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BIQS Presentation 2017.pdf

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BIQS PRESENTATION 2017
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| August 17, 2017 Hutchinson Antivibration Systems Direct Ship Suppliers BIQS Training 1:30 P.M. Welcome and Opening Remarks ?Introductions – Purchasing Team ?Quality Team ?Safety & Facilities Information ?BIQS Training Presentation ?Sections 30, 1,8, 9, 10, 11 ?Sections 2, 3, 4, 19, 20, 21 ?Sections 5, 6, 14, 22, 24, 26 ?Break – 20 minutes ?Sections 12,13, 25, 27, 28, 29 ?Sections 7, 15, 16, 17, 18, 23 4:45 P.M. Closing Remarks - Next steps | What is BIQS ? BIQS is a Guideline established by General Motors: ?Built in Quality Supply ?Promotes Zero Defects through controls in manufacturing ?Uses the Elements of the ISO 9001and IATF ?Integrates GM Customer Specific Requirements ?All Suppliers of Materials shipped to GM will be audited ?Minimum score of 75 % is required in 2017 ?Score good for three years ?Presentation will be made available after the presentation. | BIQS Operating Guideline | The BIQS has 30 elements in the audit Comprehensive measurement of the of your quality system and your ability to mange the manufacturing and delivery of product to the Automotive OEMs BIQS 30 Elements | BIQS strategy #1 - Utilize a layered audit process that includes identifying frequency, schedule, findings, and corrective action. BIQS Strategy #2 – Analyze the risk for all operations using Process-FMEA and Process-FMEA methodology BIQS Strategy #3 – Implement a fast response, problem solving process with daily monitoring **Three Key GM BIQS Controls Every Organization Should Implement | BIQS Operating Guideline BIQS - 30 (Safety) | BIQS-30 Safety The Organization is focused on safety. Work place is safe. Safety rules are addressed in work instructions, including PPE. Systems are in place to reduce safety risks and communicate/address safety concerns. Safety issues/concerns are tracked, reviewed, and addressed. *BIQS 30 is not used to calculate BIQS level scoring. **Select all safety concerns (below) that are observed during audit. These concerns can be selected (all that apply) when uploading the audit into SCMS. No Safety Process In Place? Safety issues/concerns are not communicated? Corrective actions are not taken to address safety concerns? Safety knowledge and actions are not read across within site and corporation? Lock out/ Tag out is not followed? Machinery Safety guards are off and machine is running? Slip/Trip hazards (Oil/coolant in the floor)? Air quality is poor (Mist/fog/odor)? Vehicle traffic concerns? Parking lot safety concerns (ice, trip hazards)? Personal protective equipment (PPE) is not available or not used? Fire hazards (weld flash/spark/molten metal)? Overhead hazard concerns? Crush hazard concerns? Pinch point hazards concerns? No issues found? HAVS Response 1. SPL 071 - Health & Safety Program 2. Safety Alert System, iQRQC 3. iQRQC details safety actions and resolutions 4. SPL 071 - Health & Safety Program. Safety Alerts cascaded worldwide throughout Hutchinson, and are assessed for applicability and pertinence at each site. 5. GWI 0918 - Hazardous Energy Lock Out 6. As evidenced by observation of safety equipment an operations at the cell. 7. GEWI 403 - Spill Kit Usage & Maintenance, spill drills 8. RTO and regular filter changes, monitoring and reduction of VOC's 9. PL 080 - Safe Driving 10. As per observation during walkthrough 11. Vests, steel-toe shoes, permanent side shielded eye protection, ear protection, bump caps, helmets, etc. 12. Non-sparking tool requirement in cementing, fire safety drills 13. Bump caps / helmets