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BIQS-供应商BIQ策略 中文版.pdf

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BIQS 供应商 BIQ 策略 中文版
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Built In Quality Supply-based BIQS-供应商BIQ策略 定义:通过控制制造过程质量实现不制造、不流出缺陷。 高丽娟 lijuan.gao@gm.com GM China SQ1/11/2018 Maturity of Predictable Quality Processes Quality Results Quality System Basics (QSB) Quality System Basics Plus (QSB+) 2013-2015 2015- XXXX Built in Quality Supply-based (BIQ-S) PPTH PPM IpB Severity Common Quality System Implementation Journey Why we changeEnhance QSB certification requirements - formally align to GM internal GMS BIQ standard - include performance thresholds and monitoring. ? Change to a Systems Based Audit ? Align Audit with BIQ ? Add Metrics similar to BIQ Previous QSB+ QSB+ has 11 Elements, the supplier must achieve 85% compliance to event based audit. ? Audit is conducted every 3 years Supplier Metrics ? Quality PRRs ? Plant Disruptions ? Field Actions ? Severity Score Current BIQS Align QSB+ to BIQ ? 1) Reduce audit variation 2) Provide Solid Data to allow our Leadership to make good sourcing decisions 3) Use a proven Best Practice to drive our suppliers to the next level in Quality 1/11/2018 Why we change4 BIQ迁移图-质量文化的改变,从探测/遏制缺陷到预防缺陷的发生 1.提升制造过程 质量,从缺陷的 探测/遏制到预防 缺陷的发生 2.通过提升制造 过程质量,减少 检查和纠正的投 入,降低整体质 量成本。 ? 质量控制从以质量部门为核心转变到以制造部门为核心。 ? 通过公司各部门如产品工程,制造工程和供应商质量的大力支持来提升制造质量。 Why we change2016年BIQS1-5级要求 BIQS Migration Certification & Metrics Level I Level II Level III Level IV Level V TS/ISO Certification Not Certified Certified Certified Certified Certified BIQS Score to 29 Elements N/A 62% (Green to 18 of the total 29 elements) >75% (Green to 22 of the total 29 elements with NO REDS) >86% (Green to 25 of the total 29 elements with NO REDS) Quality PRR >15 in 6 months 15 to 12 in 6 months 11 to 6 in 6 months 5 to 1 in 6 months 1PRR/1 million parts shipped in 12 months Field Action >1 in 6 months Zero in 6 months Zero in 6 months Zero in 6 months Zero in 12 months Major Disruptions >1 in 6 months 25 in 6 months 24.75 to 7 in 6 Months 6.75 to 4 in 6 months 3.75 to 1 in 6 months 0.75 to 1 in 12 months 2016 Model Non Sourceable 从质量表现和现场审核结果两方面对供应商进行评价! 请注意即使QSB没有过期,如果当月的质量表现达不到 L3要求,QSB状态会自动变为Revoked,直到质量表现满 足L3要求为止。# Statement BIQS -1 Nonconforming Material / Material Identification BIQS-2 Layered Audit BIQS-3 PFMEAs BIQS-4 PFMEAs - Risk Reduction & Annual Review BIQS-5 Bypass / Deviation Management BIQS-6 Error proofing Verification BIQS-7 Gage Calibration / Measurement System Analysis BIQS-8 Fast Response Problem Solving Process BIQS-9 Team Problem Solving Process BIQS-10 Quality Focused Checks BIQS-11 Standardized Work BIQS-12 Process Change Control BIQS-13 Verification Station (Final Inspection/CARE / GP12) BIQS-14 Change Control - Production Trial Run (PTR) # Statement BIQS-15 Andon System Implementation BIQS-16 Alarm and Escalation BIQS-17 Visual Controls BIQS-18 Visual Standards - Communicated and Understood BIQS-19 Process Control BIQS-20 Process Control Plan Implemented BIQS-21 Process Capability Review BIQS-22 Rework / Repair Confirmation BIQS-23 Feedback / Feedforward BIQS-24 Training BIQS-25 Contamination Requirements BIQS-26 Maintenance BIQS-27 FIFO / Material Handling Process BIQS-28 Shipping Approved Packaging BIQS-29 Supply Chain Management 这29个要素对制造工厂来讲都是最基本的要求!BIQS Migration