Site Assessment
现场审核
Site Assessment Outline
现场审核的概述
The Site Assessment defines Ford quality expectations and is a key component of Q1 2002.
现场审核定义了福特的质量期望，是Q1 2002的一个重要组成部分。
Site assessments are tools for suppliers to gage their performance.
它是供应商衡量自身表现的主要工具。
The assessment reviews the fundamental areas of any robust quality system by evaluating how well the site has planned for and can demonstrate manufacturing process capability.
它以工厂计划及实际的工序能力来审查所有稳健质量系统的基础项目.
The Site Assessment addresses Planning and Demonstration of Manufacturing Process, Variability Improvement (Consumer Driven 6-Sigma), Manufaturing Efficiencies, Customer Satisfaction.
它从工序能力的计划和表现、变差的改进（顾客驱动的6-Sigma）、生产效率、顾客满意度四个方面进行评估。
The Purposes of Site Assessment (1)
现场审核的目的（1）
The Manufacturing Site Assessment provides a:
制造现场审核提供了：
Framework for Ford/Supplier working relationship
福特/供应商之间的工作关系架构
Confirmation of QS-9000/TS 16949 expectations
确认QS-9000/TS16949的期望
Process to identify improvement opportunities
确定改进机会的程序
Process to confirm corrective actions
确定整改行动的程序
Process to drive continual improvement
推动持续改进的程序
The Purposes of Site Assessment (2)
现场审核的目的（2）
The assessment provides an opportunity for the Supplier to:
评估提供了供应商一个机会
Closely observe a site’s manufacturing processes
更近地观察制造程序
Identify opportunities for improvement
确定改善机会
Prioritize corrective action plans
整改行动计划的优先顺序
Become even more productive
变成更高的生产效率
The Requirements of Site Assessment (1)
现场审核的要求（1）
Q1 supplier must satisfy the Q1 site expectations.
Q1供应商必须满足所有的Q1生产现场的期望。
The supplier will perform a full site assessment annually and a partial assessment every 6 months on the ‘focus’ areas.
供应商要每年进行一次全要素评审, 每半年进行一次重点要素的评审。
Suppliers should submit the site assessment results to Ford STA and share the self assessment finding with the responsible Ford STA engineers upon request.
供应商应将现场审核的结果提交给福特STA并根据要求与STA工程师共享自我评估发现的问题。
Ford STA will participate in the site assessment process, including corrective action plan follow-up, on a case-by-case basis.
福特的STA将根据情况参加评审, 包括整改措施的跟踪。
The Requirements of Site Assessment (2)
现场审核的要求（2）
The supplier not meeting Q1expectations will be requested to develop and design implementation of the corrective action plan within 30 days of the site assessment.
不能满足福特的Q1要求的供应商现场要在30天内制定整改计划并实施。
Failure to execute an effective and timely corrective action plan, as jointly determined by Ford STA and the supplier, will result in loss of 250 points and Q1 revocation.
没有及时有效地实施由福特STA和供应商共同制定的整改计划，其结果是现场将失去250分，且其Q1地位将被取消。
Suppliers are required to keep completed copies of the Site Assessment checklist, and accompanying corrective action plans, covering the prior 24 months.
供应商需保存前24个月现场审核的检查表及整改计划。
Site Assessment Process
现场审核的程序
Led by the Supplier
由供应商牵头
Involves Ford on-site with selected Suppliers
对选定的供应商福特将到供应商现场执行
Develops and implements action plans for improvement opportunities
对改善机会制定并执行行动计划
Reaches agreement between Ford and the Supplier regarding timing for corrective actions
福特及供应商间达成关于整改计划时间要求的共同意见
Communicates high-level results via website with data that is held in SIM
通过设置在SIM中的数据网页交流评估结果
STA Engineer Assessment Responsibilities
STA工程师的审核职责
Coaching and mentoring the Supplier to establish action plans
指导供应商制定行动计划
Assessing a Supplier’s action plans
评估供应商的行动计划
Providing necessary feedback on action plans
提供必要的行动计划反馈
Guiding the Supplier toward continuous improvement
指导供应商持续改进
Ensuring that Suppliers are consistently meeting Ford’s standards for maintenance of Q1 status
确保供应商始终满足福特的标准以维持Q1的状态
Pre-Meeting Requirements for the Supplier
对供应商开会前的要求
Arrangements may include:
应包括下列安排
Gathering documentation requested by the STA Engineer
收集STA工程师要求的文件
Making available all necessary resources
预先安排所有所需资源
Planning and scheduling interviews and walk-throughs
排定面谈及参观的时间计划
Arranging for inspections of facilities
安排设施的检查
Arranging for evaluation of processes
安排程序评估
Sample Agenda for STA on-site Assessment
STA现场审核议程范例
Introductions
介绍
Plant Overview
工厂简介
General Plant Tour
工厂总体参观
Planning for Manufacturing
制造计划
Demonstration of Manufacturing Capability (on the shop floor)
制造能力的演示(在车间)
Wrap-up Meeting
总结会
Introductions
介绍
The Introductions:
介绍
Set the tone
开场白
Allow all participants to get to know who is who
人员介绍
Plant Overview
工厂简介
The supplier should present :
供应商应介绍：
The organization (with chart) 组织结构图
The history 历史
Customers顾客
Awards 奖项
Philosophy 公司价值观
QOS measurables, what is the supplier measuring and how 公司QOS的衡量准则及操作方式
General Plant Tour
工厂总体参观
The general walk-through:
总体的参观是：
Starts where the raw materials are received
从原料入厂的地方开始
Ends where product is shipped (or vice versa)
在产品出厂初结束
Includes everything in between
包括所有的过程
Is a general get-to-know-the-process overview of the Supplier’s facilities and operations.
