【正文】 Visually “describing” the defect is Not a Boundary Sample! 目視化標(biāo)明缺陷不是邊界樣件！Crater more than this size is not acceptable不接受焊口大于此尺寸Example of a Boundary Sample邊界樣品的范例GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 27DIMC GMSCreate a “StandardsBased” Culture創(chuàng)造一個以標(biāo)準(zhǔn)為基點的文化氛圍創(chuàng)造一個以標(biāo)準(zhǔn)為基點的文化氛圍I wouldn’t buy this!Doesn’t look good to me!My opinion is…This does not meet the standard..Talk in terms of The Standard, not opinions! 以標(biāo)準(zhǔn)為基點，而非觀點！GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 28DIMC GMSManufacturingProcess Validation QualitySystemManagementProduct Quality StandardsQualityFeedback/FeedforwardStandardizedWorkVisualManagementManagementby TAKT TimeWorkplaceOrganizationAndonConceptProblemSolvingEarly Mfg. and DesignIntegration (DFM / DFA)ContinuousImprovementProcessLean Design of Facilities, Equipment,Tooling and LayoutBusiness PlanDeploymentTotal ProductiveMaintenanceControlledExternal TransportationScheduledShipping /ReceivingLevel VehicleOrder Schedules SupplyChainManagementInternal Pull /DeliverySimpleProcessFlowSmall LotPackagingTemporaryMaterialStorage Fixed Period Ordering System/ Order PartsHealth andSafety Priority Qualified People Team ConceptPeopleInvolvementOpenCommunicationProcessValuesVision/MissionShop FloorManagementInProcessControlVerificationManufacturingProcess Validation制造工序認(rèn)證GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 29DIMC GMSWhat is a process?什么是工序？Inputs投入Outputs輸出A process is a set of interrelated resources and activities which transforms inputs into outputs.工序是集中相關(guān)的資源進(jìn)行一系列活動，把投入轉(zhuǎn)換成輸出！Environment環(huán)境Process 工序 Man MachinesMethod MaterialsGMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 30DIMC GMSWhere can Errors Occur?問題會出在哪？Defects缺陷Materials:材料?Parts out of standard 不符標(biāo)準(zhǔn)的零件?Wrong parts錯誤零件?Poor design 設(shè)計不當(dāng) Method: 方法?Poor std. Work 不好的標(biāo)準(zhǔn)工作?Lack of Training 缺乏培訓(xùn) Machine/Process: 機(jī)器/工序?No TPM 沒有 TPM?Process not capable 工序不好?Improper specification 規(guī)格不當(dāng) Man:人力?Not follow std. Work 不遵循標(biāo)準(zhǔn)化工作?Distractions, Fetfulness 分心、遺忘?Lack of Experience 缺乏經(jīng)驗Errors Result InGMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 31DIMC GMSValidate the manufacturing process prior to Start of Production! 在生產(chǎn)啟動前認(rèn)證制造工藝！Do not切勿Accept 接受Build 制造Ship 傳遞a Defect! 缺陷！Living Up to the Motto…達(dá)到口號“Eliminate the Need for Inspection on a Mass Basis by Building Quality into the Product in the First Place” Dr. Deming PFMEAWorkstationReadiness工位準(zhǔn)備Process ControlPlan 工藝控制計劃Errorproofing Plan防錯計劃GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 32DIMC GMSError Proofing Hierarchy 防錯層次Prevention 預(yù)防Detection 檢測HumanJudgment人為判斷人為判斷None無Product / Process Design Change 產(chǎn)品 /工藝設(shè)計改變? DFM/A D/PFMEA ? Robust Designs Capable Processes 機(jī)器設(shè)計及可行工藝? OneWay Assembly 同一裝配?Process Controls 工藝控制?Locating Pins Stops 固定點及停點?Sensors Process Monitors 傳感器及工藝監(jiān)控?Electro Mechanical Devices 電子機(jī)械儀器?Color Coding 顏色信號?Visual Controls 直觀控制?Andon Systems 暗燈系統(tǒng)?Standardized Work 標(biāo)準(zhǔn)化工作Errors Can’t Happen Small Improvement小改進(jìn)Significant Improvement 重大改進(jìn)Introduction to Error Proofing防錯介紹GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 33DIMC GMS0515100396OLHM51020150151012457810115051510 0 39 6 OLHM 5102015 0 151045781011 51 2Original:Best:Visual Control ExampleHuman Judgment0515100396OLHM51020150151012457810115Better:GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 34DIMC GMSABExample: Vehicle Identification車輛認(rèn)證 (Mutilation Cover Color)(蓋板顏色毀損 )Human Judgment 人為判斷人為判斷Visual Control ExampleGMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 35DIMC GMSVertical Plate垂直板Battery Post電池接頭Process Control ExampleDetection 檢測檢測GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 36DIMC GMSXWork Piece 加工件 Work Piece 加工件Fixture 夾具 Fixture 夾具Process Control ExamplePrevention 預(yù)防預(yù)防GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 37DIMC GMSProduct Design Example (Before)REC STOP PAUSEREC STOP PAUSEOLDDESIGN老設(shè)計Can be Installed Upside Down 可以反安裝 Application of Labels on Cassette Prevention 預(yù)防預(yù)防GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 38DIMC GMSREC STOP PAUSENEWDESIGN新設(shè)計Application of Labels on Cassette Can Only Be Installed Correctly!Product Design Example (After)PreventionGMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 39DIMC GMSLeft Hand Locator TabRight Hand Locator Tab Example Product Error Proofing (One Way to Install Seat Belt)防錯樣品 — 只有一種安全帶安裝方法Product Design Example 產(chǎn)品設(shè)計范例PreventionGMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 40DIMC GMSSimple Everyday Examples1) Error Prevention ?? ??Automatic shutoff自動斷電GMS OrientationBuiltin quality GMDAT/DIMC ConfidentialVersion Date Slide 41DIMC GMSErro