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1、GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 1DIMC GMSBuilt-In Quality制造制造质量量GMS不不断断改改进员工工参与参与标准化准化缩短制造周期短制造周期制造制造质量量GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 2DIMC GMSManufacturingProcess ValidationProductQualityStanda
2、rdsQualitySystemManagementIn-ProcessControl&VerificationQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg.and DesignIntegration(DFM/DFA)ContinuousImprovementProcessLean Design of Facilities,Equipment,Tooling an
3、d LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping/ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull/DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/Order PartsHealth andS
4、afety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVisionShop FloorManagementManufacturingProcess Validation制造工制造工艺认证In-ProcessControl&Verification工工艺控制控制与与确确认QualitySystemManagement质量体系管理量体系管理QualityFeedback/Feed-forward质量反量反馈/前前馈ProductQualityStandards产品品质量量标准
5、准Built-In Quality制造质量制造质量GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 3DIMC GMSBuilt-In-Quality制造制造质量量uWhat Is Quality?什什么么是是质量？量？uGroup Discussion 小小组讨论GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 4DIMC GMSDefinitions 定定义
6、Quality is what the customer perceives to be acceptable to achieve his/her enthusiasm质量是客量是客户感感觉能能够接受接受并并满足足其其热忱的忱的东西西GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 5DIMC GMSMad Cow 疯牛牛(Diseased Meat 病牛肉病牛肉)Poor Quality Means Lost Sales质量差意味着失去客量差意味着失去客户Firestone
7、燧石燧石(Unintended Accidents)意外意外事故事故uninstalled shift lock漏装移位漏装移位锁定定(Sudden Acceleration)突然加速突然加速GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 6DIMC GMSPP100:Not Reported Due To Insufficient Sample 样品不足不汇报样品不足不汇报()J.D.Power IQS Trend By BrandGMS OrientationBuilt-
8、in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 7DIMC GMS NCSI By Makers-2002 2002 NCSI CustomerExpectationsPerceivedQualityPerceivedValueCustomerLoyaltyCustomerRetentionCustomerComplaints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GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 200
9、3.03.12Slide 8DIMC GMSGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 9DIMC GMSVoice of Customer 客客户意意见GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 10DIMC GMSVoice of Customer客客户意意见 1.停车方便(Convenience of parking)2.外观式样(Exteri
10、or 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.
11、坐骑(Ride)L61.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 l
12、ight)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)GMS OrientationBuilt-in quality GMDA
13、T/DIMC ConfidentialVersion Date 2003.03.12Slide 11DIMC GMSBuilt-in-Quality制造制造质量量What is Built-In-Quality?什什么么是制造是制造质量？量？Group Discussion 小小组讨论GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 12DIMC GMSWhat is Built-In Quality?什什么么是制造是制造质量？量？Definition 定定义Method by
14、 which quality is built into the manufacturing process,so that defects are prevented,detected,and countermeasures are implemented to prevent reoccurrence.指指质量在生量在生产过程中程中产生，因此可以生，因此可以预防、防、发现缺陷缺陷，以及采取措施防止以及采取措施防止缺陷缺陷再再发生的方法。生的方法。Purpose 意意图 Ensures defects are not passed to the customer.确保不确保不传递缺陷。缺陷。
15、GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 13DIMC GMSDesigners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客客户链 公司公司远景景Built-In-Quality制造质量制造质量GMS OrientationBuilt-in quality GMDAT/DIMC Confidential
16、Version Date 2003.03.12Slide 14DIMC GMSAssembly总装Supplier供应商Paint涂装Body车身The Customer Chain.Production Perspective客户链客户链 公司远景公司远景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每个阶段至少有一个客户和一个供应商Built-In-Quality制造质量制造质量GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVe
17、rsion Date 2003.03.12Slide 15DIMC GMSDo not不要不要Accept接受接受Build制造制造Ship传递a Defect!缺陷缺陷Solve Problems Through Teamwork!团队合作解合作解决决问题！Built-In-Quality Motto制造制造质量口量口号号Satisfy Your Customer满足足你你的客的客户GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 16DIMC GMSQuality Thro
