1、质量阀总结/Quality Valve Summary,正式生产质量阀 SOP Quality Valve,议程/Agenda,项目综述/Program Overview 项目质量矩阵/Program Quality Metrics 1.4 产品工程状态/Product Engineering Status 2.6, 2.6, 2.7, 2.8, 3.3 供应商质量状态/Supplier Quality Status 4.2, 4.3, 4.4, 4.5, 4.6 制造工程状态/Manufacturing Engineering Status 6.2, 6.4, 6.5, 6.6, 6.7,
2、6.8 生产状态/Manufacturing Status 7.1, 7.3, 7.4, 7.5, 7.6, 质量状态/Quality Status 7.7, 7.8, 7.9, 7.10 PC&L状态/PC&L Status 8.1, 8.3, 8.4 客户及制造主要问题/Significant Customer and Build Issues 10.3, 11.1, 11.2 质量阀总结及决议/Quality Valve Summary and Decision 12.1, 12.2, 13.0,风 险 评 估 表 评 判 准 则 Risk Assessment Chart Defini
3、tions,无 修 复 计 划， 或 由 于 未 知 原 因， 不 可 执 行 No recovery plan exists, or plan is rejected for unknowns,修 复 计 划 已 存 在 并 得 到 批 准 Issues that have and agreed to recovery plan,红/Red,黄/Yellow,绿/Green,关 键 日 期 未 确 定； Key dates not established; 不 可 接 受 风 险； Unacceptable risk; 认 证 计 划 未 完 成； Validation plan not c
4、omplete; 进 度 来 不 及。 Timing insufficient.,修 复 计 划 可 接 受； Recovery plan is accepted; 有 望 得 到 认 证； Validation is expected; 已 知 的 中 等 程 度 风 险。 Moderate risk is present.,已 结 案 或 风 险 可 接 受 Closed status, or risk is accepted,2.6 设计释放/Design Release,定义/Definition: 设计释放进程推动项目和工艺开展，是及时有效地完成设计释放是项目成功的关键The des
5、ign release process drives much of the activities of program and process development, and as such, the timely and effective execution of the phases of design release is critical to the success of the program. 期望/Expectation:没有对项目有重大风险的设计更改No Design changes that would add significant risk to the prog
6、ram. 状态/Status: 计划/Plan:,2.7 制造文件/Build Documents,定义/Definition: 通过产品和制造工程建立最佳的装配工艺，制造文件设置了标准化工作的基础，并通过减小制造偏差来改进质量Build documents set the baseline for standardized work by establishing the best assembly process as defined by product and process engineering. This impacts quality by minimizing build v
7、ariation. 期望/Expectation: 完成SORP级的制造文件SORP level Build Documents completed. 状态/Status:计划/Plan:,2.8 工程制造问题Engr Build Incidents,定义/ Definition: 找出，跟踪并解决工程制造问题有助于在项目早期改进质量Capturing engineering build incidents and tracking to closure provides an opportunity to make quality improvements early in the proc
8、ess. 期望/ Expectation: 无重大制造问题延续到下一制造阶段, 项目无风险No significant build issues carrying over to next build phase which would put the program at risk. 状态/ Status: 绿/Green计划/Plan:,2.12 Integration Issues,Definition: Effectively integrating the engine, transmission, and controller into the vehicle is critica
9、l to the customers overall satisfaction with the driving experience. Integration issues may include: NVH, Performance/Driveability, Electrical Interfaces, Controller Software, Powertrain Packaging, Powertrain Cooling/HVAC, and Fuel System.在整车中有效地将发动机、变速箱及控制系统集成是确保有驾驶经验的顾客全面满意的关键集成的问题主要包括：NVH，性能/驾驶性，
10、电子干扰，控制软件动力总成装配，动力总成冷却/HVAC，及燃油系统 Expectation: PTSIE Checklist completed to extent possible and significant issues are highlighted.完成PTSIE检查清单，关注所有重要的潜在问题 Status: Plan:,3.1产品认证/Product Validation,定义/Definition: 产品认证的目的是通过分析计算，计算机模拟，制造评估/检查，及硬件试验(通过完整的整车耐久的零件级试验)确认产品与技术规范一致 The purpose of product val
11、idation is to confirm that the product meets its technical requirements through analytical calculations, computer simulations, build evaluations/inspections, and hardware testing (component level through full vehicle durability schedules). 期望/Expectation: 更新认证试验状态,完成认证批准Validation Plan metric status
12、 update and Validation Sign-off completed. 状态/Status:计划/Plan:,3.2 试验故障总结/Test Incident Summary,定义/Definition: PRTS+系统是北美通用追踪从试生产到正式生产及以后的质量问题的流程, 它提供了解决问题的信息来源，有助于对问题分级管理促进沟通解决问题Problem Resolution Tracking System (PRTS) is a GMNA process for tracking issues from Pre-Production into Production and be
