General Motors
Globális Gyártási Rendszer
General Motors Global Manufacturing System
General Motors Powertrain – Magyarország Kft.
Dátum:
2008. Április 16
Előadó:
Kovács János
Minőségügyi Igazgató
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
2
Globális Gyártási Rendszer
General Motors-Global Manufacturing System
3
4
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
•
Prevent the flow of defects from department to department and station to station
process.
 To Internal customer (from supplier).
• Protect Team Members from non-compliant parts from suppliers through
and prompt containment during spills.
advanced quality planning
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Folyamatközi ellenőrzés és folyamat igazolás
(In-Process Control and Verification)
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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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Folyamatközi ellenőrzés és folyamat igazolás
(In-Process Control and Verification)
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 Verification
process, 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
Team has the ability to stop the line and complete standardized work in station.
If the Team Member has a quality issue within their standardized work they
activate 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
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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 support
functions 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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Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect
Analysis)
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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Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect
Analysis)
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
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
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.
Vehicle / item operable but at a
reduced level of performance.
Customer very dissatisfied.
10
Very
High:
Persistent
Failures
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.
≥100 per
thousand per
pieces per
pieces
9
50 per
thousand per
pieces per
pieces
8
20 per
thousand per
pieces per
pieces
High:
Frequent
Failures
7
10 per
thousand per
pieces
Absolute
Almost
certainty
Impossibl
of none
detection.
A
B
C
Ranking
Criteria
Detection
Manufacturing Assembly Effect
Inspection Types
Ranking
Customer Effect
Probability
This ranking results w hen a potential failure m ode results in a final
custom er and/or a m anufacturing/assem bly plant defect. The final custom er
should alw ays be considered first. If both occur, use the higher of the tw o
severities.
Detection
Suggested Range of
Detection Methods
Occurence
Likely Failure Rates
Severity
X
Cannot detect or is not
checked.
9*
Controls
Very
will
Remote probably
not detect.
X
Control is achieved with
indirect or random checks
only.
9
8
Controls
have poor
Remote
chance of
detection.
X
Control is achieved with
visual inspection only.
8
7
Controls
have poor
Very Low
chance of
detection.
X
Control is achieved with
double visual inspection
only.
7
10
10
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Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect
Analysis)
Or a portion (less than 100%) of the
Vehicle / item operable but Comfort product, may have to scrapped with
Moderate / Convenience item(s) inoperable. no sorting, or vehicle / item repaired
Customer dissatisfied.
in repair department with a repair
time less than a half-hour.
Low
Or 100% of product may have to be
Vehicle / item operable but Comfort
reworked, or a vehicle / item repaired
/ Convenience item(s) operable at a
offline but does not go to repair
reduced level of performance.
department.
Fit and Finish/Squeak and Rattle
item does not conform. Defect
Very Low
noticed by most customers
(greater than 75%)
Minor
Very Minor
None
Or the product may have to be
sorted, with no scrap,and a portion
(less than 100%) reworked.
5 per thousand
per pieces
6
5
Moderate:
Occasion
2 per thousand
al
per pieces
Failures
Fit 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-ofstation.
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-ofstation.
2
No discernible effect.
Or slight inconvenience to operation
or operator, or no effect.
1
3
Low:
Relatively
Few
Failures
Remote:
Failure is
Unlikely
Low
Controls
may
detect.
5
Controls
Moderate may
detect.
4
Controls
have a
Moderatel
good
y High
chance to
detect.
0,5 per
thousand per
pieces
3
High
Controls
have a
good
chance to
detect.
0,1 per
thousand per
pieces
2
Very High
Controls
almost
certain to
detect.
≤ 0,01 per
thousand per
pieces
1
Very High certain
1 per thousand
per pieces
4
6
X
X
Control is achieved with charting
methods, such as SPC
[Statistic Process Control]
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.
X
Error detection in subsequent
operations, or gauging performed
on setup and first-piece check
(for set-up causes only)
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.
X
X
Error detection in-station
(automatic gauging with
automatic stop feature). Cannot
pass discrepant part.
X
Discrepant parts cannot be
made because item has been
error-proofed by process/product
design.
Controls
X
to detect.
Inspection Types:
A = Error-proofed
B = Gauging
C = Manual Inspection
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Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect
Analysis)
Dehydration
Function:
5
Drink cold beer
1
Requirement:
Increased
irritability
10
Wrong brand
3
RPN
Daily inventory
(layered audit)
6
60
Random Sampling visual inspection
8
160
Registered complaints
- Warning
4
120
Current Process Controls
PREVENTION
Automatic restocking system
Thermostatically controlled
Temperature too high 2
environment -a.k.a. refrigerator
Still thirsty
Satisfy thirst
Not enough
available
DETECTION
Potential Effects
of Failure
Potential Cause
Mechanism of
Failure
OCCURANCE
Process Function
and Requirements
Potential
Failure
Mode
SEVERITY
A practical example –
„with user friendly logistic solution „
Remove people who don’t like
my favorite brand of beer from
invitation list
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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Minőség visszajelzés - előrejelzés rendszere
(Quality Feedback/Feedforward)
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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Minőség visszajelzés - előrejelzés rendszere
(Quality Feedback/Feedforward)
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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Minőség visszajelzés - előrejelzés rendszere
(Quality Feedback/Feedforward)
Example: Inspection Ticket
Build and quality status of each vehicle is communicated to downstream processes.
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Minőség visszajelzés - előrejelzés rendszere
(Quality Feedback/Feedforward)
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
countermeasure follow up
process and
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Minőségirányítási rendszer
(Quality System Management)
Who is responsible for Quality?
• Team work is absolutely essential to deliver world-class quality.
Everyone! Quality is a shared responsibility
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Minőségirányítási rendszer
(Quality System Management)
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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Minőségirányítási rendszer
(Quality System Management)
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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Minőségirányítási rendszer
(Quality System Management)
Role of the Functions Within the Plant Quality Department
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Minőségirányítási rendszer
(Quality System Management)
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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Folyamatközi ellenőrzés és folyamat igazolás
(In-Process Control and Verification)
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?)
34
Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect
Analysis)
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?)
35
Minőség visszajelzés - előrejelzés rendszere
(Quality Feedback/Feedforward)
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?)
36
Minőségirányítási rendszer
(Quality System Management)
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!
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