18、ugh 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 shiftThe 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
19、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!不要逃避不要逃避问题!GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 17DIMC GMSLiving up to the Mot
20、to.符合符合口号口号.-What Is a Defect?什什么么是缺陷？是缺陷？-Group Discussion 小小组讨论 Defect 缺陷缺陷GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 18DIMC GMSA defect is a product that does not meet the established quality standard.缺陷是不合缺陷是不合已已定定标准的准的产品。品。Measurement of a quality charac
21、teristic质量性能量性能测量量Vehicle#车辆 号号Upper Specification Limit规格上限格上限Lower Specification Limit规格下限格下限Quality Standard质量量标准准Defect 缺陷缺陷Defect 缺陷缺陷xxGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 19DIMC GMSWhy are defects undesirable?为什么缺陷不受欢迎？为什么缺陷不受欢迎？lDefects may also
22、 result in 缺陷还可能导致L High warranty costs 过高保修成本L Lost customer sale 失去客户Defects Require Correction=Correction is Waste 缺陷需要缺陷需要纠正正纠正就是浪正就是浪费GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 20DIMC GMS QUALITY IS EVERYONES RESPONSIBILITY质量是每量是每个个人的人的职责Design,Engineeri
23、ng,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 员工工OUR Goal:我们的目标：Everyone is a Quality Inspector 人人都是人人都是质检员 Everyone is a Problem Solver 人人都是人人都是问题解解决决者者GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide
24、 21DIMC GMSWHO IS RESPONSIBLE FOR QUALITY?谁对质量负责？谁对质量负责？WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?WHO IS RESPONSIBLE FOR QUALITY?GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVer
25、sion Date 2003.03.12Slide 22DIMC GMSME!我！我！GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 23DIMC GMSHealth andSafety PriorityQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessControlledExternal TransportationManufacturingProcess ValidationIn-Pr
26、ocessControl&VerificationQualitySystemManagementScheduledShipping/ReceivingLevel VehicleOrder SchedulesSupplyChainManagementValuesVision/MissionShop FloorManagementInternal Pull/DeliveryAndonConceptProblemSolvingSimpleProcessFlowProduct Quality StandardsStandardizedWorkSmall LotPackagingTemporaryMat
27、erialStorageQualityFeedback/Feed-forwardVisualManagementManagementby TAKT TimeWork-placeOrganizationEarly Mfg.and DesignIntegration(DFM/DFA)ContinuousImprovementProcessLean Design of Facilities,Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenance Fixed Period Ordering Syste
28、m/Order PartsProductQualityStandards产品质量标准产品质量标准GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 24DIMC GMSReflect voice of the customer反映顾客的心声反映顾客的心声Simple,clear&support user简单、清晰，简单、清晰，有利操作者有利操作者Clearly Measurable at point of use在使用上可明确测量在使用上可明确测量Key Points of Go
29、od Quality Standards:质量标准的要点：质量标准的要点：In users Std.Work&posted visual在操作者的标准化在操作者的标准化工作或张贴出来工作或张贴出来Standards Must Support the Operator,too Not only the Engineer!标准不仅有益于设计者，标准不仅有益于设计者，也有益于操作工人也有益于操作工人GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 25DIMC GMSNot tigh
30、ter than those applied at the previous process 不要比前道工序的更严格不要比前道工序的更严格Key Points of Good Quality Standards:质量标准的要点：质量标准的要点：Final Inspection Standard:Gap+/-1mmFINAL INSPECTIONBODY SHOPBody ShopStandard:Gap+/-2mmGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 26DIMC
31、GMSUse master parts and boundary samples as required to make visual标准件与边界样件需要目视化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：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”
32、the defect is Not a Boundary Sample!目视化标明缺陷不是边界样件！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边界样品的范例边界样品的范例GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 27DIMC GMSCreate a“Standards-Based”Culture创造一个以标准为基点的文化氛
33、围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 isThis does not meet the standard.Talk in terms of The Standard,not opinions!以标准为基点，而非观点！以标准为基点，而非观点！GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 28DIMC GMSManufacturingProcess ValidationQuali
34、tySystemManagementProduct Quality StandardsQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganizationAndonConceptProblemSolvingEarly Mfg.and DesignIntegration(DFM/DFA)ContinuousImprovementProcessLean Design of Facilities,Equipment,Tooling and LayoutBusin
