General Motors Globális Gyártási Rendszer General Motors Global Manufacturing System

General Motors Powertrain – Magyarország Kft.

Dátum: 2008. Április 16

Előadó: Kovács János

Minőségügyi Igazgató

General MotorsGeneral MotorsGlobális Gyártási RendszerGlobális Gyártási RendszerGeneral Motors Global Manufacturing SystemGeneral Motors Global Manufacturing System

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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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Globális Gyártási RendszerGeneral Motors-Global Manufacturing System

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)

The GMS element “In-Process Control & Verification”

incorporates the intent and purpose of the BIQ motto:

Quality expectations are achieved in each process to ensure

defects are not passed on to downstream process.

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)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

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Benefits

To External customers (people buying our vehicle).

• Protect Customers from sub-standard vehicle quality.

• Assure customer satisfaction

To Internal customer (downstream operation).

• Prevent major repair and rework by detecting a non-conformity early in the process.

• Prevent the flow of defects from department to department and station to station

To Internal customer (from supplier).

• Protect Team Members from non-compliant parts from suppliers through advanced quality planning and prompt containment during spills.

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Process Equipment Capability Reviews (Prevention)

Periodic checks (typically monthly), are conducted to identify trends or shifts in capability over periods of time.

1. Identify process equipment with high risk/impact

2. Conduct initial capability confirmation

3. Conduct regular scheduled reviews to confirm capability

4. Implement corrective action as required

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Detection

Purpose of Detection:

To make non-standard conditions in the manufacturing process visible - identify when defects or non-standards have occurred.

This supports the “Do Not Accept” element of the quality motto:

inspection process that confirms quality as soon as possible following manufacture

measures the output of the manufacturing process

alerts organization to out of standard conditions

supports containment and provides input into continuous improvement

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Quality Check System Update

Internal/external ‘Customers’ are monitored for feedback:

Where there is an indication of defect flow-out through the Verificationprocess, a systematic analysis will be conducted; typically for:

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Inspection Frequencies of Critical Operations

The quality check system must be established in consideration of the ‘Supplier-Customer’ relationship.

Inspection frequencies must be established by each ‘supplier’ that prevent shipping defects to downstream ‘customers’.

This is a requirement for safety & compliance items, key characteristics

and for issues that will significantly impact the next process or customer.

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Independent Repair Confirmation

During a repair, the risk for

a discrepancy to occur is

increased - many aspects of

the repair operation are

non-standard:

Any documented repair must be verified by Repair Confirmation (both on- and off-line) Repair Confirmation must be conducted independently (e.g. by Quality). Standardized work (non-cyclic) should be used for the confirmation process – quality standards must be available. Appropriate training and knowledge of standards must be developed to conduct or confirm repairs. Repair confirmation should be as close to the repair process as possible. Repair confirmation can be conducted by man or machine.

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Using Andon To Stop The Process: Work Station

If the Team Member has a quality issue within their standardized work theyactivate the Andon system to: initiate a call for help through station light, Andon board, and

melody empower the Team Member to stop line & organization responds to provide support stop at FPS (Fixed Position Stop) to contain and complete the repair where Andon is not available the principles still apply

Team has the ability to stop the line and complete standardized work in station.

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Alarm & Escalation Processes

When a defect is detected, feedback to the

appropriate team or individual will be given

by using a communication system.

The alarm is raised by using audio/visual

signals (e.g. Andon).

The alarm process directs the supportfunctions to: ‘Go and See’ the problem Apply containment to prevent further flow of defects Initiate problem solving

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Containment

Purpose of Containment:

•The achievement of customer expectations relies on a method to contain defects within the manufacturing process, and implement corrections to protect the next/downstream customer.

•This supports the “Do Not Ship” element of the quality motto: vehicle delivery to the customer Powertrain and MFD plants to vehicle assembly external supplier to the manufacturing plant internal departments (e.g. between body, paint and GA) between work stations within a department

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Containment Process Overview

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Folyamatközi ellenőrzés és folyamat igazolás (In-Process Control and Verification)Summary

Standardized work is performed in every process and includes the required quality checks.

Process control activities are implemented on equipment to control variation on a daily basis and maintain capability over a period of time.

Detection confirms the manufacturing process and ensures both internal (Production Team Members) and External Customers (people who buy our products) are receiving products that meet or exceed the quality standards.

A process is in place to contain defects within the manufacturing process and implement permanent corrective actions that are verified as being effective.

