通用大宇制造质量

GMS,Orientation,Built-in quality,GMDAT/DIMC Confidential,Version Date 2003.03.12,Slide,69,DIMC,GMS,Built-In Quality,制造质量,GMS,不断改进,员工参与,标准化,缩短制造周期,制造质量,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-InQuality,制造质,量,量,Built-In-Quality制造质,量,量,What Is Quality,?,?,什么是,质,质量？,GroupDiscussion,小组讨,论,论,Definitions定义,Quality is whatthe customer perceivestobeacceptable to achievehis/herenthusiasm,质量是,客,客户感,觉,觉能够,接,接受并,满,满足其,热,热忱的,东,东西,MadCow疯牛,(DiseasedMeat病牛肉),Poor QualityMeansLostSales,质量差,意,意味着,失,失去客,户,户,Firestone,燧石,(Unintended Accidents),意外事故,uninstalledshiftlock,漏装移,位,位锁定,(SuddenAcceleration),突然加,速,速,PP100,:NotReportedDue To InsufficientSample,样品不,足,足不汇,报,报,(,),),J.D,.,. PowerIQSTrendByBrand,NCSIByMakers,-,-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,VoiceofCustomer客户意,见,见,VoiceofCustomer客户意,见,见,1.停车方,便,便(Convenienceofparking),2.外观式,样,样(Exteriorstyling),3.内部空,间,间(Interiorroominess,),),4.节能(Fuel economy,),),5.安全(Safety,),),1.外观式,样,样(Exteriorstyling),2.内部空,间,间(Interiorroominess,),),3.噪音与,静,静音(Noiseandquietness),4.节能(Fuel economy,),),5.空调性,能,能(Airconditionerperformance,),),1.发动机,性,性能(EnginePerformance,),),2.发动机噪音(EngineNoise,),),3.外观式,样,样(Exteriorstyling),4.噪音与,静,静音(Noiseandquietness),5.坐骑(Ride),L6,1.节能(Fuel economy,),),2.噪音与,静,静音(Noiseand quietness),3.内部空,间,间(Interiorroominess,),),4.坐骑(Ride),5.外观式,样,样(Exteriorstyling),1节能(Fuel economy,),),2.空调(Airconditioner,),),3.噪音(Noise),4.发动机噪音(EngineNoise,),),5.M/T转换(M/T Shift),1.节能(Fuel economy,),),2.OSRVM手工控,制,制(ManualOSRVMcontrol),3.发动机,噪,噪音(Enginenoise,),),4.检查发,动,动机点,火,火(CheckEnginelight,),),5.法人形,象,象(CorporateImage,),),1.节能(Fuel economy,),),2.制动性,能,能(Brakeperformance),3.喇叭性,能,能(Speaker performance),4.内饰品,质,质(Interiorquality),5.喷涂质,量,量差(Poor paint quality,),),1.3排坐椅,相,相称(Seatscomport :3rd line,),),2.节能(Fuel economy,),),3.发动机,启,启动(Poor enginestart),4.法人形,象,象(CorporateImage,),),5.级别(Gradablity),Built-in-Quality制造质,量,量,What is Built-In-Quality,?,?,什么是,制,制造质,量,量？,GroupDiscussion,小组讨,论,论,What is Built-In Quality,?,?,什么是,制,制造质,量,量？,Definition定义,Methodbywhichqualityisbuiltinto themanufacturing process, so thatdefectsareprevented,detected,and countermeasuresareimplementedtopreventreoccurrence,.,.,指质量,在,在生产,过,过程中,产,产生，,因,因此可,以,以预防,、,、发现缺陷，以及,采,采取措,施,施防止缺陷再发生,的,的方法,。,。,Purpose意图,Ensures defectsare notpassedtothe customer.,确保不,传,传递缺,陷,陷。,Designers,设计师,Suppliers,供应商,Production,生产人,员,员,Dealers,经销商,Buyers,采购员,Sales,&,& Marketing,销售人,员,员,TheCustomerChain,.,. .,.,.Company Perspective,客户链公司远,景,景,Built-In-Quality制造质,量,量,Assembly,总装,Supplier,供应商,Paint,涂装,Body,车身,TheCustomerChain,.,. .,.,.Production Perspective,客户链公司远,景,景,Each ProcessHas at Least One,“,“Customer,”,” andOne,“,“Supplier”,每个阶,段,段至少,有,有一个,客,客户和,一,一个供,应,应商,Built-In-Quality制造质,量,量,Donot,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷,SolveProblemsThrough Teamwork!,团队合,作,作解决,问,问题！