mandatory at Mixer 14. Like curtains and keys for entry into robotic cells 15. To be observed during work cell operations review 16. To be observed during walk-through | BIQS Operating Guideline BIQS - 1 (Nonconforming Material/Material Identification) | Scope: ? All Material inside the facility . BIQS – 1 Nonconforming Material /Material Identification Definition: ? Standardized process of identification of all material in the plant including traceability rule and Segregate Nonconforming material from good material . Purpose: ? Minimize risk of sending NC parts, incomplete parts and mixed parts to customer BIQS -1 Nonconforming Material / Material Identification Team members have standardized work and understand what to do with non conforming / suspect material. Conforming material is handled, stored and identified appropriately. Non conforming / suspect material is clearly identified and/or segregated for review/disposition (i.e. appropriate color coding for foot printing – red, yellow, green). A containment method is in place to ensure that an effective breakpoint has been established. Containment activities and results are documented. Traceability is applied according to the traceability methods of the finished product , and reworked parts when needed . Sample audit to verify that team members understand what to do with nonconforming / suspect material. Confirm that conforming material is handled, stored and identified appropriately. Confirm that nonconforming / suspect material is clearly identified and/or segregated. Red, Yellow, Green stoplight approach is adhered to for foot printing, containerization, table marking and tagging. Audit that all parts removed from the process are identified, accounted for (FTQ), and reconciled to eliminate mishandling of material. Verify use of Department Containment Worksheets, with potential parts locations by operation identified to ensure no parts are missed during a containment and all parts are reconciled. The containment worksheets must cover from the incoming material, process and shipment. Scrap or Suspect parts/containers clearly segregated from other Y * Suppluier has containment sheet form covering all locations but not used ( Review Page one ) - Supplier use red tab to identify NC parts - then segregate them in red bins acrros the stations - Red tabbing before segregation in red bins are not used - There is risk of mixing bad parts in the transition period between rejecting the part and segregate them in red bin . ( checked for Gp12 rejection bin was not taped and also same for test board table ) . Supplier has good tracibility system in place . All parts from crimping process till final product are identifed using dates , lot number . Nonconforming Material / Material Identification| BIQS – 1 Nonconforming Material /Material Identification A)Identification ? Identify Good and NC Material in all steps ? WI for Identification process B)Segregation ? Containment process & Worksheet ? Segregation of NC material ? Record NC C)Traceability ? Follow Traceability rules A) Identification Standardized Work | A) Identification Good Material identified by green tag BIQS – 1 Nonconforming Material /Material Identification NC material identified and segregated Suspected material for containment is segregated 1st Hour 2nd Hour 3rd Hour 4th Hour 5th Hour 6th Hour 7th Hour 8th Hour # Defects VS Alarm 6:00-7:00 7:00-8:00 8:00-9:00 9:00-10:00 10:00-11:00 12:00-1:00 1:00-2:00 2:00-3:00 Total Trigger # 4:00-5:00 5:00-6:00 6:00-7:00 7:00-8:00 8:00-9:00 11:00-12:00 12:00-1:00 1:00-2:00 1 Scratches 6 ll l ll 5 2 Bolt Reject 1 l l 2 3 Lash Reject 4 ll l 3 4 Crank Torque 5 ll lll l 6Trigger an Alarm! 