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2016
This presentation was developed by General Motors Corporation Global Purchasing Supply Chain.
All rights reserved. No part of this material may be reproduced in any form, or by any method,
for any purpose, without written permission of General Motors Global Purchasing Supply Chain.
Esta presentación
MISSION: fue desarrollada por General
To be leaders Motors
of an Corporationapproach
enterprise Global Purchasing
to Supply
ensureChain.
Todos los derechos reservados. Ninguna parte
our suppliers de este material
achieve launch puede
andserquality
reproducido de ninguna forma, o por ningún
excellence.
método, y para ningún propósito, sin permiso escrito de General Motors Global Purchasing Supply Chain.
Global Built-in Quality Supply Based (BIQ-S)
MISSIO N :
Lead suppliers to achieve operational excellence by developing a Quality Culture through
Built-In Quality (BIQ) manufacturing systems for suppliers.
• Principios Comunes
• Métodos Comunes
• Procesos Comunes
Desarrolle Prioridades de
Capacitación de:
• Planes de Negocio
• Planes de Implementación (ej. BIQ-S)
valoración
• Scorecard /resultados de Planta
Necesita
Capacitación • Iniciativas Regionales /Globales
Disponible • Encuesta del Empleado
Programas de • Situación de la Contratación
• Evaluaciones de Desempeño
Capacitación
(Cursos y Métodos)
Necesita Valoración / Datos Existentes
Course Target
Plan de Capacitación Anual
• (Ejemplo)
Content number Duration group Method Location Instructor Timetable Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
PFMEA
PFMEA
6 hours
6 hours
SQE/SQO
SQE/SQO
Classroom Ramos
Classroom Silao
Mark Waligora
Mark Waligora
9:00 AM - 4:00 PM
9:00 AM - 4:00 PM
X
X
Infor del Gráfico de Flexibilidad TM – Plan de Capacitación
Dimensional Apprentice
DFSS - Part 1
DFSS - Part 1
16 hours
33341 20 hours
33341 20 hours
SQE/SQO
SQ&D
SQ&D
Classroom Ramos
Classroom Ramos
Classroom Toluca
Daniel Barrera
C. Uribe / G. Davila
F. Bobadilla
8:00 AM - 5:00 PM
8:00 AM - 5:00 PM / 12:00 PM
8:00 AM - 5:00 PM / 12:00 PM
X
X
X
• Evaluación de Capacitación Individual Operations - Training Plan
AREA:
DFSS - Part 1 33341 20 hours SQ&D Classroom SLP A. Bancia / R. Perez 8:00 AM - 5:00 PM / 12:00 PM X GL Month Month Month
Week Week Week Week Week Week Week Week Week Week Week Week
Dimensional Apprentice 16 hours SQE/SQO Classroom Ramos Daniel Barrera 8:00 AM - 5:00 PM X Team ID Name
Station Operation Operation Operation
DFSS - Part 1 33341 20 hours SQ&D Classroom Silao J. Ceballos / D. Arredondo 8:00 AM - 5:00 PM / 12:00 PM X
BIQ - S 8 hours SQE/SQO Classroom Toluca C. Bispo/L. Mata 8:00 AM - 5:00 PM X
BIQ - S 8 hours SQE/SQO Classroom SLP A. Sandoval 8:00 AM - 5:00 PM X
SPC 8 hours SQ&D Classroom Guanajuato AIAG 8:00 AM - 5:00 PM X
Run at Rate 4 hours SQ&D Classroom Guanajuato E. Gray 8:00 AM - 12:00 PM X
BIQ - S 8 hours SQE/SQO Classroom Silao C. Bispo/A. Rangel 8:00 AM - 5:00 PM X
DFSS - Part 1 33341 20 hours SQ&D Classroom Ramos C. Uribe / G. Davila 8:00 AM - 5:00 PM / 12:00 PM X
BIQ - S 8 hours SQE/SQO Classroom Ramos M. Nabte 8:00 AM - 5:00 PM X
Dimensional Apprentice 16 hours SQE/SQO Classroom Ramos Daniel Barrera 8:00 AM - 5:00 PM X
*Mandatory
**Available
(Ejemplo)
Gráfico de Flexibilidad – Estado de Equipo e identificación
de necesidades (requerimientos de trabajo)
(Ejemplo)
Capacitación Estándar - Evaluación
Individual
Team Member (T/M): _________________________ Team: Shift:
Operation 1
Operation 2
Operation 3
Operation 4
Operation 5
Operation 6
Requerimientos
Step 4 - Follow-up
R-1. Safety Check
R-2. Standardized Work Check
R-3. Quality Check - Goal of ZERO defects
de trabajo
Check minimum of 15 Jobs - Complete Verification Checksheet with Team Member Initials
R-4. Takt Check
R-5. Standardized Tools Check
R-6. Error-proofing Check
R-7. Materials Check
R-8. Andon Check
R-9. Workstation Documentation Requirements
S. Verification (later in shift or next day)
T. Provide Feedback
U. Certify the T/M to 3/4 on flexibility chart (must complete steps for all models )
Sign Team Member initials required for each job certified
Date ( T/M signoff that these steps were used by trainer to certify )
Sign
Date
FLEX
Sign
Date
Team Leader initials required for each job certified
There is read across of corrective actions to like operations. Confirm that there is read across of corrective actions to like operations.
