In-Process,Control&,Verification,ManufacturingProcess Validation,制造工序认证,What is a process?什么是工序？,Inputs,投入,Outputs,输出,A process is a set of inter-related resources and activities which transforms inputs into outputs.,工序是集中相关的资源进行一系列活动，把投入转换成输出！,Environment,环境,Process 工序,Man Machines,Method Materials,Where can Errors Occur?问题会出在哪？,Defects,缺陷,Materials:材料,Parts out of standard 不符标准的零件,Wrong parts错误零件,Poor design 设计不当,Method:方法,Poor std.Work 不好的标准工作,Lack of Training 缺乏培训,Machine/Process:机器/工序,No TPM 没有TPM,Process not capable 工序不好,Improper specification 规格不当,Man:人力,Not follow std.Work 不遵循标准化工作,Distractions,Forgetfulness 分心、遗忘,Lack of Experience 缺乏经验,Errors Result In,Validate the manufacturing process prior to Start of Production!在生产启动前认证制造工艺！,Do not,切勿,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,Living Up to the Motto,达到口号,“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place”-Dr.Deming,PFMEA,Workstation,Readiness,工位准备,Process Control,Plan 工艺控制计划,Error-proofing,Plan,防错计划,Error Proofing Hierarchy 防错层次,Prevention,预防,Detection,检测,Human,Judgment,人为判断,None,无,Product/Process Design Change,产品/工艺设计改变,DFM/A&D/PFMEA,Robust Designs&Capable Processes,机器设计及可行工艺,One-Way Assembly 同一装配,Process Controls 工艺控制,Locating Pins&Stops 固定点及停点,Sensors&Process Monitors 传感器及工艺监控,Electro-Mechanical Devices 电子机械仪器,Color Coding 颜色信号,Visual Controls 直观控制,Andon Systems 暗灯系统,Standardized Work 标准化工作,Errors Cant Happen,Small Improvement,小改进,Significant Improvement 重大改进,Introduction to Error Proofing,防错介绍,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,4,5,7,8,10,11,5,1,2,Original:,Best:,Visual Control Example,Human Judgment,0,5,15,10,0,3,9,6,O,L,H,M,5,10,20,15,0,15,10,1,2,4,5,7,8,10,11,5,Better:,A,B,Example:Vehicle Identification,车辆认证,(Mutilation Cover Color),(盖板颜色毁损),Human Judgment 人为判断,Visual Control Example,Vertical Plate,垂直板,Battery Post,电池接头,Process Control Example,Detection 检测,X,Work Piece 加工件,Work Piece 加工件,Fixture 夹具,Fixture 夹具,Process Control Example,Prevention 预防,Product Design Example(Before),REC STOP PAUSE,REC STOP PAUSE,OLD,DESIGN,老设计,Can be Installed Upside Down 可以反安装,Application of Labels on Cassette Decks.门板标签,Prevention 预防,REC STOP PAUSE,NEW,DESIGN,新设计,Application of Labels on Cassette Decks.门板标签,Can Only Be Installed Correctly!,Product Design Example(After),Prevention,Left Hand Locator Tab,Right Hand Locator Tab,Example-Product Error Proofing,(One Way to Install Seat Belt),防错样品只有一种安全带安装方法,Product Design Example 产品设计范例,Prevention,Simple Everyday Examples,1)Error Prevention,Automatic shut-off,自动断电,Error Proofing Exercise,Think of an example at work or at home where error proofing can prevent an undesirable thing from happening 想想工作或生活中使用防错措施避免不好事情发生的例子,Discuss as a team and report Take 5 minutes 小组讨论、汇报5分钟,ManufacturingProcess Validation,ProductQualityStandards,QualitySystemManagement,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,AndonConcept,ProblemSolving,Early Mfg.and DesignIntegration(DFM/DFA),ContinuousImprovementProcess,Lean Design of Facilities,Equipment,Tooling and Layout,Business Plan,Deployment,Total,ProductiveMaintenance,ControlledExternal,Transportation,ScheduledShipping/,Receiving,Level VehicleOrder Schedules,SupplyChain,Management,Internal,Pull/,Delivery,SimpleProcessFlow,Small LotPackaging,TemporaryMaterialStorage,Fixed Period Ordering System/,Order Parts,Health andSafety Priority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision/,Mission,Shop FloorManagement,In-Process,Control&,Verification,工序控制与认证,Product Quality Standards,In-Process Control&Verification (3)Elements,工序控制与认证,1.Prevention,Outputs,输出,Inputs,投入,NOK,2.Detection,OK,Next Process,下道工序,Feedback,反馈,Do not,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,Living Up to the Motto,符合标准,3.Containment,包容,1)Standardized,Work 标准化工作,Follow and,Continuously Improve,Standardized Work!,遵守及不断,改进标准化工作！