13、yond. It provides a source of information on issue resolution in order for management to prioritize and communicate resolution. 期望/Expectation:更新IR状态总结(在FA阶段, 所有1,2级IR均已解决,3,4级IR有关闭计划)Summary status update (At FA all Code 1 and 2 IRs resolved. Code 3 and 4 have a plan for closure). 状态/Status: 计划/Pla
14、n:,3.3 主要故障报告Significant IR s,定义/Definition: 一级问题与二级问题在主要故障报告中被标注为“红色”状态，附有详细描述及当前阶段解决状态 Incident Report (IR) codes 1 and 2 that have been identified as “Red” are to be reported in detail with current 5 phase resolution status. 期望/Expectation: 需采取合适的及时的行动(分析和纠正计划)来降低风险并关闭问题Appropriate and timely act
15、ivity (analysis and corrective action) being taken on issues for risk mitigation and issue closure. 状态/Status: 计划/Plan:,4.2 APQP/供应商质量APQP/Supplier Quality,定义/Definition:产品质量先期策划(APQP)是一套包含了定义和相关必须步骤的方法以确保产品能令顾客满意。APQP需要供应商建立和执行一套质量计划以期能够：合理安排资源使顾客满意，尽早的识别所需的更改，确保所有步骤的按时完成，沟通，以有竞争力的成本按时提供高质量的产品。 Adv
16、anced Product Quality Planning (APQP) is a structured method of defining and establishing the steps necessary to assure that a product satisfies the customer. This process requires a supplier to develop and implement a quality plan that: directs resources that satisfy the customer, promotes early id
17、entification of required changes, assures all required steps are completed on time, facilitates communication, and provides a quality product on time at a competitive cost. 期望/Expectation:对高/中风险的供应商进行APQP评审APQP Program review held on H/M Risk Suppliers. 状态/Status: 计划/Plan:,4.3 生产件批准程序/PPAP,定义/Defini
18、tion: 生产件批准程序的目的是用于确定供应商是否了解了所有的顾客工程设计记录和规范要求以及供应商的生产过程是否有能力在实际生产时持续稳定的生产出满足所有要求的产品。The purpose of the Production Part Approval Process (PPAP) is to determine if all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the
19、 potential to produce product consistently meeting these requirements during an actual production run.期望/Expectation: 零件100%完成 PPAP/ 100% parts PPAPed 状态/Status: 计划/Plan:,4.4 GP-9按节拍生产/GP-9 (Run at Rate),定义/Definition:按节拍生产的目的是用于验证供应商的实际制造过程是否有能力按照PPAP所批准的，以及报价的工装能力持续满足GM的产量和质量要求。The purpose of a Ru
20、n at Rate is to verify the suppliers actual manufacturing process is capable of producing components that meet GMs on-going quality requirements, as stated in the PPAP, at quoted tooling capacity for a specified period of time. 期望/Expectation:制定按节拍生产计划以满足在SSF前8个星期完成RunRate(9.25,2003).Run at rate pla
21、n developed to complete Run at Rate 8 wks prior to SSF (September 25). Review exceptions 状态/Status:计划/Plan:,4.4.1 按节拍生产/GP9 (Run at Rate),相关问题的整改计划格式,4.5 供应商启动就绪Supplier Launch Readiness,定义/Definition:供应商启动就续是一个有序的过程，用以评估须启动小组关注的供应商，确定须关注的关键区域并跟踪供应商进度至完全就绪此流程仅用于新项目及关键项目Supplier Quality Launch Proces
22、s is a structured process to assess suppliers requiring launch team attention, to identify key areas of concern and to monitor progress of the supplier to full launch readiness. This process is applied on NEW /MAJOR programs only. 期望/Expectation : 确定早期生产的联络方式, 评估供应商的早期生产风险, 跟踪高风险供应商, 对于有红色警报的项目进行评审L
23、aunch Liaison identified, Suppliers assessed for Launch Risk, High Risk Launch Suppliers tracked, Red Launch alerts reviewed . 状态/Status: 计划/Plan:,4.6 主要供应商问题/未关闭问题 Significant Supplier Issues / Open Concerns,定义/Definition: 采购和供应商质量列出所有与项目就绪相关的供应商问题。Purchasing and Supplier Quality are to bring forwa
24、rd any concerns they have relative to the readiness of the supply base to support the program. 期望/Expectation :列出主要的供应商问题和整改计划. 目标是没有可能导致整个项目有风险的重大问题Bring forward major supplier concerns with action plans. The expectation is that they have no significant issues that would put the program at risk. 状态
25、/Status:计划/Plan:,6.2 设备要求说明/验证计划/设备能力,定义: 制造工程要求说明（SOR阶段的）是针对供应商设备，检具，和/或者刀具的要求。制造验证计划是证明制造系统能达到制造期望和工程设计要求。设备能力是达到工程设计要求的证据。 期望 所有设备/控制过程和能力均被批准 状态: 计划:,6.2 Equipment SORs/Validation Plan/Capability,Definition: Manufacturing Engineering Statements of Requirements (SORs) are the requirements for the