Identificación de problema
En la preparación para la reunión de Respuesta Rápida, al inicio del día, se debe
identificar temas significativos de calidad ocurridos las pasadas 24 horas los cuales
deben incluir:
• Reclamos Externos:
− Reclamos de clientes (PRR’s, problemas de calidad, llamadas del
cliente, etc..)
− Preocupaciones hacia tus proveedores. (Los proveedores deben ser
notificados con antelación cuando se deban reportar en la reunión).
• Reclamos Internos:
(Ejemplo)
− Hallazgos de las estaciones de verificación
− Problemas sistémicos de auditorías de proceso escalonadas
− Paradas de línea y problemas de productividad
− Otras preocupaciones internos de calidad (hallazgos en auditorías de
embarque y/o actividades de contención)
− Fallas en los dispositivos error proof.
Todos los problemas de calidad significativos son rastreados en el Tablero
de Respuesta Rápida.
24 H 7D 14 D 34 D 35 D 40 D Location:
Duns:
N/A Not Applicable
Completed & 3rd Party/GM verified
Contact Name: Completed & Supplier verified only
Operator Instructions
Contact Phone: Not Completed
Corrective Action
Corrective Action
(Institutionalized)
Lessons Learned
Layered Process
E-mail: P Pass Through
Proof/Detection
Containment -
Standard Work
Implemented
PFMEA / CP
Quality Alert
Breakpoint -
Root Cause
Tiered
Duns
Supplier
Identified
Validated
Updated
Classification
Audits
Error
Product /
Process
Press 1
Press 2
Press 3
Line 1
Line 2
Line 3
Cell 1
Cell 2
Cell 3
Tier 2
Tier 3
Tier 4
Part Name & EFFECT OF FAILURE N/C or CS DDW Completion
GM Plant FAILURE MODE PRR Number / Issue
Number MODE CPV Status & Verification 1 Champion Symbols
Containment
Corrective Action
Cause of Failure Mode Corrective Action
Prevent Corrective Action
Protect Corrective Action
Predict Corrective Action
Key Findings Corrective Action
Documentation Updated
Una Alerta de Falla de Proceso debe ser usada para «extrapolar» medidas
preventivas a otras plantas e ingeniería cuando un problema de calidad del
producto (mfg. controlable) no es captado por la primera línea de detección
de errores; se emite una Carta de Acción Preventiva (PAL, Preventive Acción
Letter), un Plan de Control de Procesos no seguido ha escapado al control de
la planta o un fallo importante de proceso se produce (por ejemplo,
seguridad, reglamentaria, legal, etc.). APFA también puede ser utilizado para
comunicar una mejora significativa de proceso. La planta (s) de recepción
debe poner en práctica medidas preventivas comunicadas a través de la PFA
(Process Failure Alert).
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):
MISSION: To be leaders of an enterprise approach to ensure 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
our suppliers achieve launch and quality excellence. 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.
Respuesta Rápida
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Team Problem Solving Process To provide common methods for solving problems that are understood and
used by all.
A well developed, standardized problem solving process exists at
all levels of the organization. A standardized problem solving process exists. A range of problem solving
activities are conducted for different problem types and complexities, including
Formal problem solving activities are initiated according to a single (special) cause, common (repetitive) cause, as well as more complex
specified criteria. multiple-cause problems.
Issues are identified, root causes analyzed and robust actions Ask to talk through some problems with Team Leaders and Supervisors.
completed in a timely manner. Ask how many formal problem solving activities the team has worked on in
BIQS -9 recent months?
