此处是大标题样稿字样十五
字以内
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 2
GMS
Manufacturing
Process
Validation
Product
Quality
Standards
Quality
System
Management
In
-P
ro
ce
ss
C
on
tr
ol
&
Ve
rif
ic
at
io
n
Quality
Feedback/
Feed-
forward
Standardized
Work
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Andon
Concept
Problem
Solving
Early Mfg. and Design
Integration (DFM / DFA)
Continuous
Improvement
Process
Lean Design of Facilities, Equipment,
Tooling and Layout
Business Plan
Deployment
Total
Productive
Maintenance
Controlled
External
Transportation
Scheduled
Shipping /
Receiving
Level Vehicle
Order Schedules
Supply
Chain
Management
Internal
Pull /
Delivery
Simple
Process
Flow
Small Lot
Packaging
Temporary
Material
Storage
Fixed Period
Ordering
System/
Order Parts
Health and
Safety Priority
Qualified People
Team Concept
People
Involvement
Open
Communication
Process
Values
Vision
Shop Floor
Management
Manufacturing
Process
Validation
制造工艺认证
In-Process
Control &
Verification
工艺控制与确认
Quality
System
Management
质量体系管理
Quality
Feedback/
Feed-
forward
质量反馈/前馈Pr
od
uc
t
Q
ua
lit
y
St
an
da
rd
s
产
品
质
量
标
准
Built-In Quality
制造质量
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 3
GMSBuilt-In-Quality
制造质量
u What Is Quality?
什么是质量？
u Group Discussion
小组讨论
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 4
GMS
Definitions 定义
• Quality is what the customer
perceives to be acceptable to
achieve his/her enthusiasm
• 质量是客户感觉能够接受并满足
其热忱的东西
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 5
GMS
Mad Cow 疯牛
(Diseased Meat 病牛肉)
Poor Quality Means Lost Sales
质量差意味着失去客户
Firestone
燧石
(Unintended Accidents)
意外事故
uninstalled shift lock
漏装移位锁定
(Sudden Acceleration)
突然加速
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 6
GMS
P
P
10
0
: Not Reported Due To Insufficient Sample
样品不足不汇报
( )
• . Power IQS Trend By Brand
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 7
GMS
• NCSI By Makers - 2002
2002 제작사별 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
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 8
GMS
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 9
GMS
Voice of Customer 客户意见
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 10
GMS
Voice of Customer客户意见
차 종 만 족 사 항 불 만 족 사 항
마티
즈
1. 停车方便 (Convenience of parking)
2. 外观式样 (Exterior 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)
칼로
스
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. 坐骑 (Ride)
L6
매그너
스
1. 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)
레
조
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 light)
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 Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 11
GMSBuilt-in-Quality
制造质量
• What is Built-In-Quality?
什么是制造质量？
• Group Discussion
小组讨论
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 12
GMSWhat is Built-In Quality?
什么是制造质量？
• Definition 定义
Method by which quality is built into the
manufacturing process, so that defects are
prevented, detected, and countermeasures are
implemented to prevent reoccurrence.
指质量在生产过程中产生，因此可以预防、发现缺陷，
以及采取措施防止缺陷再发生的方法。
• Purpose 意图
Ensures defects are not passed to the customer.
确保不传递缺陷。
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 13
GMS
Designers
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
客户链… 公司远景
Built-In-Quality
制造质量
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 14
GMS
Assembly
总装
Supplier
供应商
Paint
涂装
Body
车身
The Customer Chain. . . Production Perspective
客户链… 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
Built-In-Quality
制造质量
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 15
GMS
Do not
不要
Accept
接受
Build制造
Ship传递
a Defect!
缺陷
Solve Problems Through Teamwork!
团队合作解决问题！
Built-In-Quality Motto
制造质量口号
Satisfy Your Customer…
满足你的客户
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 16
GMS
Quality Through Teamwork – Know Your Customer!
What water leaks?
I don’t see any water leaks
什么漏雨？我没发现漏雨。
This car wasn’t
made on my
shift
The problem is Press
Shop. The flange is too
long.