对供应商设备及操作工序的大致了解
Planning for Manufacturing
制造计划
Review the categories and sub-categories
审查涉及的要素及子要素
Reviews the supplier documentation and then verifies the documents on the plant floor
审查文件，并在车间验证文件
Write results, comments, or notes on the Manufacturing Site Assessment Summary form
将结果、评论、注释填写在现场审核汇总表中
Demonstration of Manufacturing Capability
制造能力的演示
STA Engineers gather objective evidence and verify data on the shop floor by:
在车间收集资料
Reviewing the Supplier’s processes
审查供应商的工艺
Observing and speaking with employees
察看员工的操作并与之交谈
Walking the line
考察整条生产线
Supplier Action Plans
供应商行动计划
The Manufacturing Site Assessment checklist lists:
制造现场评估查检表:
Comments/findings/examples
意见/发现/实例
Action Plans
行动计划
Person with lead responsibility
牵头的负责人员
Timing associated with Action Plan
行动计划的时间表
Wrap-up Meeting
总结会
Manufacturing Site Assessment Summary Form review
制造现场评估汇总表格的讨论
Document the next steps， The Supplier should respond within 30 days with the corrective Action Plan
下一步计划的制定， 供应商需在30天内提出整改计划
Exit interview with the Plant Manager
离开前对工厂一把手的会谈
Action Plans （1）
行动计划（1）
Action Plans should:
行动计划应：
Use G8D when the root cause of the concern is unknown
当问题的真正原因未明时使用G8D.
Develop a procedure that defines the requirements to implement corrective and preventive actions
制定一个程序来定义实施改正及预防行动的要求
Document sources of information used to detect, analyze, and eliminate causes of nonconformance
记录用来探测，分析，消除不符合原因的信息来源
Identify and use additional disciplined problem-solving tools
确定并使用其他问题解决工具
Action Plans （2）
行动计划（2）
Document verification of the effectiveness of corrective actions
记录对改正计划的有效性的验证
Provide evidence that actions to prevent recurrence have been addressed
提供已实施预防再次发生相同问题行动的证据
Provide evidence of the communication of quality concerns to the appropriate personnel
对适当的人员进行质量问题的沟通提供证据
Action Plans （3）
行动计划（3）
Assure that relevant information on actions taken is submitted for review
确定已采取行动的相关信息已经提交审查
Implement and record any changes to documented procedures resulting from corrective and preventive actions
实施并记录由于改正及预防行动而引起的任何书面程序的变更
Ensure regular Management reviews to implement actions over time
确保管理层定期审查实施计划
Elements of Site Assessment（1）
现场审核的要素（1）
Planning for Manufacturing Capability 制造过程能力策划
Quality Procedures/QS-9000/TS16949,QOS 质量程序/QS9000/ /TS16949, QOS
FMEAs/Control Plans* FMEA/控制计划*
Employee Readiness/Training Review 员工准备/培训评审
PPAP/Run-at-Rate PPAP Review 评审和生产节拍评审
Manage the Change 管理变更
Remark:The asterisked(*) is the focus areas.
备注：标示（ *）为重点项目
Elements of Site Assessment（2）
现场审核的要素（2）
Demonstration of Manufacturing Capability制造过程能力示范
Sub-Supplier Quality Management* 分承包方质量管理*
Control of Incoming Quality 进货质量管理
Control Plans/ Operator Instructions* 控制计划/操作指导书*
Process Variability Monitoring* 监控过程变差*
Gages Calibration and Use* 量具校准和使用*
Part Identification/Nonconforming Parts/Packaging/Shipping 零件标示/不合格零件/包装/发运
Testing/Engineering Specifications 试验/工程规范
Preventive Maintenance(PM)/Housekeeping* 预防性维护/整洁*
Manufacturing Flow/Lean manufacturing Metrics* 制造流程/精益生产指标*
Problem Solving/Corrective Actions问题解决/纠正措施
Sample for filling in the Assessment Form
填写评估表范例
QOS(1)
质量操作系统（1）
Definition:A Quality Operating System is a systematic, disciplined approach that uses standardized business tools and practices to manage business and achieve ever-increasing levels of customer satisfaction.
定义：质量操作系统是一套系统的、科学的方法，使用标准的商务工具和实践来管理业务和达到不断提高的顾客满意度。
QOS is the catalyst that holds the system together.