2nd Alarm is Escalated! NC Material Is recorded | B) Containment QUALITY ISSUE # FAST RESPONSE PROCESS USED DEPT CONTAINMENT WORKSHEET USED QUALITY ALERT POSTED ADDED TO CARE / GP12 PROBLEM SOLVING FORM COMPLETE ADDED TO LAYERED AUDIT CORRECTIVE ACTION EFFECTIVENESS MONITORED ERROR PROOFED ERROR PROOFING VERIFICATION COMPLETE FMEA UPDATED CONTROL PLAN UPDATED STANDARDIZED WORK UPDATED TRAINING COMPLETED GENERAL AREA TAGGING / NC MATL SEGREGATION ENGINEERING CHANGE REQUEST / PROCESS CHANGE REQUEST PTR CONDUCTED READ ACROSS TO SIMILAR LINES / PROCESSES CHANCES OF RECURRENCE ISSUE DESCRIPTION 841222( 10/12/1 6) O O O O O O O NA NA O X O Check O X X O L Missing Bracket Internal Issue (Jan5th - 16) O O O O O NA O NA NA O O O Check O X X O L Wrong Oreientation 843867 ( Oct 20, 2016) O O O O Auditor checks this PRR to make sure that prcoess of FR is used and found that it is enough from above that FR process is used with some fine tuning ( Review BIQS -8 Comment in page 2) BIQS – 1 Nonconforming Material/Material Identification Containment work sheet done at least for fast response issues - Break point is identified . | C) Traceability BIQS – 1 Nonconforming Material /Material Identification Vehicle Counts 2,000 244,892 36,754 0 50,000 100,000 150,000 200,000 250,000 300,000 count of vehicles potentially affected vehicle count using available trace vehicles with actual bad parts (better trace)| BIQS Operating Guideline BIQS Element 8 – Fast Response Problem Solving | BIQS - 8 Fast Response Problem Solving Process Definition: ? Systematic approach to act fast for quality issues using standardized exit criteria . Scope: ? All customer issues ( Formal /informal ) and key internal issues . Purpose: ? Ensures that quality issues are immediately addressed and closed using standardized approach and avoid reoccurrence . | Input * Create Fast response (FR) process to address external and key internal issues . Process * Identify meeting time , attendee , leader (plant manager) * Identify issue exit criteria * Identify issue owner Output * All customer and key internal issues are communicated . * All issues closed against standardized documented exit criteria BIQS –8 Fast Response Process QUALITY ISSUE # FAST RESPONSE PROCESS USED DEPT CONTAINMENT WORKSHEET USED QUALITY ALERT POSTED ADDED TO CARE / GP12 PROBLEM SOLVING FORM COMPLETE ADDED TO LAYERED AUDIT CORRECTIVE ACTION EFFECTIVENESS MONITORED ERROR PROOFED ERROR PROOFING VERIFICATION COMPLETE FMEA UPDATED CONTROL PLAN UPDATED STANDARDIZED WORK UPDATED TRAINING COMPLETED GENERAL AREA TAGGING / NC MATL SEGREGATION ENGINEERING CHANGE REQUEST / PROCESS CHANGE REQUEST PTR CONDUCTED READ ACROSS TO SIMILAR LINES / PROCESSES CHANCES OF RECURRENCE ISSUE DESCRIPTION| What to Look For: ? Verify the Fast Response process is used for all significant quality issues (customer/visual inspection station/GP-12). ? Review the board for the log file and select 3 closed problems to check how they are closed (evaluate fast response problems on pg 1 of the BIQS audit). ? Confirm the Plant Management ensures the applicability and the timely completion of the items being tracked. ? Confirm the plant staff level personnel actively participate in daily meeting and confirm that natural owner is assigned for FR issues. ? Verify the required documents are reviewed and updated (e.g. Fast Response tracking sheet, problem solving document, PFMEA, process control plan, standardized work, layered audits, lessons learned, etc.) ? Confirm there is read across of corrective actions to like operations. BIQS - 8 Fast Response Problem Solving Process | BIQS - 8 Fast Response Problem Solving Process Fast Response Daily Meetings: | BIQS - 8 Fast Response Problem Solving Process Minimum