Match Internal BIQ Requirements Certification & Metrics 2016 2017 2018 2019 TS/ISO CertificationNot Certified Certified Certified Certified Certified BIQS Overall Score all 29 Elements 62% (Green to 18 of the total 29 elements) >75% (Green to 22 of the total 29 elements with NO REDS) >86% (Green to 25 of the total 29 elements with NO REDS) >93% (Green to 27 of the total 29 elements with NO REDS) Quality PRR 15 to 12 in 6 months 11 to 6 in 6 months 11 to 6 in 6 months 11 to 6 in 6 months 11 to 6 in 6 months Field Action Zero in 6 months Zero in 6 months Zero in 6 months Zero in 6 months Zero in 6 months Major Disruptions <1 in 6 months <1 in 6 months <1 in 6 months <1 in 6 months <1 in 6 months Severity Score 6.75 to 4 in 6 months 6.75 to 4 in 6 months 6.75 to 4 in 6 months 6.75 to 4 in 6 months 6.75 to 4 in 6 monthsNon Sourceable Non Sourceable Non Sourceable Non Sourceable Minimum Sourceable Requirements 从质量表现和现场审核结果两方面对供应商进行评价!BIQS vs. QSB+审核打分方法 10 ? 用红、黄、绿三种颜色代表每一个要素的结果,最终结 果计算绿色项的百分比: ? 绿色 Green: 供应商有成熟的/好的质量系统或过程, 并得到有效执行。 ? 黄色Yellow: 供应商有相关系统或过程, 但是没有得到 有效执行。 ? Red: 供应商质量系统或过程不完善,或者现有的系 统或过程风险比较高。Top 10 not-meet from 10 months data 1.FMEA Failure mode not fully identified, severity not consider effects to final customer, SOD low ranking, FMEA not reviewed and updated periodically. 2.Bypass Supplier not understand the requirement for Bypass, no bypass process 3.Fast Response and team problem solving not effective FR, problems not closed on a timely manner 4.Maintenance Spare parts not managed well, maintenance plan not followed, down time data not used for improvement.BIQS-1 Nonconforming Material / Material Identification合格/不合格物料的区分 要求: 1.有不合格零件的处理流程,员工理解如何处 理不合格/可疑零件。 2.合格物料得到正确的处理,存储和识别。 3.对不合格/可疑品进行清晰的标识/隔离, 以进行评价和处理。(例如 红/黄/绿颜色) 4.有相应的遏制方法来确认有效的断点已经 被建立,遏制行动和结果要保留记录。 5.零部件的追溯要求 审核关注点: 1.现场抽样确认员工理解如何处理不合格/可疑零件 2.确认现场及物料存储区域合格物料得到正确的处理 ,存储和识别(譬如温湿度要求,保质期要求,静电防 护要求等 BIQS25 contamination)。 3.确认现场不合格/可疑品进行了清晰的标识和隔离, 对可疑品/报废品有适当的防护以避免损坏,定期回顾 并清理不合格品/可疑品(BIQS23 FF/FB)。 4.检查不良遏制记录,确保遏制措施涵盖到各个环节 (从来料到客户端)。 OK-001 R ev: 11/12 Date: S mart #: Family/ R P O: P art #: S erial #: Test Order #: Last Op/ Area: Tagged By: R eason C hecked: OK FOR US E SC-001 R ev: 11/12 Date: S mart #: Family/ R P O: P art #: S erial #: Test Order #: Last Op/ Area: Tagged By: R eason for S C R AP : S C R AP DO NOT US E!SH-001 R ev: 11/12 Date: S mart #: Family/ R P O: P art #: S erial #: Test Order #: Last Op/ Area: Tagged By: R eason for S US P E C T: S US PEC T HOL D 例子:用红黄绿标签识别零件状态 对可疑品/不合格品进行隔离区分的例子 不合格物料:包含供应商来料不良,过程产生的缺陷件,成品不良,物料超过保质期等。 Problem found Contain Root cause Update standard CloseBIQS-2 Layered Audit 分层审核 要求: 1.有分层审核流程以确认标准化作业的实施,识别 持续改善机会,并对员工提供现场指导 2.领导层负责分层审核的实施,分层审核计划应该 包含每一级管理层。 3.跟踪分层审核的实施并记录审核结果。 4.对审核发现的不符合项需要改进对策。 审核关注点: 1.检查分层审核计划,确认分层审核的人员和频次 要求 2.确认分层审核表的内容适用,审核表的内容有定 期更新以关注工厂的薄弱环节,客户特殊要求和质 量关注检查(BIQS10)内容在分层审核中得到确认。 3.检查分层审核记录确保分层审核的实施,发现的 问题点在不能立刻纠正时要做记录并采取对策,确 认对策的有效性。 (例子:分层审核计划)BIQS-2 Layered Audit 分层审核 第一部分: 一般工位问题 第三部分: 一般制造系统问题 第二部分: 特殊质量关注问题(BIQS-10) 例子:分层审核表 HEADER: Enter the System NameProduct line or an area of the Plant 1. Molding 2. Paint/Coating 3. Assembly 4. Warehouse/Shipping (例子:分层审核问题跟踪表)Level Purpose Min Frequency Team Leader Maintain process and standards in the team. Coach T/Ms. 1/ week – 1/day - (team quality focused checks), cover all workstations in 1 month. Group Leader Maintain process and standards within the group. Coach T/Ls. 1/ week Superintendent/Shift leader Verify process is in place and standards are maintained. Coach/Teach G/Ls & T/Ls 1/ week Plant Mgr & Plant Joint Leadership (may do individual or group audits) High level overview to verify the process is working. Coach /Teach lower levels. 