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Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis)

Purpose of this procedure:Investigation, documentation and if necessary reduction of the risk potential (Risk Priority Number-RPN) for all production processes

RISK PRIORITY NUMBER

S x O x D = RPN

• S = Severity

• O = Occurrence

• D = Detection

• RPN = Risk Priority Number*

* 1 = Lowest 1000 = Highest

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Potential failure mode: What things have gone wrong ?

What things could go wrong ?

Effects of failure: What does a failure mean to the next

operation, the assy plant, the final customer?

Potential Cause of failure: Root cause what has gone wrong in the past

Brainstorm what could cause failures?

Current controls: What do we do today to prevent the defect

from occurring and getting to our customer ?

Recommended actions: If current controls are not 100% effective,

what actions should be taken ?

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Customer Effect Manufacturing Assembly Effect A B C

Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation without warning.

Or may endanger operator (machine or assembly) without warning 10

≥100 per thousand per

pieces per pieces

10Almost

Impossible

Absolute certainty of non-detection.

XCannot detect or is not checked. 10

Very high severity ranking when a potential failure mode affects safe vehicle operation and/or involves noncompliance with government regulation with warning.

Or may endanger operator (machine or assembly) with warning 9

50 per thousand per

pieces per pieces

9*Very

Remote

Controls will probably not detect.

XControl is achieved with indirect or random checks only.

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Vehicle / item inoperable (loss of primary function).

Or 100% of product may have to be scrapped, or vehicle / item repaired in repair department with a repair time greater than one hour.

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20 per thousand per

pieces per pieces

8 Remote

Controls have poor chance of detection.

XControl is achieved with visual inspection only. 8

Vehicle / item operable but at a reduced level of performance. Customer very dissatisfied.

Or product may have to be sorted and portion (less than 100%) scrapped, or vehicle / item repaired in repair department with a repair time between a half-hour and an hour.

710 per

thousand per pieces

7 Very Low

Controls have poor chance of detection.

XControl is achieved with double visual inspection only.

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Ran

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Inspection Types

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High: Frequent Failures

Very High:

Persistent Failures

This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly plant defect. The final customer should always be considered first. If both occur, use the higher of the two

severities.

Severity

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ModerateVehicle / item operable but Comfort / Convenience item(s) inoperable. Customer dissatisfied.

Or a portion (less than 100%) of the product, may have to scrapped with no sorting, or vehicle / item repaired in repair department with a repair time less than a half-hour.

6 5 per thousand per pieces 6 Low

Controls may detect.

X XControl is achieved with charting methods, such as SPC [Statistic Process Control]

LowVehicle / item operable but Comfort / Convenience item(s) operable at a reduced level of performance.

Or 100% of product may have to be reworked, or a vehicle / item repaired offline but does not go to repair department.

5 2 per thousand per pieces 5 Moderate

Controls may detect.

X

Control is based on variable gauging after parts have left the station, or Go/No Go gauging performed on 100% of the parts after parts have left the station.

Very Low

Fit and Finish/Squeak and Rattle item does not conform. Defect noticed by most customers (greater than 75%)

Or the product may have to be sorted, with no scrap,and a portion (less than 100%) reworked.

4 1 per thousand per pieces 4 Moderatel

y High

Controls have a good chance to detect.

X X

Error detection in subsequent operations, or gauging performed on setup and first-piece check (for set-up causes only)

MinorFit and Finish/Squeak and Rattle item does not conform. Defect noticed by 50% of customers.

Or a portion (less than 100%) of the product may have to be reworked, with no scrap, on-line but out-of-station.

30,5 per

thousand per pieces

3 High

Controls have a good chance to detect.

X X

Error detection in-station, or error detection in subsequent operations by multiple layers of acceptance: supply, select, install, verify. Cannot accept discrepant part.

Very Minor

Fit and Finish/Squeak and Rattle item does not conform. Defect noticed by discriminating customers (less than 25%).

Or a portion (less than 100%) of the product may have to be reworked, with no scrap, on-line but out-of-station.

20,1 per

thousand per pieces

2 Very High

Controls almost certain to detect.

X X

Error detection in-station (automatic gauging with automatic stop feature). Cannot pass discrepant part.

None No discernible effect.Or slight inconvenience to operation or operator, or no effect. 1

Remote: Failure is Unlikely

≤ 0,01 per thousand per

pieces1 Very High

Controls certain to detect.

X

Discrepant parts cannot be made because item has been error-proofed by process/product design.