问题出自冲压，边缘过长
I won’t run any trial until I have an
assembly method from Industrial
Engineering and the manpower.
The problem is that the
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 it’s 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
Don’t run away from the problem!
不要逃避问题!
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 17
GMS
Living up to the Motto. . .
符合口号. . .
- What Is a Defect?
什么是缺陷？
- Group Discussion
小组讨论
Defect 缺陷
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 18
GMS
A defect is a product that does not meet the
established quality standard.
缺陷是不合已定标准的产品。
Measurement of a quality characteristic
质量性能测量
Vehicle #
车辆 号
Upper Specification Limit
规格上限
Lower Specification Limit
规格下限
Q
ua
lit
y
S
ta
nd
ar
d
质
量
标
准
Defect 缺陷
Defect 缺陷
x x
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 19
GMSWhy are defects undesirable?
为什么缺陷不受欢迎？
Defects may also result in …
缺陷还可能导致
High warranty costs 过高保修成本
Lost customer sale 失去客户
Defects Require Correction = Correction is Waste
缺陷需要纠正—纠正就是浪费
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 20
GMS QUALITY IS EVERYONE’S
RESPONSIBILITY
质量是每个人的职责
• Design, Engineering, 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
OUR Goal :
我们的目标：
→ Everyone is a Quality Inspector 人人都是质检员
→ Everyone is a Problem Solver 人人都是问题解决者
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 21
GMS
WHO IS RESPONSIBLE FOR
QUALITY? 谁对质量负责？
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 22
GMS
ME!!!
我！
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 23
GMS
Health and
Safety
Priority Qualified Peop
le
Team Concept
People
Involvement
Open
Communication
Process
Controlled
External
TransportationManufacturing
Process
Validation
In-Process
Control &
Verification Quality
System
Management
Scheduled
Shipping /
Receiving
Level
Vehicle
Order
Schedules
Supply
Chain
Management
Values
Vision/
Mission
Shop Floor
Management
Internal
Pull /
Delivery
Andon
Concept
Problem
Solving
Simple
Process
Flow
Pr
od
uc
t
Q
ua
lit
y
S
ta
nd
ar
ds
Standardized
Work
Small Lot
Packaging
Temporary
Material
Storage
Quality
Feedback/
Feed-
forward
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Early Mfg. and
Design
Integration
(DFM / DFA)
Continuous
Improvement
Process
Lean Design
of Facilities,
Equipment,
Tooling and
Layout
Business Plan
Deployment
Total
Productive
Maintenance
Fixed Period
Ordering
System/
Order Parts
Pr
od
uc
t
Q
ua
lit
y
St
an
da
rd
s
产
品
质
量
标
准
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 24
GMS
Reflect voice
of the customer
反映顾客的心声
Simple, clear
& support user
简单、清晰，
有利操作者
Clearly Measurable
at point of use
在使用上可明确测量
Key Points of Good Quality Standards:Key Points of Good Quality Standards:
质量标准的要点：质量标准的要点：
In user’s Std. Work
& posted visual
在操作者的标准化
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，
也有益于操作工人
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 25
GMS
Not tighter than
those applied at the
previous process
不要比前道工序的更严格
Key Points of Good Quality Standards:Key Points of Good Quality Standards:
质量标准的要点：质量标准的要点：
Final Inspection
Standard:
Gap +/- 1mm
FINAL INSPECTIONBODY
SHOP
Body Shop
Standard:
Gap +/- 2mm
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 26
GMS
Use master parts and
boundary samples as
required to make visual
标准件与边界样件需要目视化
Key Points of Good Quality Standards: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” the defect
is Not a Boundary Sample!
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
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 27
GMSCreate a “Standards-Based” CultureCreate a “Standards-Based” Culture
创造一个以标准为基点的文化氛围创造一个以标准为基点的文化氛围
I
wouldn’
t buy
this!
Doesn’t
look
good to
me!
My
opinio
n is…
This
does not
meet the
standard
..
Talk in terms of The Standard, not opinions!