Problem solving is driven at the Team level and all Teams are
involved. Leaders are actively involved coaching and guiding the Look for all teams should be involved in problem solving activities.
process. Look for a standardized process that includes: issue description and
definition, containment, probable cause analysis, root cause analysis (5
Whys), countermeasures, implementation plan, verification, approval to close,
and escalation or read across if needed.
PPS (Ejemplo)
(Ejemplo)
PLAN DE ACCIÓN
Date Reference Problem Root Cause - Why? Countermeasure - How? Responsible - Who? Status Support/Comments
Due Date
Root Cause Analysis: Problem Containment:
Problem Description - What?
Why?
Why?
Problem Correction:
Why?
Why?
Problem Prevention:
Deviation - How much?
Y / N = Yes /No (circle one for each question, #2 - #5) *S=Supplier, A=Assembly/Build issue
Inmediata
VERIFICATION STATIONS RESPOND PRODUCTION RESPONDS
(Completed by the Verification Operator) (Completed by the responder)
Corrective Action:
1-Identify Point of Cause Station # ?
Date/ Product Who Was Escalation Immediate Fix 2-Standardized work followed?
*S Who Breakpoint
# Shift Line
Serial# Defect Description / Number
Called
Time
Level 1-5 What was done with the defective 3-Correct Tools / Fixtures / Error Proofing?
A Answered
Time
CSN #
Part? 4-Correct Parts?
5-Parts in spec?
6-What did you do to STOP a REPEAT defect from occurring?
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
1 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
2 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
3 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
4 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
5 6:
(Ejemplo)
PPS Contramedida
PLAN DE ACCIÓN
Date Reference Problem Root Cause - Why? Countermeasure - How? Responsible - Who? Status Support/Comments
Due Date
Root Cause Analysis: Problem Containment:
2
Problem Description - What?
Why?
1 2 3
Why?
1
Problem Correction:
Problem Definition: Where? When? Why?
Why?
Why?
Problem Prevention:
Deviation - How much?
3 Respuesta Inmediata
VERIFICATION STATION:
IMMEDIATE RESPONSE ACTION SHEET / ALARM SHEET
Y / N = Yes /No (circle one for each question, #2 - #5) *S=Supplier, A=Assembly/Build issue
VERIFICATION STATIONS RESPOND PRODUCTION RESPONDS
(Completed by the Verification Operator) (Completed by the responder)
Corrective Action:
1-Identify Point of Cause Station # ?
2
Date/ Product Who Was Escalation Immediate Fix 2-Standardized work followed?
*S Who Breakpoint
# Shift Line
Serial# Defect Description / Number
Called
Time
Level 1-5 What was done with the defective 3-Correct Tools / Fixtures / Error Proofing?
A Answered
Time
CSN #
Part? 4-Correct Parts?
5-Parts in spec?
6-What did you do to STOP a REPEAT defect from occurring?
1
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
1 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
2 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
3 6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
4 6:
3
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
Leadership
Engineers
Members
Manager
Leaders
Leaders
Leaders
Group
Team
Team
Plant
Area
Shift
Tasks
P a rtic ipa te in
P ro ble m S o lving
Le a d/F o llo w-Up o n
P ro ble m S o lving
within a Te a m
Le a d/F o llo w-Up o n
P ro ble m S o lving
within a Gro up
(Ejemplo)
Department
Task Instruction Sheet Area
General Assembly
Date Prepared
Non-Conforming Material 9/10/2015 T. Harris / A. Taylor
Page 1 of 1
Prepared By:
Equipment Description/No. Location Est. Time
Symbols Mandatory Mandatory
TM Scrap Material Processing GA Critical 1 min
Safety Sequence within a Quality Sequence of STEPS Environmental
Step Description Step Detail (How, Why, Key Points) Diagram: (Tools, Special Parts, Special PPE, Layout, etc.)
P Sym . No
En GM el
miembro de
equipo firma el
Signature Block Date
TIS después de
Name Change Description
Shift
1
Sign
Date
Team Leader Group Leader
revisarlo para
demostrar que
Sign
2
Date
Sign
3
Date
ella/él lo
MISSION: To be leaders of an enterprise approach to ensure
entendió
our suppliers achieve launch and quality excellence.