,Built-In-Quality Motto制造质,量,量口号,Satisfy YourCustomer,满足你,的,的客户,Quality ThroughTeamwork,Know YourCustomer,!,!,What water leaks?,I dont seeanywaterleaks,什么漏,雨,雨？我,没,没发现,漏,漏雨。,This carwasntmade on my shift,TheproblemisPressShop.The flangeistoolong.,问题出,自,自冲压,，,，边缘过长,I wont runany trial until IhaveanassemblymethodfromIndustrial Engineering andthemanpower,.,.,Theproblemisthat thepiecesare badfrom thesupplier.,问题在,于,于供应,商,商的材,料,料不好,。,。,Itisnotfrommyarea,maybeits thesealer,这辆车,不,不是我,轮,轮班造,的,的。,在没有,工,工业工,程,程装配,方,方法及,人,人力的,情,情况下,，,，我不,做,做任何,试,试验。,这不是,我,我负责,的,的地方,，,，也许,是,是粘胶负责,Don,trunawayfrom theproblem!不要逃,避,避问题!,Livinguptothe Motto.,.,. .,符合口号. .,.,.,-What Is aDefect?,什么是,缺,缺陷？,GroupDiscussion,小组讨,论,论,Defect缺陷,Adefectisa productthatdoes notmeet theestablishedquality standard.,缺陷是,不,不合已定标准,的,的产品,。,。,Measurementofa qualitycharacteristic,质量性,能,能测量,Vehicle #,车辆号,UpperSpecification Limit,规,格上限,LowerSpecification Limit,规格下,限,限,Quality Standard,质量标,准,准,Defect缺陷,Defect缺陷,x,x,Whyare defectsundesirable,?,?,为什么,缺,缺陷不,受,受欢迎,？,？,Defects mayalso resultin,缺陷还,可,可能导,致,致,High warranty costs过高保修,成,成本,Lost customer sale失去客,户,户,Defects RequireCorrection,=,=Correction is Waste,缺陷需,要,要纠正纠正就,是,是浪费,QUALITY ISEVERYONESRESPONSIBILITY质量是,每,每个人,的,的职责,Design, Engineering,Production,Quality,Support Departments andSuppliers,.,.,设计，,工,工程，,生,生产，,质,质量，,相,相关部,门,门及供,应,应商,OURBestResources,:,:,我们最,好,好的资,源,源:,PEOPLE员工,OURGoal,:,:,我们的,目,目标：,Everyoneisa QualityInspector人人都,是,是质检,员,员,Everyoneisa ProblemSolver人人都,是,是问题,解,解决者,WHOISRESPONSIBLEFOR QUALITY,?,?谁对质,量,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,ofthecustomer,反映顾,客,客的心,声,声,Simple, clear,& supportuser,简单、,清,清晰，,有利操,作,作者,Clearly Measurable,atpointofuse,在使用,上,上可明,确,确测量,KeyPoints of GoodQualityStandards,:,:质量标,准,准的要,点,点：,InusersStd.Work,& postedvisual,在操作,者,者的标,准,准化,工作或,张,张贴出,来,来,StandardsMust,Support theOperator,too, Notonly theEngineer!,!,!,标准不,仅,仅有益,于,于设计,者,者，,也有益,于,于操作,工,工人,Nottighterthan,thoseapplied at the,previousprocess,不要比,前,前道工,序,序的更,严,严格,KeyPoints of GoodQualityStandards,:,:质量标,准,准的要,点,点：,Final Inspection,Standard:,Gap +/- 1mm,FINAL INSPECTION,BODY SHOP,Body Shop,Standard:,Gap +/- 2mm,Usemaster parts and,boundarysamples as,requiredtomake visual,标准件,与,与边界,样,样件需,要,要目视,化,化,KeyPoints of GoodQualityStandards,:,:质量标,准,准的要,点,点：,BoundarySamples should,visuallyindicateOK, NotOK,conditiontohelpoperators,make quick,good decisions,边界样,件,件应该,标,标明好,或,或不好,，,，以便,操作人,员,员迅速,且,且更好,地,地下决,定,定。,Visually,“,“describing”the defect,isNota Boundary Sample!,目视化,标,标明缺,陷,陷不是,边,边界样,件,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,Createa,“,“Standards-Based”Culture创造一,个,个以标,准,准为基,点,点的文,化,化氛围,I wouldnt buy this!,Doesnt look good to me!,My opinion is,This does not meet the standard.,Talk in terms ofTheStandard, notopinions!,以标准,为,为基点,，,，而非,观,观点！