General Motors rtási Rendszer General Motors Global Manufacturing System

General Motors Globális lis Gyárt rtási 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 2

Built In Quality Beépített Minőség 3

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 4

5

A vevő fogalma, vevői elégedettség(definition of customer, customer satisfaction) The CUSTOMER is an organization or person that receives a product. Example: NOTE: consumer, client, end-user, retailer, beneficiary and purchaser. A customer can be internal or external to the organization. The SUPPLIER is an organization or person that provides a product. Example: NOTE: Producer, distributor, retailer or vendor of a product, or provider of a service or information. A supplier can be internal or external to the organization. 6

A vevő fogalma, vevői elégedettség(definition of customer, customer satisfaction) Supplier Machining Line The costumer chain Eng. Assembly Line Car Plant Costumer 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 7

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 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. 9

Termékminőségi Követelmények (Product Quality Standards) 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 10

Termékminőségi Követelmények (Product Quality Standards) 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 11

Termékminőségi Követelmények (Product Quality Standards) Types of Product Quality Standards Completed Vehicle Inspection Standards (CVIS) At a minimum defines item to be inspected on the vehicle and the criteria for acceptability In-Process Product Quality Standards In-process (upstream) inspection standards are used to achieve completed vehicle inspection standards when required Parts and Subassembly Inspection Standards Used for confirming quality of supplied parts or assemblies when required Shipping 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.) Powertrain Product Quality Standards Used for confirming quality of all Powertrain supplied components and assemblies. Temporary Product Quality Standards Used for interim standards (e.g. launch, temporary product or part issues) with a set start/stop time frame. 13

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. 14

Korai Gyártás és Tervezés Egységesítés (Early Manufacturing and Design Integration (DFM/DFA)) DFM Tools and Benefits 15

Termékminőségi Követelmények (Product Quality Standards) 16

Termékminőségi Követelmények (Product Quality Standards) 17

Termékminőségi Követelmények (Product Quality Standards) 18

Termékminőségi Követelmények (Product Quality Standards) 19

Termékminőségi Követelmények (Product Quality Standards) Incorporation into Standardized Work PFMEA and Process Control Plans Input output Production Operation output Reference PCP xx-xxx Inspection Operation 20

Termékminőségi Követelmények (Product Quality Standards) The Product Quality Standard Must 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 21

Termékminőségi Követelmények (Product Quality Standards) The Product Quality Standard Act Plan Do Review PQS with Team Leaders to ensure standards are clear & understood Act Plan Do Implement Countermeasures Check Check PTR/Validation Builds Evaluate Product and process capability to meet quality standard (PQS) Build Issues Feedback Build issues are entered into the Problem Solving Process and assigned to appropriate owners: Engineering Production Suppliers 22

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. 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. 23

Termelési folyamat jóváhagyása (Manufacturing Process Validation) 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 24

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. 25

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Benefits of a Validated Process 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 26

Termelési folyamat jóváhagyása (Manufacturing Process Validation) 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 27

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Validate The Manufacturing System 28

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 Global Launch Process Validate Under Production Conditions Product & Process Identify Implement Countermeasures Identify Implement Countermeasures Process & Capability Validated DFMEA KCDS X OK Engineering Build Event Build Event Build Event Ready for SOVP 29

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Manufacturing Process Validation 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 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 Process is validated under well-defined conditions (usually Run @ Rate production condition) 30

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Manufacturing Process Validation Risk Analysis 31

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. 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 32

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Process Controls 33

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Validate The Manufacturing System 34

Termelési folyamat jóváhagyása (Manufacturing Process Validation) Operational Readiness Process 35

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 36

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?) 37

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.) 38

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 39

Köszönöm a figyelmet! Thank you for your attention! 40

Words and expressions 41