GM-QSB+ 通用汽车质量系统强化版 13 - 培训用

Nb of late trains
Owner
T. Jones
60 66 60 65 132 125
6 6 1 7
66
2 7:00-8:00 A
Sta. 50 part present switch faulted and caused 2 minutes of downtime
Clean the switch or install a new switch
M. Spark
3
8:00-9:00 A
4
9:00-10:00 A
5
10:00-11:30 A
6
11:30-12:30
7
12:30-1:30P
8
1:30 - 2:30 P
• • •
9
2:30 - 3:30P
10
3:30 - 4:00P
9
Q-D-C
• •
:
10
Q-D-C
•
• • • •
(constraint): bottleneck): (throughput): (inventory):
B = Bulk Storage C = Sequence Staging D = Eng. Change and Overflow “Zone” E = Scrap and Obsolescence “Zone” F = Returnable and Waste “Zone” EC = Engineering Change
=
100%
(8
A:
))
: 10 : 54%
(8
B:
)
6 : 90%
(10 x 0.54 = 5.4)
(6 x .90 = 5.4)
• •
4
Q-D-C
A
(
)
*
*
B
1
X
PPC
*
2
A
1 S&OP 4
MPS
( )
B
3
/
X
5
5
S&OP & MPS Process
• • • / • • • )
Q-D-C
S&OP • • • • • • • / & /
Rotation = Stock Level / Out (days) Target mini
1.5 1 0.5 0 Jan 12 Feb 12 Mar 12 Apr 12 May 12 Jun 12 Jul 12 Aug 12 Sep 12 Oct 12 Nov 12 Dec 12 Target maxi
Date: Shift: 1/8/2008 1 2 3
Actual
Hourly Cum. Cum.
(
Area: Group Leader: Target: Underbody D. Spooner 500 Jobs/Shift
)
Target
Hourly
Difference Note: Record Loss in Red
: n : -
:
:
Q-D-C (PFD) PFMEA: • • PFMEA PFD
Process Flow Diagram
Process #1
WIP
Process #2
PFMEA Material Storage and Handling – Potential Failure Modes
24
Q-D-C
14
Q-D-C
(Global Container Responsible)
(ME Responsible)
“WIP” Racks (*)
(*) WIP: Work In Progress WIP: /
“Kit” Racks
Racks on Wheels
(Tier 1 Responsible*)
* Global Containers Will Provide Specifications, Standards, and Approvals To Expendable Container Designs
Hourly Cum.
Hour 66
1 6:00-7:00 A
Problem
Sta.10 Good parts mixed with bad parts
Counter Measure
Material sort parts and investigate the mix up of parts and contact the part supplier
External Sequence Rack
Minomi Racks
Internal Sequence Racks
15
Q-D-C /
/
EC
D
A
FIFO
E
B
A
B
C
FIFO
4
A B
3
2
1
F
7 - 12 1-6
( ) / / Dolly Exchange
1-6
C
Key: A = Carton Storage
Jan Feb Mar Apr May Jun 12 12 12 12 12 12
Jul Aug Sep Oct Nov Dec 12 12 12 12 12 12
-8.0% -10.0% Inventory gaps Target +
30
Q-D-C
•
–
Jan 12 Feb 12 Mar 12 Apr 12 May 12 Jun 12 6000 5000 5000 5000 4000 4000 4750 4630 4450 4300 3900 3950 11450 11820 12370 13070 13170 13220 2,4 2 3 2,6 2 3 2,8 2 3 3,0 2 3 3,4 2 3 3,3 2 3 Jul 12 Aug 12 Sep 12 Oct 12 Nov 12 Dec 12 3500 0 3500 3700 3900 4000 3930 4030 3970 3920 3870 3600 12790 8760 8290 8070 8100 8500 3,3 2 3 2,2 2 3 2,1 2 3 2,1 2 3 2,1 2 3 2,4 2 3
Jul 12 Aug 12 Sep 12 Oct 12 Nov 12 Dec 12 92% 88% 95% 98% 96% 90% 80% 80% 80% 80% 80% 80% 105% 105% 105% 105% 105% 105% 18 16 16 14 15 10 4720 3850 4700 3200 2960 3900 4500 3900 4600 3200 3000 3800 4,9% -1,3% 2,2% 0,0% -1,3% 2,6% 2,50% 2,50% 2,50% 2,50% 2,50% 2,50% -2,50% -2,50% -2,50% -2,50% -2,50% -2,50%
In (parts/day) Out (parts/day) Stock Level (parts) Rotation = Stock Level / Out (days) Target mini Target maxi
4 3.5 3 2.5 Days 2
Stock Rotation – Part number xxxxxx
• • • /•来自5S/FIFO/25
Q-D-C
( )
• (JES) SOS) • JES
26
Q-D-C : • • 1. 2. 3. 4. 5. 6. 7. • (PFEP)
27
Q-D-C (PFEP)
1
• • • • • • • • • • • • •
2
• • • •
3
• • •
4
PFEP
28
31
Q-D-C
•
4 3 2 1 0 Jan 12 Feb 12 Mar 12 Apr 12 May 12 Mar 12 1 2 2 1 2 2 Jun 12 Apr 12 0 2 1 Jul 12 May 12 0 1 1 Aug 12 Jun 12 0 0 1 Sep 12 Jul 12 0 0 1 Oct 12 Nov 12 Dec 12 Oct 12 2 3 1 1 1 0 Nov 12 0 0 0 Dec 12 0 0 0 Nb of emergency delivery Target for stockout
FIFO
( )
16
Q-D-C
: • • • • • / ;
17
Q-D-C
•
•
• • • • •
18
Q-D-C –
• • • • Requirements ( )
19
Q-D-C –
( )
20
Q-D-C •
21
Q-D-C : • • • •
…
22
Q-D-C
– – – – –
/
Stocks
23
11
Q-D-C :
<
3000
A
4000
B
5000
A : A B
12
Q-D-C :
–
<
, , CT > TT , ,
• •
:
–
>
: : 6
• • •
13
Q-D-C 5
• Step 0 – • Step 1 – • Step 2 – • Step 3 – • Step 4 – • Step 5 – step 1 step 2 GP-9