质量操作系统是将系统集合在一起的催化剂。
QOS （2）
质量操作系统（2）
The basis operation of a QOS
QOS的基本步骤
First Time Through Calculation (FTT)
首次通过率
Definition:
First Time Through is the percentage of units that complete a process and meet quality guidelines the first time without being scraped, rerun, retested, diverted for off-line repair, or returned. It is a measure of the quality of the manufacturing process.
定义:
首次通过率是指一次性完成一个生产过程并且满足质量要求的零件的百分率， 不包括报废，返工，再测试，下线修理或返回。FTT 用于衡量制造过程的质量。
FTT=
Units entering process-(scrap+reruns+retests+repaired off-line+returns)
Units entering process
Total Dock To Dock Calculation (DTD)
进货到出货
Definition:
Dock to Dock is the elapsed time between the unloading of raw materials and the release of finished goods for shipment. DTD measures how fast raw materials are converted to finished goods and shipped. It is a measure of the speed of material through the plant, not the speed of the processes.
定义:
DTD指从原材料到发运产品之间的总运转时间间隔。DTD用于测量原材料转化成成品发运的速度。也就是指材料通过工厂的速度，而不是加工工艺的速度。
DTD (Single Operation) = Total Units of Control Part
End of line Rate
DTD (Multiple Operation)= DTD(OP 1)+DTD(OP 2)+…
End of line Rate
Overall Equipment Effectiveness (OEE)
设备总效率
Definition:OEE is a combination of three different calculations. It is a measure of the availability, performance efficiency, and quality rate of a given piece of equipment.
OEE data will help identify several wastes caused by machine/process inefficiencies.
Stretch objective: 85%
定义：OEE是三个不同计算值的乘积，用于测量指定设备的利用率，性能效率和质量率。OEE 数据可以帮助识别由设备/过程不足引起的不同的浪费。
接受标准： 85%
OEE = Availability X Performance Efficiency X Quality
Availability = Operation Time
Net Available Time
Performance = Ideal cycle time X Total parts run
Efficiency Operating Time
Quality = Total parts run – Total defects
Total parts run
Build to Schedule (BTS)（1）
按计划制造（1）
Definition:
Build to schedule is the percentage of products shceduled for a given day that are produced on that day, in the correct sequence. BTS reflects the plant’s ability to produce what it’s customers want, when it’s customers want it, and in the order the customers use the product.
定义:
BTS是指在指定的生产日按照正确的生产顺序完成生产计划的比例情况。BTS 反映了工厂能够按照客户的要求完成生产的能力,客户需何种产品,何时需要和客户使用产品的顺序。
BTS% = Volume% X Mix% X Sequence%
Build to Schedule (BTS)（2）
按计划制造（2）
Volume Performance:
Volume Performance, is the traditional measure that manufacturing has used to monitor their performance to schedule.
产量性能用于监控生产计划完成情况。
Mix Performance:
The Mix component of BTS measures the percentage of product derivatives/models/types that a plant builds on the right day.
BTS的混线性能用于测量在厂内制造的产品系/型号/类型等在适当的生产日的完成比率。
Sequence Performance:
The sequence component of BTS measures the percentage of those products built on the right day that were also built in the right sequence.
BTS的顺序性能用于测量在适当的生产日按照正确的生产顺序完成生产任务的比率
Characteristic Classification（1）
特性说明 （1）
Critical Characteristics (CC) - Part or process requirements (dimensions, specifications, tests, processes, assembly sequences, tooling, torque, welds, attachments, component usages, etc.) which affect regulatory compliance or safe vehicle/product function and require specific supplier, manufacturing, assembly, shipping, monitoring, and/or inspection actions.
关键特性(CC) - "影响对法规的符合性或车辆/产品安全功能，并需要供应商在制造，装配，装运，监督，和/或检查特别措施的零件或过程要求（尺寸，规范，测试，过程，装配顺序，工具/模具，扭矩，焊接，附件，零件用途，等）
Significant Characteristics (SC) - Categorized characteristics of products, processes, and tests, where a reduction in variation, within a specified tolerance, around a proper target will improve Customer Satisfaction.
关键特性(SC) - "产品，过程和测试类特性，当其在规定的公差范围内减少变差，围绕目标值会改进顾客满意度
Characteristic Classification（2）
特性说明 （2）
High Impact Characteristics (HIC) - product or process characteristics that, when outside of the specification tolerance, severely affect subsequent manufacturing operations or customer satisfaction; the product or process is not, however, unsafe.
高影响度特性(HIC) - 产品和过程特性，当超出规格范围会严重影响下一步的操作或顾客满意度；但产品或过程本身却并非不安全。
Pass-through characteristics are defined as: Those characteristics which are produced at outside suppliers and are transparent to the customer plant processes and controls. Quality defects are at risk of being "passed through" to our final customers.
传递特性（Pass-through Characteristics）的定义：是由外部供应商产生的，对于顾客工厂的过程与控制有影响的所有特性。质量缺陷就是能将风险传递到最终顾客