,In-Process Control&Verification 1)PREVENTION,Prevention,Vehicle Manifest,Manual,2-Door,Sunroof,2)Focus on,Operation,集中精力生产,Keep Your,Concentration&,Respect Standardized,Work of Others!,注意及尊重他人的,标准化工作,In-Process Control&Verification 1)PREVENTION,Prevention,3)Error Proofing,Prevention,&Operator Aids,防错预防与操作者支持,The Best Process is,One That Cannot Fail!,最好工序就是不会失败的！,In-Process Control&Verification 1)PREVENTION,Prevention,DAEWOO,4)Regular Checks,of Systems&Processes,定时检查系统与工艺,Std.Work,Checks!,检查标准化工作,In-Process Control&Verification 1)PREVENTION,Prevention,CHECK,CHECK,?,CHECK,Process Control,Checks!,检查工序控制！,TPM,Checks!,检查TPM,Safety/5S,Checks!,检查安全/5S,Self-Checks,自检,Include Quality Checks,in Standardized Work!,把质检作为标准化工作,的一部分,In-Process Control&Verification 2)DETECTION,Detection,Check Methods:,POINT,TOUCH,LISTEN,COUNT,2)Error Proofing,Detection,检测防错,Use Visual and,Audio Signals!,使用视觉、,听觉信号！,In-Process Control&Verification 2)DETECTION,Detection,Stop the Line,or,停线或,Use Alarms,or,使用警报或,Combination of Both,depending on Criticality 根据危险程度兼用两种方法,3)InProcess,Verification,工序认证,Inspectors are not there,as a policeman,they,support production by,confirming the process!,检察员不充当警察角色，,而是作为确定工序的生产支持者,In-Process Control&Verification 2)DETECTION,Detection,Verification Stations,Final Line,C.A.R.E.,3a)Focus on,Critical items,集中注意重大问题,Frequency of checks to,not allow Critical defects,to leave the shop!,经常检查，不让重大缺陷,走出车间！,In-Process Control&Verification 2)DETECTION,Detection,Safety Items,“Walk-Home”Items,Major Customer Dissatisfier,S/C,F/F,4)Defect,Escalation,缺陷逐层汇报,Escalate defects to,leadership for support,depending on,frequency and criticality!,根据缺陷出现频率与严重程度,逐层向领导汇报以寻求支持！,In-Process Control&Verification 2)DETECTION,Detection,Example:,Team Leader,Section Leader,Group Leader,2 defects/1 hour,4 defects/1 hour,1)Use Andon,(taught more,later)使用暗灯,Make problems visual,&pull in support!,问题直观，,拉线寻求帮助！,In-Process Control&Verification 3)CONTAINMENT,Always Remember the Priorities:一定要牢记：,1)Safety安全,2)Quality质量,3)Responsiveness(Throughput)响应,Containment,包容,2)Follow,Containment,Process,遵循包容程序,Extraordinary actions,to prevent defects from,being passed!,采取特别行动防止,缺陷传递！,In-Process Control&Verification 3)CONTAINMENT,Some examples:,1)Stop the line停线,2)100%checks,100%检查,3)On-line repair 线上维修,4)Reworks返工,5)Sorting 整理,Containment,包容,How Does our Quality Motto relate to Containment?,Do not,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,It means empowered leaders make,judgments how to control quality,while trying to keep the line running!,意味着领导有权作出决定：在尽量不停线的情况下怎样控制好质量！,Does this mean we stop the line every time we have a problem?,这是不是意味着一有问题就停线呢？,How Does our Quality Motto relate to Containment?,Sometimes the best decision may be to let a defect pass to the next process,but有时最好的办法是让差错转到下工序，但是,It is a conscious decision made by the appropriate level,Action must be communicated to next“customer”,Defect must be clearly identified on vehicle,Containment must be in place to prevent further defects,Examples of Some Andon Guidelines:暗灯使用的指导方针,1)Will the problem affect the next process?问题会不会影响下道工序？,2)Can I effectively repair the defect out of station?能不能在