1/week Lordstown To define the adequate frequency, take into consideration the following factors: Plant turnaround level, Plant Level of maturity (provided by data*), Business Result (internal and external) associated with past LPA results. As recommendation, start with daily frequency (Example) (Example)BIQS-3 PFMEAs 过程失效模式和后果分析 要求: 1.运用PFMEA来辨识所有操作存在的风险。PFMEA workshop 应由跨功能小组完成,包括制造团队的输入,严 重度,频度和探测度打分严格遵循SOD表要求。 2.FMEA中要包含物料选取的失效模式(譬如拿错料,混料, 遏制措施等等) 审核关注点: 1.确认PFMEA编制小组包含了不同功能团队的人员,譬如 设计,制造,质量, SQ,维护等。 2.询问PFMEA是如何用于防错和过程控制的,查看相关案 例。 3.询问工厂是否使用为每种工艺编制的SOD评级表(比如冲 压,焊接,油漆,装配等工艺) 4.确认SOD打分是否正确,严重度考虑了对最终客户的影 响,严重度为9~10的失效模式在PFMEA和控制计划内是否 有足够的控制手段。 5.是否分析了物料选取的失效模式(相似件,不同配置)。 6.风险评估矩阵的应用。 PFMEA ME PE Supply Chain SQE MFG MT QE (风险评估矩阵) 团队合作开发PFMEA1.失效模式识别不完全,没有 识别所有的产品或过程要求对 可能的失效模式进行分析 2.失效的后果和严重度没有考 虑对GM及最终客户的影响 3.发生频次打分过低 4.探测方法的理解有偏差,探 测度打分偏低 FMEA容易出现的问题 不能正确评估风险,FMEA停 留在文件上 Ambient temperature too high / / , Cause orange peel/bubble/pinhol e,Cause rework 6 (1) Air conditioning system failure 3 (1) (1)Before starting test and inspection of air conditioning system (2) Regular maintenance of equipment maintenance (1) (1)Display the temp and control (2) (2)Check the parameter 4 72 Ambient temperature too low / , Cause folwing/fuzzy,caus e rework 6 (1) Air conditioning system failure 3 (1) (1)Before starting test and inspection of air conditioning system (2) Regular maintenance of equipment maintenance (1) (1)Display the temp and control (2) (2)Check the parameter 4 72 Ambient humidity too high , , , , , Surface whitening, golss lower, bubbles, pinhole paint sticky, easy bruising, cause rework 6 (1) Air conditioning system failure 3 (1) (1)Before starting test and inspection of air conditioning system (2) Regular maintenance of equipment maintenance (1) (1)Display the temp and control (2) (2)Check the parameter 4 72 Ambient humidity too low / , Products produced on the surface of particles / fibers, cause rework 6 (1) Air conditioning system failure 3 (1) (1)Before starting test and inspection of air conditioning system (2) Regular maintenance of equipment maintenance (1) (1)Display the temp and control (2) (2)Check the parameter 4 72 6 (1) (1)Not timely replacement of filtering cotton 2 (1) (1)According to the filtering cotton use cycle change regularly and record (2) (2)Regular maintenance of equipment maintenance Wind speed measuring instrument monitoring 4 48 6 (2) (2)The exhaust system is not timely maintenance 3 (1)Regular maintenance of equipment maintenance Cleanliness testing instrument for monitoring dust 4 72 油漆用错 Wrong paint 产品批量报废 Mass sscrap 8 油漆标识混淆 Wrong/ confused label 2 (1)标识,定置存放管理 (1) Labeling, storage area management (2)专人负责保管,调漆 (2) Assigned person to monitor 目视检测 Visual inspection 4 64 油漆配比调错 Wrong mixing ratio 影响零件外观或 者性能 Affect part apperance or Performance 7 (1)电子秤失效 (1)Scale out of control (2)操作失误 (2)Wrong operation 2 (1)设备点检及定期校验 (1) Equipment management and calibration (2)增加带打印功能的电子 秤 (2)To increase the printing function with the electronic scale 目视检测 Visual inspection 4 56 