Criteria for Initiating Fast Response is Being Met: | BIQS - 8 Fast Response Problem Solving Process Plant manager ensures the applicability and the timely completion of the items being tracked: | BIQS - 8 Fast Response Problem Solving Process Fast Response Board Example: | BIQS - 8 Fast Response Problem Solving Process 24 H 7 D 34 D 40 D Containment - Breakpoint - Quality Alert Root Cause Identified Corrective Action Implemented Error Proof/Detection Layered Process Audits Corrective Action Validated PFMEA / CP Updated Standard Work Operator Instructions Lessons Learned (Institutionalized) 14 D Target Timing, Status, & Date Green 35 D Exit Criteria with Appropriate Timing are Defined for Closing Issues. | BIQS - 8 Fast Response Problem Solving Process SYMBOL & STATUS KEY: SUPPLIER: O Name: X Location: N/A Duns: Contact Name: Completed & Supplier verified only Contact Phone:E-mail: PProduct / Process Classification Line 1 Line 2 Line 3 Press 1 Press 2 Press 3 Cell 1 Cell 2 Cell 3 Tier 2 Tier 3 Tier 4 Part Name & Number GM Plant N/C or CPV CS Status PRR Number / Issue Containment Cause of Failure Mode Corrective Action Prevent Corrective Action Protect Corrective Action Predict Corrective Action Key Findings Corrective Action Documentation Updated Corrective Action EFFECT OF FAILURE MODE Tiered Supplier DDW Completion& Verification Champion 1 Symbols Duns Not Applicable Completed & 3rd Party/GM verified Not Completed Pass Through Original location Location with similar process DRILL WIDE MATRIX (Ref. GM 1927-69 Drill Wide Matrix) FAILURE MODE There is read across of corrective actions to like operations: A Process Failure Alert must be used to “read across” to other facilities and engineering for preventive measures when a product quality issue (mfg. controllable): is missed by first line of error detection, a Preventive Action Letter (PAL) letter is issued, a Process Control Plan not followed has escaped the control of the plant or a significant process failure occurs(e.g. safety, regulatory, statutory, etc.). A PFA may also be used to communicate a significant process improvement. The receiving plant(s) must implement preventive measures communicated through the PFA.| BIQS - 8 Fast Response Problem Solving Process What goes wrong? | BIQS –8 Fast Response Process QUALITY ISSUE # FAST RESPONSE PROCESS USED DEPT CONTAINMENT WORKSHEET USED QUALITY ALERT POSTED ADDED TO CARE / GP12 PROBLEM SOLVING FORM COMPLETE ADDED TO LAYERED AUDIT CORRECTIVE ACTION EFFECTIVENESS MONITORED ERROR PROOFED ERROR PROOFING VERIFICATION COMPLETE FMEA UPDATED CONTROL PLAN UPDATED STANDARDIZED WORK UPDATED TRAINING COMPLETED GENERAL AREA TAGGING / NC MATL SEGREGATION ENGINEERING CHANGE REQUEST / PROCESS CHANGE REQUEST PTR CONDUCTED READ ACROSS TO SIMILAR LINES / PROCESSES CHANCES OF RECURRENCE ISSUE DESCRIPTION 834719 ( Aug,26) O O (need to add Storage in other location O X O X X NA NA O O X X O NA NA O M Wrong Part Number shipped 17-026( Feb-10- 17) O O O O X X X X X X X X X X X X X Deep line around coil during cold colling process QUALITY ISSUE # FAST RESPONSE PROCESS USED DEPT CONTAINMENT WORKSHEET USED QUALITY ALERT POSTED ADDED TO CARE / GP12 PROBLEM SOLVING FORM COMPLETE ADDED TO LAYERED AUDIT CORRECTIVE ACTION EFFECTIVENESS MONITORED ERROR PROOFED ERROR PROOFING VERIFICATION COMPLETE FMEA UPDATED CONTROL PLAN UPDATED STANDARDIZED WORK UPDATED TRAINING COMPLETED GENERAL AREA TAGGING / NC MATL SEGREGATION ENGINEERING CHANGE REQUEST / PROCESS CHANGE REQUEST PTR CONDUCTED READ ACROSS TO SIMILAR LINES / PROCESSES CHANCES OF RECURRENCE ISSUE DESCRIPTION 841222( 10/12/1 6) O O O O O O O NA NA O O O Check O O O O L Missing
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