,ManufacturingProcess Validation,QualitySystemManagement,Product QualityStandards,QualityFeedback/Feed-,forward,StandardizedWork,VisualManagement,Managementby TAKT,Time,Work-,placeOrganization,AndonConcept,ProblemSolving,Early Mfg. and DesignIntegration (DFM / DFA),ContinuousImprovementProcess,Lean DesignofFacilities,Equipment,Tooling andLayout,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,HealthandSafetyPriority,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 aprocess?什么是,工,工序？,Inputs,投入,Outputs,输出,A processisasetofinter,-,-relatedresourcesand activitieswhichtransformsinputsintooutputs.,工序是,集,集中相,关,关的资,源,源进行,一,一系列,活,活动，,把,把投入,转,转换成,输,输出！,Environment,环境,Process工序,ManMachines,MethodMaterials,WherecanErrors Occur?问题会,出,出在哪,？,？,Defects,缺陷,Materials,:,:材料,Partsoutofstandard,不符标,准,准的零,件,件,Wrongparts,错误零,件,件,Poor design,设计不,当,当,Method,:,:方法,Poor std.Work不好的,标,标准工,作,作,Lack of Training缺乏培,训,训,Machine/Process,:,:机器/,工,工序,NoTPM没有TPM,Process notcapable工序不,好,好,Improperspecification规格不,当,当,Man,:,:人力,Notfollow std.Work不遵循,标,标准化,工,工作,Distractions, Forgetfulness分心、,遗,遗忘,Lack of Experience缺乏经,验,验,ErrorsResult In,Validatethemanufacturingprocess prior to Start of Production,!,!在生产,启,启动前,认,认证制,造,造工艺,！,！,Donot,切勿,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,LivingUptothe Motto,达到口,号,号,“Eliminatethe Needfor InspectiononaMass Basis by Building QualityintotheProductintheFirstPlace” -Dr,.,. Deming,PFMEA,Workstation,Readiness,工位准,备,备,Process Control,Plan工艺控,制,制计划,Error-proofing,Plan,防错计,划,划,ErrorProofingHierarchy防错层,次,次,Prevention,预防,Detection,检测,Human,Judgment,人为判断,None,无,Product /ProcessDesignChange,产品/,工,工艺设,计,计改变,DFM,/,/A,&,&D/PFMEA,RobustDesigns,&,& CapableProcesses,机器设,计,计及可,行,行工艺,One,-,-Way Assembly同一装,配,配,Process Controls工艺控,制,制,LocatingPins &Stops固定点,及,及停点,Sensors &ProcessMonitors传感器,及,及工艺,监,监控,Electro -MechanicalDevices电子机,械,械仪器,ColorCoding颜色信,号,号,VisualControls直观控,制,制,AndonSystems暗灯系,统,统,StandardizedWork标准化,工,工作,ErrorsCantHappen,SmallImprovement,小改进,SignificantImprovement重大改,进,进,IntroductiontoErrorProofing,防错介,绍,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:,VisualControlExample,HumanJudgment,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,证,(Mutilation Cover Color),(盖板颜,色,色毁损),HumanJudgment人为判,断,断,VisualControlExample,VerticalPlate,垂直板,Battery Post,电池接,头,头,Process ControlExample,Detection检测,X,Work Piece加工件,Work Piece加工件,Fixture夹具,Fixture夹具,Process ControlExample,Prevention预防,Product DesignExample (Before,),),REC,STOPPAUSE,REC,STOPPAUSE,OLD,DESIGN,老设计,CanbeInstalled UpsideDown可以反,安,安装,ApplicationofLabelsonCassetteDecks,.,.