35、ess PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping/ReceivingLevel VehicleOrder SchedulesSupplyChainManagementInternal Pull/DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/Order PartsHealth andSafety Priorit
36、yQualified PeopleTeam ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementIn-ProcessControl&VerificationManufacturingProcess Validation制造工序认证制造工序认证GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 29DIMC GMSWhat is a process?什么是工序
37、？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！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 工序工序 Man MachinesMethod MaterialsGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 20
38、03.03.12Slide 30DIMC GMSWhere can Errors Occur?问题会出在哪？Defects缺陷缺陷Materials:材料材料Parts out of standard 不符标准的零件Wrong parts错误零件Poor design 设计不当 Method:方法方法Poor std.Work 不好的标准工作Lack of Training 缺乏培训 Machine/Process:机器机器/工序工序No TPM 没有TPMProcess not capable 工序不好Improper specification 规格不当 Man:人力人力Not follo
39、w 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 InGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 31DIMC GMSValidate the manufacturing process prior to Start of Production!在生产启在生产启动前认证制造工艺！动前认证制造工艺！Do not切勿切勿Accept 接受接受Build
40、 制造制造Ship 传递传递a Defect!缺陷！缺陷！Living Up to the Motto达到口号达到口号“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place”-Dr.DemingPFMEAWorkstationReadiness工位准备Process ControlPlan 工艺控制计划Error-proofing Plan防错计划GMS OrientationBuilt-in quality GMDAT/DIMC Con
41、fidentialVersion Date 2003.03.12Slide 32DIMC GMSError Proofing Hierarchy 防错层次PreventionPrevention 预防预防预防预防DetectionDetection 检测检测检测检测HumanHumanJudgmentJudgment人为判断人为判断人为判断人为判断NoneNone无无无无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
42、 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GMS
43、 OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 33DIMC GMS0515100396OLHM510201501510124578101150515100396OLHM51020150151045781011512Original:Best:Visual Control ExampleHuman Judgment0515100396OLHM51020150151012457810115Better:GMS OrientationBuilt-in quality GMDAT/DIM
44、C ConfidentialVersion Date 2003.03.12Slide 34DIMC GMSABExample:Vehicle Identification车辆认证车辆认证 (Mutilation Cover Color)(盖板颜色毁损盖板颜色毁损)Human Judgment 人为判断人为判断Visual Control ExampleGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 35DIMC GMSVertical Plate垂直板Battery Post
45、电池接头Process Control ExampleDetection 检测检测GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 36DIMC GMSXWork Piece 加工件Work Piece 加工件Fixture 夹具Fixture 夹具Process Control ExamplePrevention 预防预防GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12
46、Slide 37DIMC GMSProduct Design Example(Before)REC STOP PAUSEREC STOP PAUSEREC STOP PAUSEREC STOP PAUSEOLDDESIGN老设计老设计Can be Installed Upside Down 可以反安装 Application of Labels on Cassette Decks.门板标签Prevention 预防预防GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 38DIM
47、C GMSREC STOP PAUSEREC STOP PAUSENEWDESIGN新设计新设计Application of Labels on Cassette Decks.门板标签Can Only Be Installed Correctly!Product Design Example(After)PreventionGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 39DIMC GMSLeft Hand Locator TabRight Hand Locator Tab
48、 Example-Product Error Proofing(One Way to Install Seat Belt)防错样品防错样品只有一种安全带安装方法只有一种安全带安装方法Product Design Example 产品设计范例PreventionGMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 40DIMC GMSSimple Everyday Examples1)Error Prevention Automatic shut-off自动断电GMS Orienta
49、tionBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 41DIMC GMSError 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
50、5 minutes 小组讨论、汇报小组讨论、汇报5分钟分钟GMS OrientationBuilt-in quality GMDAT/DIMC ConfidentialVersion Date 2003.03.12Slide 42DIMC GMSManufacturingProcess ValidationProductQualityStandardsQualitySystemManagementQualityFeedback/Feed-forwardStandardizedWorkVisualManagementManagementby TAKT TimeWork-placeOrganiza