以标准为基点，而非观点！
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 28
GMS
Manufacturing
Process
Validation Quality
System
Management
Pr
od
uc
t Q
ua
lit
y
St
an
da
rd
s
Quality
Feedback/
Feed-
forward
Standardized
Work
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Andon
Concept
Problem
Solving
Early Mfg. and
Design
Integration
(DFM / DFA)
Continuous
Improvement
Process
Lean Design
of Facilities,
Equipment,
Tooling and
Layout
Business Plan
Deployment
Total
Productive
Maintenance
Controlled
External
Transportation
Scheduled
Shipping /
Receiving
Level Vehicle
Order Schedules Supply
Chain
Management
Internal
Pull /
Delivery
Simple
Process
Flow
Small Lot
Packaging
Temporary
Material
Storage
Fixed Period
Ordering
System/
Order Parts
Health and
Safety Priority
Qualified People Team Concept
People
Involvement
Open
Communication
Process
Values
Vision/
Mission
Shop Floor
Management
In-Process
Control&
Verification
Manufacturing
Process
Validation
制造工序认证
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 29
GMSWhat is a process?
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！
Environment
环境
Process 工序
Man Machines
Method Materials
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 30
GMS
Where can Errors
Occur?
问题会出在哪？
Defects
缺陷
Materials: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
•Poor std. Work 不好
的标准工作
•Lack of Training 缺乏
培训
Machine/Process: 机
器/工序
•No TPM 没有TPM
•Process not capable 工
序不好
•Improper specification
规格不当
Man:人力
•Not follow 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 In
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 31
GMS
Validate the manufacturing process
prior to Start of Production! 在生产启
动前认证制造工艺！
Do not
切勿
Accept 接受
Build 制造
Ship 传递
a Defect!
缺陷！
Living Up to the Motto…
达到口号
“Eliminate the Need for Inspection on a Mass Basis by Building
Quality into the Product in the First Place” - Dr. Deming
PFMEA
Workstation
Readiness
工位准备
Process Control
Plan 工艺控制计划
Error-proofing
Plan
防错计划
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 32
GMS
Error Proofing
Hierarchy 防错层
次
PreventionPrevention
预防预防
DetectionDetection
检测检测
HumanHuman
JudgmentJudgment
人为判断人为判断
NoneNone
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 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 Can’t
Happen
Small
Improvement
小改进
Significant
Improvement
重大改进
Introduction to Error Proofing
防错介绍
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 33
GMS
0
515
10
0
39
6
O
LH
M
5
1020
15
0
15
10
1 2
4
57
8
10
11
5
0
5
15
10 0 3
9
6 OL
HM 5
10
20
15 0 15
10
4
5
78
10
11 5
1 2
Original:
Best:
Visual Control Example
Human Judgment
0
515
10
0
39
6
O
LH
M
5
1020
15
0
15
10
1 2
4
57
8
10
11
5Better:
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 34
GMS
A
B
Example: Vehicle Identification
车辆认证
(Mutilation Cover Color)
(盖板颜色毁损)
Human Judgment 人为判断
Visual Control Example
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 35
GMS
Vertical Plate
垂直板
Battery Post
电池接头
Process Control Example
Detection 检测
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 36
GMS
X
Work Piece 加工件 Work Piece 加工件
Fixture 夹具 Fixture 夹具
Process Control Example
Prevention 预防
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 37
GMS
Product Design Example (Before)
REC << > >> STOP PAUSEREC << > >> STOP PAUSE
REC << > >> STOP PAUSE REC << > >> STOP PAUSE
OLD
DESIGN
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
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 38
GMS
REC << > >> STOP PAUSEREC << > >> STOP PAUSENEW
DESIGN
新设计
Application of Labels on Cassette Decks.门板标签
Can Only Be Installed Correctly!