Inspection Types:

A = Error-proofed B = Gauging C = Manual Inspection

Moderate: Occasion

al Failures

Low: Relatively

Few Failures

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A practical example – „with user friendly logistic solution „

Function:

Drink cold beer

Requirement

: Satisfy thirst

Still thirsty

Dehydration

Increased irritability

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10

Not enough available

Temperature too high

Wrong brand

Automatic restocking system

Thermostatically controlled environment -a.k.a. refrigeratorRemove people who don’t like my favorite brand of beer from invitation list

Daily inventory(layered audit)

Random Sampling -visual inspection

Registered complaints- Warning

1

2

3

6

8

4

60

160

120

RPN

DE

TE

CT

ION

PREVENTION

OC

CU

RA

NC

EPotential Cause

Mechanism of

Failure S

EV

ER

ITY

Potential Effects of

Failure

Potential Failure

Mode

Process Function

and Requireme

nts

Current Process Controls

DETECTION

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Minőség visszajelzés - előrejelzés rendszere (Quality Feedback/Feedforward)

Definition The communication of quality expectations and results between customers and suppliers through standardized communication pathways.

Purpose:To ensure that information on quality reaches those who need it.

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Feed Information Forward

Internal and external suppliers communicate known/potential problems and/or problem solving status to their customers in a timely manner.

This provides the customer with sufficient lead time to react to upcoming changes and take appropriate measures.

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Feed Information Back

Internal and external customers communicate known/potential problems and/or problem solving resolution to their suppliers in a timely manner. This provides the supplier with sufficient lead time to react to customer issues and take appropriate measures.

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Example: Inspection TicketBuild and quality status of each vehicle is communicated to downstream processes.

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Summary

Feedback/Feedforward promotes the communication of quality expectations and results between customers and suppliers through:

• Clearly defining customer/supplier communication requirements

• Defining timing, content, and format of information

• Establishing metrics and the subsequent management process

• Effective implementation of the Feedback/Feedforward communication tools

• Problem identification, input into the plant problem solving process and countermeasure follow up

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Minőségirányítási rendszer (Quality System Management)

Who is responsible for Quality?

Everyone! Quality is a shared responsibility

• Team work is absolutely essential to deliver world-class quality.

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Quality Function Resource Allocation

Manufacturing and quality resources are allocated to support the quality system and interface with engineering. Each area requires sufficient resources to properly focus on supporting production and driving continuous improvement through P-D-C-A.

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Quality Function Resource Allocation

Resource allocation needs to consider the quality and production components that are required to support the team member.

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Role of the Functions Within the Plant Quality Department

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Summary

Quality System Management provides the supporting structure and framework for the implementation of the quality system and ongoing improvement to the quality of our products through:

•Establishment and implementation of a strategic quality plan for the organization

•Allocation of manufacturing and quality resources to support the quality plan

•Development of an organization for quality that incorporates the “Planning”, “Doing” and “Checking” functions into their structure

•Identification of requirements for documentation, procedures, practices and assessments

•Integration of both quality and manufacturing BPD’s at all levels of the organization

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Ellenőrző kérdések: 1. Mi a beépített minőségi előírások jelmondat? (What is the

motto of the BIQ?)

2. Mi az a három alapelv amivel ki lehet vívni a vevői elégedettséget? (What is the three principle wherewith you can achieve the costumer satisfaction?)

3. Miknek a folyamatos ellenőrzésével és milyen módon lehet a hiba előfordulásának megelőzését támogatni? (What monitoring and what way can you support the prevention with?)

4. Mire használják az Andon rendszert, és mi történik a működtetésekor? (What is the Andon system for and what happen when it is activated?)


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Ellenőrző kérdések:1. Mi a PFMEA és mit támogat a quality jelmondatban? (What is

the PFMEA and what supports in the quality motto?)

2. Mit jelent a súlyosság az RPN szám meghatározásánál? (What is the severity at the calculation of the RPN number?)


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Ellenőrző kérdések:1. Mi a meghatározása a minőség visszajelzés-előrejelzés

rendszerének? (What is the definition of the Quality Feedback/Feedforward system?)

2. Milyen információkat kell továbbítania a szállítónak a vevő felé? (What information have to be forwarded to the costumer by supplyer?)

3. Milyen információkat továbbít a vevő a szállító felé? (What information is forwarded back to the supplier?)


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Ellenőrző kérdések:1. Milyen fő funkciók vannak a Quality osztályon belül a GMS

szerint? (What functions are there in the Quality Department according to the GMS?)

2. Mi a „Quality Engineering” feladata? (What is Quality Engineering responsible for?)

3. Mi a „Quality Confirmation” feladata? (What is Quality Confirmation responsible for?)

4. Mi a „Quality Assurance” feladata? (What is Quality Assurance responsible for?)


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Köszönöm a figyelmet!

Thank you for your attention!

Documents

General Motors Globális Gyártási Rendszer General Motors Global Manufacturing System