门板标,签,签,Prevention预防,REC,STOPPAUSE,NEW,DESIGN,新设计,ApplicationofLabelsonCassetteDecks,.,.门板标,签,签,CanOnlyBeInstalledCorrectly!,Product DesignExample (After),Prevention,Left Hand Locator Tab,Right Hand Locator Tab,Example -,-,- ProductErrorProofing,(One WaytoInstall SeatBelt),防错样,品,品只,有,有一种,安,安全带,安,安装方,法,法,Product DesignExample产品设,计,计范例,Prevention,SimpleEverydayExamples,1)ErrorPrevention,Automaticshut-off,自动断,电,电,ErrorProofingExercise,Thinkofanexample at workorathomewhereerrorproofingcanpreventanundesirablethingfrom happening,想想工,作,作或生,活,活中使,用,用防错,措,措施避,免,免不好,事,事情发,生,生的例,子,子,Discuss as ateamandreport Take5 minutes小组讨,论,论、汇,报,报5,分,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 DesignofFacilities,Equipment,Tooling andLayout,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,HealthandSafetyPriority,Qualified People,Team Concept,PeopleInvolvement,OpenCommunicationProcess,Values,Vision/,Mission,Shop FloorManagement,In-Process,Control &,Verification,工序控制与认证,Product QualityStandards,In-Process Control,&,&Verification,(,(3)Elements,工序控,制,制与认,证,证,1.Prevention,Outputs,输出,Inputs,投入,NOK,2.Detection,OK,Next Process,下道工序,Feedback,反馈,Donot,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,LivingUptothe Motto,符合标,准,准,3.Containment,包容,1)Standardized,Work标准化,工,工作,Followand,ContinuouslyImprove,StandardizedWork!,!,!,遵守及,不,不断,改进标,准,准化工,作,作！,In-Process Control,&,&Verification, 1,),) PREVENTION,Prevention,Vehicle Manifest,Manual,2-Door,Sunroof,2)Focuson,Operation,集中精,力,力生产,Keep Your,Concentration &,Respect Standardized,Work of Others!,注意及,尊,尊重他,人,人的,标准化,工,工作,In-Process Control,&,&Verification, 1,),) PREVENTION,Prevention,3)ErrorProofing,Prevention,& Operator Aids,防错预,防,防与操,作,作者支,持,持,TheBestProcess is,OneThatCannotFail!,最好工,序,序就是,不,不会失,败,败的！,In-Process Control,&,&Verification, 1,),) PREVENTION,Prevention,DAEWOO,4)Regular Checks,ofSystems &Processes,定时检,查,查系统,与,与工艺,Std,.,. Work,Checks,!,!,检查标,准,准化工,作,作,In-Process Control,&,&Verification, 1,),) PREVENTION,Prevention,CHECK,CHECK,?,CHECK,Process Control,Checks,!,!,检查工,序,序控制,！,！,TPM,Checks,!,!,检查TPM,Safety,/,/5S,Checks,!,!,检查安,全,全/5S,Self-Checks,自检,Include QualityChecks,inStandardizedWork!,把质检,作,作为标,准,准化工,作,作,的一部,分,分,In-Process Control,&,&Verification, 2,),) DETECTION,Detection,CheckMethods:,POINT,TOUCH,LISTEN,COUNT,2)ErrorProofing,Detection,检测防,错,错,UseVisual and,AudioSignals!,使用视,觉,觉、,听觉信,号,号！,In-Process Control,&,&Verification, 2,),) DETECTION,Detection,Stop theLine,or,停线或,UseAlarms,or,使用警,报,报或,CombinationofBoth,dependingonCriticality根据危,险,险程度,兼,兼用两,种,种方法,3)In-Process,Verification,工序认,证,证,Inspectors arenotthere,asa policeman,they,support productionby,confirming theprocess!,检察员,不,不充当,警,警察角,色,色，,而是作,为,为确定,工,工序的,生,生产支,持,持者,In-Process Control,&,&Verification, 2,),) DETECTION,Detection,VerificationStations,FinalLine,C.A,.,.R.E.,3a)Focuson,Criticalitems,集中注,意,意重大,问,问题,Frequencyofchecks to,notallowCriticaldefects,toleavetheshop!,经常检,查,查，不,让,让重大,缺,缺陷,走出车,间,间！