Product Design Example (After)
Prevention
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 39
GMS
Left Hand
Locator
Tab
Right
Hand
Locator
Tab
Example -- Product Error Proofing
(One Way to Install Seat Belt)
防错样品—只有一种安全带安装方法
Product Design Example 产品设计范例
Prevention
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 40
GMSSimple Everyday
Examples
1) Error Prevention
실수 방지
Automatic shut-off
自动断电
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 41
GMS
Error 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 5
minutes 小组讨论、汇报—5分钟
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 42
GMS
Manufacturing
Process
Validation
Product
Quality
Standards Quality
System
Management
Quality
Feedback/
Feed-
forward
Standardized
Work
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Andon
Concept
Problem
Solving
Early Mfg. and
Design
Integration
(DFM / DFA)
Continuous
Improvement
Process
Lean Design
of Facilities,
Equipment,
Tooling and
Layout
Business Plan
Deployment
Total
Productive
Maintenance
Controlled
External
Transportation
Scheduled
Shipping /
Receiving
Level Vehicle
Order Schedules Supply
Chain
Management
Internal
Pull /
Delivery
Simple
Process
Flow
Small Lot
Packaging
Temporary
Material
Storage
Fixed Period
Ordering
System/
Order Parts
Health and
Safety Priority
Qualified People Team Concept
People
Involvement
Open
Communication
Process
Values
Vision/
Mission
Shop Floor
Management
In-Process
Control &
Verification
工序控制与认证
Pr
od
uc
t Q
ua
lit
y
St
an
da
rd
s
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 43
GMSIn-Process Control & Verification – (3) Elements In-Process Control & Verification – (3) Elements
工序控制与认证工序控制与认证
1. Prevention
Outputs
输出
Inputs
投入
NOK
2. Detection
OK
Next Process
下道工序
Feedback 反馈
Do not
不要
Accept 接受
Build 制造
Ship 传递
a Defect!
缺陷！
Living Up to the Motto…
符合标准
3. Containment
包容
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 44
GMS
1) Standardized
Work 标准化工作
Follow and
Continuously Improve
Standardized Work!!!
遵守及不断
改进标准化工作！！
In-Process Control & Verification – 1) PREVENTION – 1) PREVENTION
Prevention
Vehicle
Manifest
Manual
2-Door
Sunroof
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 45
GMS
2) Focus on
Operation
集中精力生产Keep Your
Concentration &
Respect Standardized
Work of Others!
注意及尊重他人的
标准化工作
In-Process Control & Verification – 1) PREVENTION – 1) PREVENTION
Prevention
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 46
GMS
3) Error Proofing
Prevention
& Operator Aids
防错预防与操作者支持
The Best Process is
One That Cannot Fail!
最好工序就是不会失败的！
In-Process Control & Verification – 1) PREVENTION – 1) PREVENTION
Prevention
DAEWOO
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 47
GMS
4) Regular Checks
of Systems & Processes
定时检查系统与工艺
Std. Work
Checks!
检查标准化工作
In-Process Control & Verification – 1) PREVENTION – 1) PREVENTION
Prevention
CHECK CH
EC
K
??????
?
CHEC
K
Process Control
Checks!
检查工序控制！
TPM
Checks!
检查TPM
Safety/5S
Checks!
检查安全/5S
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 48
GMS
1) Self-Checks
2) 自检
Include Quality Checks
in Standardized Work!
把质检作为标准化工作
的一部分
In-Process Control & VerificationIn-Process Control & Verification – 2) DETECTION – 2) DETECTION
Detection
Check
Methods:
POINT
TOUCH
LISTEN
COUNT
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 49
GMS
2) Error Proofing
Detection
检测防错
Use Visual and
Audio Signals!
使用视觉、
听觉信号！
In-Process Control & VerificationIn-Process Control & Verification – 2) DETECTION – 2) DETECTION
Detection
Stop the Line, or
停线或
Use Alarms, or
使用警报或
Combination of
Both, depending
on Criticality 根
据危险程度兼用
两种方法
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 50
GMS
3) In-Process
Verification
工序认证 Inspectors are not there
as a policeman, they
support production by
confirming the process!
检察员不充当警察角色，
而是作为确定工序的生产支持者
In-Process Control & VerificationIn-Process Control & Verification – 2) DETECTION – 2) DETECTION
Detection
Verificatio
n Stations
Final Line
.
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 51
GMS
3a) Focus on
Critical items
集中注意重大问题
Frequency of checks to
not allow Critical defects
to leave the shop!