26、 supplier of equipment, gages, and/or tools. The Manufacturing Validation Plan is the plan to prove the manufacturing system meets manufacturing expectations and engineering design requirements. Capability is the proof of meeting engineering design requirements. Expectation: Approved process capabil
27、ity for each machine/process. Status: Plan:,6.4 潜在失效模式分析/PFMEA s,定义/Definition: 潜在过程失效模式分析的目的是识别潜在问题可能对制造产品质量带来的影响，并建立纠正措施的优先等级计划。The objective of the Process Failure Mode and Effects Analysis (PFMEA) is to identify potential problems which could affect the quality of manufactured parts and develop
28、prioritized plans for corrective actions.期望/Expectation: 有相应的控制手段以降低风险顺序数RPN Reduction Process in place with demonstrated progress.状态/Status:计划/Plan:,6.5 控制计划/Control Plans,定义/Definition: 控制计划是控制产品和过程质量体系的描述。它解释了过程的每个阶段操作要求，以确保输出状态的受控，将过程和产品波动有关的风险降至最小。Control Plans are written descriptions of the s
29、ystems for controlling the quality of parts and processes. It describes the actions required at each stage of the process to assure that outputs remain in a state of control, thus minimizing the risk associated with process and product variation. 期望/Expectation:正式生产版本的控制计划吸取了前阶段制造的经验，重新审定了试生产文件，已经完成
30、Production Control Plan complete based on learning from previous build and review of the launch Control Plan. 状态/Status:计划/Plan:,定义/Definition: 为了在设备调试期间有效地决定过程能力，贯彻制造质量原则并验证产品质量，须制定详尽的检具计划及采购流程还须支持进行测量系统分析In order to effectively determine process capability during machine runoff, support Built-In-Q
31、uality principles, and verify product quality, a comprehensive gage plan, procurement process, and supporting measurement system strategy is required. 期望/Expectation: 已订购剩余的检具审核检具交货进度以满足设备验收需求在Gamma样机制造的生产启动前期控制计划中列出检具Remaining gages ordered. Review gage deliveries scheduled to meet equipment qualif
32、ication needs. Gages in the Pre-Launch Control Plan for the Gamma build. 状态/Status:绿色 计划/Plan:,6.6 检具准备/Gage Readiness,6.7 生产件批准程序/PPAP,定义/Definition: PPAP的目的是确认制造商正确理解工程设计规范要求，并且过程有潜力在实际生产中按已定节拍连续制造出符合规范的产品。 The purpose of the Production Part Approval Process (PPAP) is to determine if all engineeri
33、ng design specification requirements are properly understood by the manufacturing facility and that the process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. 期望/Expectation: PPAP完成/ PPAP compliant. 状态/Statu
34、s: 计划/Plan:,6.8 制造工程未解决事项ME Open Concerns,定义/Definition: 制造工程应该提出所有与其相关的问题并对项目进行支持。Manufacturing Engineering should bring forward any concerns they have relative to their readiness to support the program. 期望/Expectation: 审核所有未解决事项或需要支持的事项，期望状态是没有对项目带来风险的事项 Review any open concerns or required assist
35、ance. The expectation is that there are no issues that would put the program at risk. 状态/Status: 计划/Plan:,7.1 人员配备和培训Launch Team Staffing/Training,定义/Definition: 对人员的要求包括贯穿整个产品启动过程的产品，工艺和连续到整个产品正式生产全过程。在产品生产过程之前和过程中都必须对每一个员工的必要培训进行识别和计划Requirements for staffing include coverage for both the product
36、and process and continues throughout the entire Production Launch Process. Applicable training for each employee must be identified and scheduled prior to and during the launch process. 期望/Expectation: 审阅计划状态/Review status to plan. 状态/Status: 计划/Plan:,7.3 工作场地有序安排和目视化控制Workplace Org. andVisual Contr
37、ols,定义/Definition:工作场地布置必须按标准制定以支持员工将浪费减到最小，并且通过提供一个安全，整洁，有效的场地安排来提高工艺质量。目视控制为标识，指导或在整个厂区如何统一协调各种控制Workplace organization are standards created to support the employee, minimize waste, and promote quality workmanship by providing a safe, neat, clean, efficient arrangement of the workplace. Visual co