,In-Process Control,&,&Verification, 2,),) DETECTION,Detection,SafetyItems,“Walk-Home”Items,MajorCustomerDissatisfier,S/C,F/F,4)Defect,Escalation,缺陷逐,层,层汇报,Escalatedefects to,leadership forsupport,dependingon,frequencyand criticality!,根据缺,陷,陷出现,频,频率与,严,严重程,度,度,逐层向,领,领导汇,报,报以寻,求,求支持,！,！,In-Process Control,&,&Verification, 2,),) DETECTION,Detection,Example:,Team Leader,Section Leader,GroupLeader,2 defects,/,/ 1hour,4 defects,/,/ 1hour,1)UseAndon,(taught more,later)使用暗,灯,灯,Make problems visual,& pullinsupport!,问题直,观,观，,拉线寻,求,求帮助,！,！,In-Process Control,&,&Verification, 3,),) CONTAINMENT,AlwaysRememberthe Priorities,:,:一定要,牢,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,容程序,Extraordinary actions,toprevent defectsfrom,beingpassed,!,!,采取特,别,别行动,防,防止,缺陷传,递,递！,In-Process Control,&,&Verification, 3,),) CONTAINMENT,Some examples:,1)Stop theline,停线,2)100,%,% checks,100,%,%检查,3)On-line repair线上维,修,修,4)Reworks返工,5)Sorting整理,Containment,包容,HowDoesourQualityMottorelatetoContainment,?,?,Donot,不要,Accept,接受,Build,制造,Ship,传递,a Defect!,缺陷！,Itmeansempoweredleadersmake,judgmentshow tocontrolquality,whiletryingtokeepthelinerunning!,意味着,领,领导有,权,权作出,决,决定：,在,在尽量,不,不停线,的,的情况,下,下，,怎样控,制,制好质,量,量！,Does thismeanwestop theline every timewehavea problem,?,?,这是不,是,是意味,着,着一有,问,问题就,停,停线呢,？,？,HowDoesourQualityMottorelatetoContainment,?,?,Sometimesthe bestdecisionmay be to leta defectpass to thenext process, but,有时最,好,好的办,法,法是让,差,差错转,到,到下工,序,序，但,是,是,Itisa consciousdecisionmade by theappropriatelevel,Actionmustbecommunicatedtonext,“,“customer,”,”,Defectmustbeclearly identifiedonvehicle,Containmentmust be in place to preventfurtherdefects,ExamplesofSomeAndonGuidelines:,暗灯使,用,用的指,导,导方针,1)Will theproblem affectthenextprocess?问题会,不,不会影,响,响下道,工,工序？,2)CanIeffectivelyrepairthe defectoutofstation?能不能,在,在工位,外,外有效,解,解决问,题,题？,3)What is thestatusofmydecouplers?自己的,切,切断器,是,是什么,状,状态？,4)Others,其他,AndonDiscussion Hoods,Situation,:,:,AttheBodyShop end-of-line Qualitystationitisdiscovered thatthereisaproblem withcrackedhoods.After workingthe linebackweknow thateverycar in thesystemhas theconditionall thewaytoHoodInstall.Aftersortingtheraw hoods,itisfoundthat there areenoughgoodhoodstokeep producingcars,however there arenotenough goodhoodstorepair thedefectivecarson-line.The supplersaysnewhoodswillarrivein6hours.Theoperatorsatend of linehavepulledtheAndonandthe escalationprocesshaspulled in theBody ShopManagerandQualityManager.Considerationsare:1)Thedecouplerbetween Bodyand Paint is almostempty,2)Hoodswithcracked metal willnot