经常检查，不让重大缺陷
走出车间！
In-Process Control & VerificationIn-Process Control & Verification – 2) DETECTION – 2) DETECTION
Detection
Safety Items
“Walk-Home”
Items
Major Customer
Dissatisfier
S/C
F/F
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 52
GMS
4) Defect
Escalation
缺陷逐层汇报 Escalate defects to
leadership for support
depending on
frequency and criticality!
根据缺陷出现频率与严重程度
逐层向领导汇报以寻求支持！
In-Process Control & VerificationIn-Process Control & Verification – 2) DETECTION – 2) DETECTION
Detection
Example
:
Team Leader
Section
Leader
Group Leader
2 defects/
1 hour
4 defects/
1 hour
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 53
GMS
1) Use Andon
(taught more
later) 使用暗灯
Make problems visual
& pull in support!
问题直观，
拉线寻求帮助！
In-Process Control & VerificationIn-Process Control & Verification – 3) CONTAINMENT – 3) CONTAINMENT
Always
Remember the
Priorities:一定要
牢记：
1) Safety安全
2) Quality质量
3) Responsiveness
(Throughput)响应
Containment
包容
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 54
GMS
2) Follow
Containment
Process
遵循包容程序
Extraordinary actions
to prevent defects from
being passed!
采取特别行动防止
缺陷传递！
In-Process Control & VerificationIn-Process Control & Verification – 3) CONTAINMENT – 3) CONTAINMENT
Some examples:
1) Stop the line停
线
2) 100% checks
100%检查
3) On-line repair
线上维修
4) Reworks返工
5) Sorting 整理
Containment
包容
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 55
GMSHow Does our Quality Motto relate to Containment?How Does our Quality Motto relate to Containment?
Do not
不要
Accept 接受
Build 制造
Ship 传递
a Defect!
缺陷！
It means empowered leaders make
judgments how to control quality
while trying to keep the line running!!
意味着领导有权作出决定：在尽量不停线的情况下，
怎样控制好质量！
Does this mean we stop the line
every time we have a problem?
这是不是意味着一有问题就停线呢？
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 56
GMSHow Does our Quality Motto relate to Containment?How Does our Quality Motto relate to Containment?
Sometimes the best decision may be to let a defect
pass to the next process, but…有时最好的办法是让差错
转到下工序，但是……
1) It is a conscious decision made by the appropriate level
2) Action must be communicated to next “customer”
3) Defect must be clearly identified on vehicle
4) Containment must be in place to prevent further defects
Examples of Some Andon Guidelines: 暗灯使用的指导
方针
1) Will the problem affect the next process? 问题会不
会影响下道工序？
2) Can I effectively repair the defect out of station?
能不能在工位外有效解决问题？
3) What is the status of my decouplers? 自己的切断器
是什么状态？
4) Others… 其他……
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 57
GMS
Andon Discussion
– Hoods Situation: At the Body Shop end-of-line Quality station it is discovered that there is a problem
with cracked hoods. After working the line back we know that every car in the
system has the condition all the way to Hood Install. After sorting the raw hoods, it
is found that there are enough good hoods to keep producing cars, however there
are not enough good hoods to repair the defective cars on-line. The suppler says
new hoods will arrive in 6 hours. The operators at end of line have pulled the Andon
and the escalation process has pulled in the Body Shop Manager and Quality
Manager. Considerations are: 1) The decoupler between Body and Paint is almost
empty, 2) Hoods with cracked metal will not affect any of the subsequent processes,
and 3) Hoods can be changed out of station relatively easily.
Discussion:
You are the Plant Quality Manager – what is your decision?
Discuss as a group!
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 58
GMS
Background: In this case, the decision is is shut down the line for (6) hours and wait
for parts or run the line and make a containment plan. Since the decoupler between
Body and Paint is almost empty, this means all Body, Paint and GA will all eventually
shut down.
Potential Decision: In this case, Quality can still be achieved while maintaining our
Responsiveness targets mostly because the hoods do not affect the next process.