38、ntrols are the identification, instruction, or indication of how each control will be implemented uniformly throughout the plant. 期望/Expectation:所有工作按计划开展，正式投产计划由生产启动经理签署。 All activities on schedule, SOP Sign off complete by Production Launch Manager 状态/Status: 计划/Plan:,7.4 标准化工作和员工操作实践Standardized
39、Work /Best People Practices,定义/Definition:标准化工作是指工作职能按可重复次序执行的文件，它应该符合基层制造实际情况，并由基层负责更新维护该文件。员工操作实践是在执行同一标准次序工作中获得最好质量水平，安全，生产力和人机工程实际的标准化。Standardized work is the documentation of work functions performed in a repeatable sequence, which are agreed to, developed and maintained by the production floo
40、r. Best People Processes are standardized work functions performed in the same standardized sequence to achieve the highest levels of quality, safety, productivity, and ergonomic practice. 期望/Expectation:所有工作按计划开展，正式投产由生产启动经理签署。 All activities on schedule, SOP Sign off complete by Production Launch
41、Manager 状态/Status: . 计划/Plan:,7.5 制造工艺过程认证Manufacturing Validation Build Process,定义/Definition:制造工艺过程认证应在SOP前，使工艺可以在模拟正常制造状态下进行，它融合各种可能的情况同时也包括所有部门。该过程主要集中在加入的新工艺，在该工艺启动之前，暴露制造系统的缺陷。The Manufacturing Validation (Bucket Build) Process takes place before SOP to allow process to run in a situation that
42、 simulates production, incorporates as many streams of variation as possible, and includes all support departments. This process focuses on uncovering deficiencies within a manufacturing system after a process is installed, but before it is launched. 期望/Expectation:审阅计划状态-所有工作按计划开展。在制造过程中发现的问题要注意类似的
43、问题是否会在不同生产线，不同机床会发生并要讨论任何潜在的风险。Review Status to Plan - All Activities on Schedule. Note families of variation (e.g. line to line, lot to lot, machine to machine) which are captured in the build and discuss any potential risks. 状态/Status: 计划/Plan:不需要 Not Required,7.6 防错和工艺认证审核Error Proofing and Proce
44、ss Verification Audits,定义/Definition: 认证审核用来维持产品质量的高水平，通过有计划地确保防错设备功能正常，已建立的质量操作程序，工艺控制按规定执行。这些审核是所有现场分层审核的一部分。Verification Audits are used to maintain high levels of outgoing quality by regularly ensuring that error proofing devices are functioning properly and established quality operating procedu
45、res and process controls are being followed with appropriate discipline. These audits are part of an overall layered audit system for the site. 期望/Expectation: 审阅认证审核计划/Review Verification Audit Plan. 状态/Status: 计划/Plan:,7.7 顾客评审及质量门CARE & Quality Gates,定义/Definition:在制造现场的建立顾客接受和审核评价过程，质量门，是为了使缺陷否会
46、达到客户处并快速反应相应的信息。A Customer Acceptance and Review Evaluation (C.A.R.E.) process and Quality Gates are established in the manufacturing site as a means to isolate our Customers from discrepancies and provide information for rapid corrective action. 期望/Expectation: 审核初步顾客评审清单。评审预试生产以来的质量门数据。Review init
47、ial CARE list. Review initial Gate data from pre-pilot. 状态/ Status: 计划/ Plan:,7.8 快速响应/Fast Response Process,定义/Definition: 为确保主要产品质量事宜得到及时关注，应指定责任人并通过目视管理系统正式跟踪，纳入日常领导层审核内容。 To ensure significant production quality concerns receive prompt attention, they are assigned an owner and formally tracked t
48、o resolution through a visual management system and regular leadership reviews. 期望/Expectation: 评审会议时间地点的初始方案及目视化状态。Review initial plan for meeting, time, and location. Review visual status. 状态/Status: 计划/Plan:,7.9 启动计划，产品测试及质量矩阵Start-up Plan, ProductTesting, and Quality Metrics,定义/Definition: 在高质量产
49、品起动的第一年，启动计划（包括产品测试）是为了在年型产品开始时提供一个无混乱的高质量产品的启动阶段跟踪质量矩阵，可以提供早期质量反馈和推动改进工作A Start-up Plan (including product testing) is developed in order to provide a disruption free, high quality production launch at the beginning of the model year. Specified quality metrics are tracked to provide early quality feedback and drive improvement activity.期望/ Expectation: 执行启动计划评审相关的质量矩阵并建立相应对策Start-up plan is being executed and pertinent quality metrics are reviewed with countermeasures as called for.状态/ Status:计划/ Plan:,
