【正文】 pport depending on frequency and criticality! 根據(jù)缺陷出現(xiàn)頻率與嚴重程度 逐層向領導匯報以尋求支持！ InProcess Control Verification – 2) DETECTION Detection Example: Team Leader Section Leader Group Leader 2 defects/ 1 hour 4 defects/ 1 hour GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 53 GMS 1) Use Andon (taught more later) 使用暗燈 Make problems visual pull in support! 問題直觀， 拉線尋求幫助！ InProcess Control Verification – 3) CONTAINMENT Always Remember the Priorities:一定要牢記： 1) Safety安全 2) Quality質(zhì)量 3) Responsiveness (Throughput)響應 Containment 包容 GMS Orientation Builtin 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! 采取特別行動防止 缺陷傳遞！ InProcess Control Verification – 3) CONTAINMENT Some examples: 1) Stop the line停線 2) 100% checks 100%檢查 3) Online repair 線上維修 4) Reworks返工 5) Sorting 整理 Containment 包容 GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 55 GMS How Does our Quality Motto relate to Containment? Do not 不要 Accept 接受 Build 制造 Ship 傳遞 a Defect! 缺陷！ It means empowered leaders make judgments how to control quality while trying to keep the line running!! 意味著領導有權(quán)作出決定：在盡量不停線的情況下， 怎樣控制好質(zhì)量！ Does this mean we stop the line every time we have a problem? 這是不是意味著一有問題就停線呢？ GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 56 GMS How Does our Quality Motto relate to Containment? Sometimes the best decision may be to let a defect pass to the next process, but… 有時最好的辦法是讓差錯轉(zhuǎn)到下工序，但是 …… 1) It is a conscious decision made by the appropriate level 2) Action must be municated 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: 暗燈使用的指導方針 1) Will the problem affect the next process? 問題會不會影響下道工序？ 2) Can I effectively repair the defect out of station? 能不能在工位外有效解決問題？ 3) What is the status of my decouplers? 自己的切斷器是什么狀態(tài)？ 4) Others… 其他 …… GMS Orientation Builtin quality GMDAT/DIMC Confidential Version Date Slide 57 GMS Andon Discussion – Hoods Situation: At the Body Shop endofline 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 online. 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 Builtin 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 acmodate that. Andon Discussion Hoods GMS Orientation Builtin 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 online 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 Builtin 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 outofstation. Since the decoupler between Trim and Chassis is about half full, this means that Chassis can continue running for a short whi