The Cost of stopping the line will not result in better Quality or Responsiveness. Thus,
a good decision would probably be to run the line and make a containment plan:
• All cars with bad hoods to be specially identified. Production and Quality in Paint and
GA notified of the situation, know the vehicle numbers and identification method.
•100% check at Hood Install operation until process capability is assured.
• Paint and Final Process notified that new hoods to be painted in Paint and will be
swapped in Final Process area and have time to make a plan how to accommodate
that.
Andon Discussion - Hoods
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 59
GMS
Situation:
At the Cockpit Load station in GA it is discovered that there is a problem with one of
the electrical harnesses within the cockpit. The cockpits are built as a module by an
outside supplier. After working the line back we know that several cockpits in the
system have the condition. The operators at Cockpit Load have pulled the Andon
and the escalation process has pulled in the Trim Line Section Leader, who consults
with the Chassis Line Section Leader. Considerations are: 1) The decoupler
between Trim and Chassis about half full, 2) The electrical harness will affect the
next assembly process, 3) Repairing the harnesses on-line will take approximately
one hour, and 4) Repairing the Cockpit later in the process is difficult and very time
consuming.
Discussion:
You are the Trim Section Leader – what is your decision?
Discuss as a group!
Andon Discussion - Cockpits
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 60
GMS
Background: In this case, the decision is is shut down the line for (1) hour and repair
the harnesses prior to Cockpit Load or run the line and repair the cockpits out-of-
station. Since the decoupler between Trim and Chassis is about half full, this means
that Chassis can continue running for a short while and then eventually shut down.
Potential Decision: In this case, Quality cannot be achieved while maintaining our
Responsiveness targets mostly because the bad cockpits affect the next process and
are extremely difficult to repair later. The Cost of stopping the line is more desirable
than the cost of repairing them later and the potential to create more defects. In this
case, the decoupler status does not really impact the final decision too much. Thus, a
good decision would probably be to stop the line and fix the harnesses prior to Cockpit
Install. The Trim Line Section Leader will inform the GA Area Manager of this decision
and the impact on our Responsiveness target.
Andon Discussion - Cockpits
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 61
GMS
Manufacturing
Process
Validation Quality
System
Management
Quality
Feedback/
Feed-
forward
Standardized
Work
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Andon
Concept
Problem
Solving
Early Mfg. and
Design
Integration
(DFM / DFA)
Continuous
Improvement
Process
Lean Design
of Facilities,
Equipment,
Tooling and
Layout
Business Plan
Deployment
Total
Productive
Maintenance
Controlled
External
Transportation
Scheduled
Shipping /
Receiving
Level Vehicle
Order Schedules Supply
Chain
Management
Internal
Pull /
Delivery
Simple
Process
Flow
Small Lot
Packaging
Temporary
Material
Storage
Fixed Period
Ordering
System/
Order Parts
Health and
Safety Priority
Qualified People Team Concept
People
Involvement
Open
Communication
Process
Values
Vision
Shop Floor
Management
Quality
Feedback/
Feedforward
质量反馈与前馈
Pr
od
uc
t Q
ua
lit
y
St
an
da
rd
s
In-Process
Control&
Verification
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 62
GMS
“Customer”
客户
Quality Information Quality Information
Feedback/FeedforwardFeedback/Feedforward
质量反馈与前馈质量反馈与前馈
“Suppliers”
供应商
You
你
Process A Process B Process C
• Defect flowing from A to B
缺陷从A流到B
• Status on Problem Resolution
问题解决状态
• Escaped defect flowing to Process C
避免缺陷流到C
• Temporary process being used in Process B
过程B的暂时方案
• Process/product change with time
工艺/产品随时间改变
• Status on Problem Resolution
问题解决状态
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 63
GMS
Motivation for Timely FeedbackMotivation for Timely Feedback
及时反馈的动机及时反馈的动机
Immediate 1 Day 1 Year High Medium Low 1s 100s 1000s
Time to Discover Defect
发现缺陷的时间
Ability to Discover
Root Cause
发现根源的能力
Number of Defective
Vehicles Built
已经生产的缺陷产品
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 64
GMS
Example -- Daily Reporting Metrics (Direct Run)Example -- Daily Reporting Metrics (Direct Run)
每天汇报制度每天汇报制度
Definition
u Percentage of vehicles that made it through to the End-of-Line inspection processes with no
defects. This is a common, global metric that is computed daily by all Assembly Plants.