affectanyofthe subsequentprocesses,and3)Hoodscan be changedout of stationrelativelyeasily,.,.,Discussion:,Youare thePlantQualityManager whatisyour decision?,Discuss as agroup,!,!,Background:Inthis case, thedecisionisisshut downthe linefor (6)hoursandwaitforpartsorrun theline andmake acontainmentplan.Since thedecouplerbetween Bodyand Paint is almostempty,thismeansallBody,Paintand GA willall eventuallyshutdown.,PotentialDecision,:,:Inthis case, Qualitycan still be achieved while maintaining ourResponsivenesstargets mostlybecause thehoodsdonotaffect thenext process,.,.TheCostofstoppingthelinewill notresultinbetter QualityorResponsiveness,.,.Thus,a gooddecisionwouldprobablybetorun theline andmake acontainmentplan:,Allcarswith badhoodstobespeciallyidentified.Productionand QualityinPaintand GA notified of thesituation, knowthe vehiclenumbersandidentificationmethod.,100,%,% check at HoodInstalloperationuntilprocesscapability is assured,.,.,PaintandFinalProcessnotifiedthat newhoodstobepainted in Paint andwill be swappedinFinalProcessarea andhave timetomakea planhow to accommodate that,.,.,AndonDiscussion -Hoods,Situation,:,:,AttheCockpitLoad stationinGAitisdiscoveredthat there is aproblemwith oneoftheelectricalharnesseswithin thecockpit.The cockpits arebuiltasa modulebyanoutside supplier.Afterworkingthelineback we knowthatseveral cockpits in thesystemhavethecondition.The operatorsatCockpit LoadhavepulledtheAndonandthe escalationprocesshaspulled in theTrim LineSectionLeader, whoconsultswith theChassis LineSectionLeader,.,.Considerationsare,:,: 1,),) Thedecouplerbetween Trimand Chassisabouthalffull,2)Theelectricalharness willaffect thenext assembly process, 3,),) Repairingtheharnesses on-linewilltake approximatelyone hour, and4)Repairingthe Cockpitlaterinthe processisdifficult andvery timeconsuming.,Discussion:,Youare theTrim SectionLeader whatisyour decision?,Discuss as agroup,!,!,AndonDiscussion -Cockpits,Background:Inthis case, thedecisionisisshut downthe linefor (1)hour andrepairthe harnessespriortoCockpit Loadorrun theline andrepairthe cockpits out-of-station.Sincethedecouplerbetween Trimand Chassisisabouthalffull,this means thatChassiscancontinuerunningforashortwhileandtheneventually shutdown.,PotentialDecision,:,:Inthis case, Qualitycannot be achieved while maintaining ourResponsivenesstargets mostlybecause thebadcockpitsaffect thenext processand areextremelydifficult to repairlater.TheCost of stopping theline is moredesirable thanthe costofrepairing themlaterand thepotentialtocreate moredefects.In thiscase,thedecouplerstatusdoesnotreally impactthefinaldecisiontoo much,.,.Thus,a gooddecisionwouldprobablybetostopthelineandfix theharnessespriortoCockpitInstall.The TrimLineSection Leaderwill i