出漆量过大,漆 膜厚度过大 Paint output too high, film thickness too thick 产生流挂,造成产 品返工 Cause droplets surface, causing rework 7 (1)参数未按程式规 定执行 (1)Parameters not according to the program 2 采用专用程式 Using a special program 生产前进行点检 Pre production inspection 4 56 出漆量过小,漆 膜厚度过小 Paint output too low, film thickness too thin 造成产品漏喷, 造成产品返工 Drain spout, causing rework 7 (1)参数未按程式规 定执行 (1)Parameters not according to the program 2 采用专用程式 Using a special program 生产前进行点检 Pre production inspection 4 56 流平时间过短 Flow time too short 产生桔皮/针孔,造 成产品返工 Cause orange peel/pinhole,caus e rework 7 (1)链速过快 (1)Chain speed too fast 2 (1)开机前对设备进行点检 (1)equipment inspection before starting (2)按照作业指导书进行各 款产品的流平时间控制 (2)According to the operating instructions for each product flow time control (3)过程中链速数显化控制 Process chain speed digital control (1)设备点检 (1)Check the equipment (2)按照作业指导 书进行各款产品 的流平时间控制 (2)According to the operating instructions for each product flow time control 4 56 流平时间过长 Flow time too long 产生颗粒纤维,造 成产品返工 Products produced on the surface of particles / fibers, cause rework 7 (1)链速过慢 (1)Chain speed too slow 2 (1)开机前对设备进行点检 (1)equipment inspection before starting (2)按照作业指导书进行各 款产品的流平时间控制 (2)According to the operating instructions for each product flow time control (3)过程中链速数显化控制 Process chain speed digital control (1)设备点检 (1)Check the equipment (2)按照作业指导 书进行各款产品 的流平时间控制 (2)According to the operating instructions for each product flow time control 4 56 8 (1)实际温度高于设 定温度 (1)The actual temperature is higher than the setting temperature 2 (1)开机前对设备进行点检 (1)equipment inspection before starting (2)按照作业指导书进行各 款产品的流平时间控制 (2)According to the operating instructions for each product flow time control (3)过程中温度数显化控制 Process temp digital control (1)设备点检 (1)Check the equipment (2)按照作业指导 书进行各款产品 的流平时间控制 (2)According to the operating instructions for each product flow time control 3 48 7 (2)风压不对 (2)Wrong wind pessure 2 (1)开机前对设备进行点检 确认风压正确 (1)Confirm correct wind pressure before the start of equipment 目视检测 Visual inspection 5 70 烘烤温度过低 Baking temp too low 漆膜硬度不够,易 擦伤,造成返工 The film hardness is not enough, easy bruising, cause rework 6 (1)实际温度低于 设定温度 (1)The actual temperature is lower than the setting temperature 2 (1)开机前对设备进行点检 (1)equipment inspection before starting (2)按照作业指导书进行各 款产品的流平时间控制 (2)According to the operating instructions for each product flow time control (3)过程中温度数显化控制 Process temp digital control (1)控制柜参数 显示监控 Display the temp parameter (2)参数点检( 每小时) Check the parameter(Every hour) (3)炉温仪监控 Furnace temperature 3 36 烘烤时间过短 Baking time too short 漆膜硬度不够,易 擦伤,且影响产品 性能,造成废品 The film hardness is not enough, easy bruising, cause scrap 6 (1)链速过快 (1)Chain speed too fast 2 (1)开机前对设备进行点检 (1)equipment inspection before starting (2)按照作业指导书进行各 款产品的流平时间控制 (2)According to the operating instructions for each product flow time control (3)过程中链速数显化控制 Process chain speed digital control (1)控制柜参数 显示监控 Display the temp parameter (2)参数点检( 每小时) Check the parameter(Every hour) (3)炉温仪监控 Furnace temperature 4 48 烘烤温度过高 Baking temp too high 产品变形,造成废 品 Parts deform,Cause scrap Environmental quality beyond the standard / , Products produced on the surface of particles / fibers, cause rework Current Process Controls Prevention Current Process Controls Detection Detection RPN DP switch panel basecoat paint Ambient temperature meet the deman
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