General Motors Globális Gyártási Rendszer General Motors Global Manufacturing System

1. General MotorsGlobális Gyártási RendszerGeneral Motors Global Manufacturing System General Motors Powertrain – Magyarország Kft. Dátum: 2008. Április 16 Előadó: Kovács János Minőségügyi Igazgató

2. Cél: Minőségügyi alapelvek alkalmazásának bemutatása a GM Globális Gyártási Rendszer ismertetésén keresztül • Első előadás témái: • A vevő fogalma, vevői elégedettség • Termékminőségi követelmények • Termelési folyamat jóváhagyás • Második előadás témái: • Folyamatközi ellenőrzés és folyamat igazolás • Minőség visszajelzés - előrejelzés rendszere • Minőségirányítási rendszer

3. Globális Gyártási Rendszer General Motors-Global Manufacturing System

5. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • The GMS element “In-Process Control & Verification” • incorporates the intent and purpose of the BIQ motto: • Quality expectations are achieved in each process to ensure • defects are not passed on to downstream process.

6. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) Customer satisfaction achievement • Customer satisfaction is achieved through three sub-elements: • Prevention:avoid defects or non-standards occurring • Detection:identify when defects or non-standards have occurred • Containment:assure defects or non-standards are not passed on

7. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Benefits • To External customers (people buying our vehicle). • Protect Customers from sub-standard vehicle quality. • Assure customer satisfaction • To Internal customer (downstream operation). • Prevent major repair and rework by detecting a non-conformity early in the process. • Prevent the flow of defects from department to department and station to station • To Internal customer (from supplier). • Protect Team Members from non-compliant parts from suppliers through advanced quality planning and prompt containment during spills.

8. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification)

9. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Process Equipment Capability Reviews (Prevention) • Periodic checks (typically monthly), are conducted to identify trends orshifts in capability over periods of time. • 1. Identify processequipment withhighrisk/impact • 2. Conduct initial capabilityconfirmation • 3. Conduct regularscheduled reviews toconfirm capability • 4.Implementcorrectiveaction asrequired

10. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Detection • Purpose of Detection: • To make non-standard conditions in the manufacturingprocessvisible - identify when defects or non-standardshave occurred. • This supports the “Do Not Accept”element of the quality motto: • inspection process that confirms quality assoon as possible following manufacture • measures the output of the manufacturingprocess • alerts organization to out of standardconditions • supports containment and provides inputinto continuousimprovement

11. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Quality Check System Update • Internal/external ‘Customers’ are monitored for feedback: • Where there is an indication of defect flow-out through the Verification • process, a systematic analysis will be conducted; typically for:

12. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Inspection Frequencies of Critical Operations • The quality check system must be established in consideration of the‘Supplier-Customer’ relationship. • Inspection frequencies must be established by each‘supplier’ that prevent shipping defects to downstream‘customers’. • This is a requirement for safety & compliance items, key characteristics • and for issues that will significantly impact the next process or customer.

13. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Independent Repair Confirmation • During a repair, the risk for • a discrepancy to occur is • increased - many aspects of • the repair operation are • non-standard: • Any documented repair must be verified by Repair Confirmation(both on- and off-line) • Repair Confirmation must be conducted independently (e.g. by Quality). • Standardized work (non-cyclic) should be used for the confirmation • process – quality standards must be available. • Appropriate training and knowledge of standards must be developed to • conduct or confirm repairs. • Repair confirmation should be as close to the repair process as possible. • Repair confirmation can be conducted by man or machine.

14. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) Team has the ability to stop the line and complete standardized work in station. • Using Andon To Stop The Process: Work Station If the Team Member has a quality issue within their standardized work they activate the Andon system to: • initiate a call for help through station light, Andon board, and melody • empower the Team Member to stop line & organization responds toprovide support • stop at FPS (Fixed Position Stop) to contain and complete the repair • where Andon is not available the principles still apply

15. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Alarm & Escalation Processes • When a defect is detected, feedback to the • appropriate team or individual will be given • by using a communication system. • The alarm is raised by using audio/visual • signals (e.g. Andon). • The alarm process directs the support • functions to: • ‘Go and See’ the problem • Apply containment to prevent furtherflow of defects • Initiate problem solving

16. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Purpose of Containment: • •The achievement of customer expectations relies on a method to containdefects within the manufacturing process, and implementcorrections toprotect the next/downstream customer. • •This supports the “Do Not Ship” element of thequality motto: • Containment • vehicle delivery to the customer • Powertrain and MFD plants to vehicleassembly • external supplier to themanufacturing plant • internal departments (e.g. between body,paint and GA) • between work stations within a department

17. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Containment Process Overview

18. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) • Summary • Standardized work is performed in every process and includesthe required quality checks. • Process control activities are implemented on equipment tocontrol variation on a daily basis and maintain capability overa period of time. • Detection confirms the manufacturing process and ensuresboth internal (Production Team Members) and ExternalCustomers (people who buy our products) are receivingproducts that meet or exceed the quality standards. • A process is in place to contain defects within themanufacturing process and implement permanent correctiveactions that are verified as being effective.

19. Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis) Purpose of this procedure: Investigation, documentation andif necessary reduction of the riskpotential (Risk Priority Number-RPN) for all productionprocesses • RISKPRIORITYNUMBER • S x O x D = RPN • S = Severity • O = Occurrence • D = Detection • RPN = Risk Priority Number* * 1 = Lowest 1000 = Highest

20. Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis) • Potential failure mode: What things have gone wrong ?What things could go wrong ? • Effects of failure: What does a failure mean to the next operation,the assy plant, the final customer? • Potential Cause of failure:Root cause what has gone wrong in the past Brainstorm what could cause failures? • Current controls: What do we do today to prevent the defect fromoccurring and getting to our customer ? • Recommended actions: If current controls are not 100% effective, whatactions should be taken ?

21. Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis)

22. Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis)

23. Potential Effects of Failure Current Process Controls • RPN • Process Function and Requirements • Potential Failure • Mode • Potential Cause Mechanism of Failure • SEVERITY • OCCURANCE • DETECTION • PREVENTION • DETECTION Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis) A practical example – „with user friendly logistic solution „ Function:Drink cold beer Requirement:Satisfy thirst Dehydration 5 Daily inventory (layered audit) 60 1 Automatic restocking system 6 Not enough available Stillthirsty 8 Random Sampling - visualinspection 160 Thermostatically controlled environment -a.k.a. refrigerator Temperature too high 2 Increased irritability 10 3 4 120 Remove people who don’t like my favorite brand of beer from invitation list Wrong brand Registered complaints - Warning

24. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) • Definition • The communication of quality expectations and resultsbetween customers and suppliers through standardizedcommunication pathways. • Purpose: • To ensure that information on quality reaches thosewho need it.

25. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) • Feed Information Forward • Internal and external suppliers communicateknown/potential problems and/or problem solving status totheir customers in a timely manner. • This provides the customer with sufficient lead time to reactto upcoming changes and take appropriate measures.

26. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) • Feed Information Back • Internal and external customers communicateknown/potential problems and/or problem solving resolutionto their suppliers in a timely manner. This provides thesupplier with sufficient lead time to react to customer issuesand take appropriate measures.

27. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) • Build and quality status of each vehicle is communicated todownstream processes. • Example: Inspection Ticket

28. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) • Summary • Feedback/Feedforward promotes the communication ofquality expectations and results between customers andsuppliers through: •Clearly defining customer/supplier communicationrequirements •Defining timing, content, and format of information •Establishing metrics and the subsequent management process •Effective implementation of the Feedback/Feedforwardcommunication tools •Problem identification, input into the plant problem solvingprocess and countermeasure follow up

29. Minőségirányítási rendszer(Quality System Management) • Who is responsible for Quality? • • Team work is absolutely essential to deliver world-classquality. Everyone! Quality is a shared responsibility

30. Minőségirányítási rendszer(Quality System Management) • Quality Function Resource Allocation • Manufacturing and quality resources are allocated to support the quality system and interface with engineering. Each area requires sufficient resources to properly focus on supporting production and driving continuous improvement through P-D-C-A.

31. Minőségirányítási rendszer(Quality System Management) • Resource allocation needs to consider the quality andproduction components that are required to support the teammember. • Quality Function Resource Allocation

32. Minőségirányítási rendszer(Quality System Management) • Role of the Functions Within the Plant Quality Department

33. Minőségirányítási rendszer(Quality System Management) • Quality System Management provides the supportingstructure and framework for the implementation of thequality system and ongoing improvement to the quality ofour products through: • Summary • •Establishment and implementation of a strategic quality planfor the organization • •Allocation of manufacturing and quality resources to supportthe quality plan • •Development of an organization for quality that incorporatesthe “Planning”, “Doing” and “Checking” functions into theirstructure • •Identification of requirements for documentation, procedures,practices and assessments • •Integration of both quality and manufacturing BPD’s at alllevels of the organization

34. Folyamatközi ellenőrzés és folyamat igazolás(In-Process Control and Verification) Ellenőrző kérdések: • Mi a beépített minőségi előírások jelmondat? (What is the motto of the BIQ?) • Mi az a három alapelv amivel ki lehet vívni a vevői elégedettséget? (What is the three principle wherewith you can achieve the costumer satisfaction?) • Miknek a folyamatos ellenőrzésével és milyen módon lehet a hiba előfordulásának megelőzését támogatni? (What monitoring and what way can you support the prevention with?) • Mire használják az Andon rendszert, és mi történik a működtetésekor? (What is the Andon system for and what happen when it is activated?)

35. Kockázatelemzési és hiba-megelőzési módszer, PFMEA (Process Failure and Effect Analysis) Ellenőrző kérdések: • Mi a PFMEA és mit támogat a quality jelmondatban? (What is the PFMEA and what supports in the quality motto?) • Mit jelent a súlyosság az RPN szám meghatározásánál? (What is the severity at the calculation of the RPN number?)

36. Minőség visszajelzés - előrejelzés rendszere(Quality Feedback/Feedforward) Ellenőrző kérdések: • Mi a meghatározása a minőség visszajelzés-előrejelzés rendszerének? (What is the definition of the Quality Feedback/Feedforward system?) • Milyen információkat kell továbbítania a szállítónak a vevő felé? (What information have to be forwarded to the costumer by supplyer?) • Milyen információkat továbbít a vevő a szállító felé? (What information is forwarded back to the supplier?)

37. Minőségirányítási rendszer(Quality System Management) Ellenőrző kérdések: • Milyen fő funkciók vannak a Quality osztályon belül a GMS szerint? (What functions are there in the Quality Department according to the GMS?) • Mi a „Quality Engineering” feladata? (What is Quality Engineering responsible for?) • Mi a „Quality Confirmation” feladata? (What is Quality Confirmation responsible for?) • Mi a „Quality Assurance” feladata? (What is Quality Assurance responsible for?)

38. Köszönöm a figyelmet! • Thank you for your attention!