下线检查合格的车辆百分比，这是全球统一在所有总装厂每天用电脑记录的制度。
Final Inspection
(End-of-Line)
下线检测
Dynamic
Vehicle Test
or equivalent
动态测试
Other 100%
Inspections **
其他10%检测
( Check)
Total Direct Run = ( 92% * 98% * 96% * 99%)
= 86% vehicles with no defect
Repair
CARE Line
# of first time vehicles with at least
one defect
至少有一个缺陷的第一次认证
80 20 40 10
% First Time Quality 一次质量
认证百分比
92% 98% 96% 99%
Total first time vehicles through
the station on a given day
在特定时间工位的第一次认证 1000 1000 1000 1000
Repair Repair Repair
** 100% Water Test and 100% Squeak
and Rattle Test results are not currently
(3/2000) included in Direct Run
** 100%的漏雨测试与异响测试并不包含在
Direct Run
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 65
GMS
Manufacturing
Process
Validation Quality
System
Management
Quality
Feedback/
Feed-
forward
Standardized
Work
Visual
Management
Management
by TAKT
Time
Work-
place
Organization
Andon
Concept
Problem
Solving
Early Mfg. and
Design
Integration
(DFM / DFA)
Continuous
Improvement
Process
Lean Design
of Facilities,
Equipment,
Tooling and
Layout
Business Plan
Deployment
Total
Productive
Maintenance
Controlled
External
Transportation
Scheduled
Shipping /
Receiving
Level Vehicle
Order Schedules Supply
Chain
Management
Internal
Pull /
Delivery
Simple
Process
Flow
Small Lot
Packaging
Temporary
Material
Storage
Fixed Period
Ordering
System/
Order Parts
Health and
Safety Priority Qualified People Team Concept
People
Involvement
Open
Communication
Process
Values
Vision
Shop Floor
Management
Quality
System
Management
质量体系管理
Pr
od
uc
t Q
ua
lit
y
St
an
da
rd
s
In-Process
Control&
Verification
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 66
GMS
GMS
Operating
Standards +
Corporate Quality
Procedures
Assembly Plant
Procedures
Work Instructions
Records and Other Documentation
IS
O
P
la
nt
Q
ua
lit
y
M
an
ua
l
IS
O
工
厂
质
量
手
册
Quality System 质量体系
GMS
制造标准+公司质
量程序
总装工厂程序
工作指导
记录及其他文
件
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 67
GMSQuality System Model Quality System Model
Don’t
a defect
Accept
Build
Ship
MANUFACTURING AREA QUALITY DPT. CUSTOMER
Production
Production
Quality
Control
SIP
Standardized
Inspection
Process
DIQS/
GCA
Continuous Improvements Feedback
Responsible for producing first time quality •Confirm process and product.
•Provide technical support.
•Support problem resolution.
Expectation
GDS
IPTV
JDP
etc.
Process Standard
(Standardized Work)
Product Quality
Standards
(CVIS)
DAILY MANAGEMENT & MANAGEMENT BY BUSINESS PLAN DEPLOYMENTDAILY MANAGEMENT & MANAGEMENT BY BUSINESS PLAN DEPLOYMENT
Principle:
GMS Orientation
Built-in quality
GMDAT/DIMC Confidential
Version Date
Slide 68
GMS
质量体系样式质量体系样式
不
缺陷!
接收
制造
传递
生产部门 质量部门 顾客
生产 生产质量控制
SIP
标准检测程序 DIQS/
GCA
CIP
Feedback
负责首次质量检查 •确定工艺及产品
•提供技术支持
•帮助解决问题
期望
GDS
IPTV
JDP
etc.
工艺标准
（标准化操作）
生产质量标准
CVIS
业务计划实施的日常管理与维护业务计划实施的日常管理与维护
原则:
THANKS