Leí, entendí y me comprometo a seguir la Hoja de Instrucción de Tareas
HI T-
Hoja de Instrucción de Tareas Departamento / Área: LINEA DE ENSAMBLE V-8
REGISTRO
No. DE REGISTRO
C - STD - II - 02 - 4
1 de 1
3
Fecha
Firma our suppliers achieve launch and quality excellence.
Fecha
Requerimiento BIQS
El material conforme es manejado, almacenado e identificado apropiadamente.
Etiqueta
Ubicación
COMUNICAR
Si CUALQUIER planta GM está en IDENTIFICACIÓN DE CONTENCIÓN ROBUSTA
Material No riesgo de presentar material no STOCK Identificar proceso de
conforme, informar contención robusta, y
Conforme inmediatamente a todos los
Ver diapositiva de
Identificación de obtener las
Identificado contactos GM clave (SQE, SQA), Material aprobaciones
en TODAS las instalaciones de apropiadas de GM SQ e
los potencialmente afectados a Ingeniería.
SOLUCIÓN
nivel mundial.
PERMANENTE
PRODUCT NAME
NUMBER:
PRODUCT
NONCONFORMANCE:
TOTAL FOUND
3 tipos de rastreabilidad:
¿Qué hace la rastreabilidad ¿Qué hace la rastreabilidad
hacia arriba en el proceso? hacia abajo en el proceso?
Identificación de partes
está relacionada a una unidad o o lotes sospechosos
Costo
Identificación de
partes o lotes
vehículo.
Rastreabilidad Temporal: La información
contenida en el flujo de logística y Identificación de vehículos Identificación de
o productos sospechosos todos los vehículos
producción es retenida. Esta realcionados
Hoja de Operaciones Estándar (SOS) – Desarrollada por el Ingeniero Industrial y Líder de Equipo
Este documento (estándar) puede ser usado para:
CON TRABAJO ESTANDARIZADO • Entrenar nuevos miembros de equipo
• Anállisis de puestos para oportunidades de mejora
• Auditar (Auditorías de Proceso Escalonadas)
• Resolución de Problemas
Una Hoja de Operación Estandarizada Debe incluir:
(Standardized Operation Sheet):
- Secuencia de Trabajo
- Tiempos de la unidad
- Tiempo de Ciclo de Operación
- Tiempo Takt – del Cliente y Real
- Inventario en-proceso estándar
Propósito:
Hoja de Elemento de Trabajo (JES) – Desarrollado por el Líder de Equipo y los miembros del Equipo
Para establecer una línea base repetible Propósito:
y predecible para la mejora continua e • proporcionar información de entrenamiento detallado para nuevos
involucrar al operador tanto en las miembros de equipo.
• Para cerrar la brecha entre la información de ingeniería y el
mejoras iniciales y en curso para lograr conocimiento del piso de produccción.
los más altos niveles de seguridad, • Proporcionar una historia escrita de dicho elemento.
calidad y productividad. • Proveeer una línea base para auditoría, resolución de problemas,
mejora continua, rebalanceo de trabajo y transferencia de
documentación.
(EJEMPLO)
2.0/2.5 Block
Task Description:
Equipment Description/Number:
Inline Rework for Excess Fins/Flashing
Location:
LGE OP200
Symbols:
Safety
Date
Prepared:
Critical
6/18/2015
Mandatory Sequence
within a STEP
KPV, PQS and or
SFT (s)
Quality
PS01.KPV-200A-1-1, PS01.PQS-LGE-SD,
PS01.PQS-LGE-HD, PS01.PQS-LGE-CC
PS01.PQS-LGE-ED
Mandatory Sequence
of STEPS Environmental
Est. Time
11 sec
(Ejemplo)
Step Description: (What) Step Detail: (How, Why, Key Points) Diagram: (Tools, Special Parts, Special PPE, Layout, etc.)
P Sym . No
Reparación / retrabajo
Use Tool Chart Key Point Visual (KPV) PS01.KPV-200A-1-1
2 Remove fins/flashing from Sides to determine which tools can be used to remove excess
fins/flashing. When removing fins from all 4 sides of block be
sure to follow your Product Quality Standards (PQS)
PS01.PQS-LGE-SD and PS01.PQS-LGE-ED for your
specifications.
Use Tool Chart Key Point Visual (KPV) PS01.KPV-200A-1-1
3 Remove fins/flashing from Crankcase to determine which tools can be used to remove excess
fins/flashing. When removing fins from the crankcase be
sure to follow your Product Quality Standards (PQS)
PS01.PQS-LGE-CC for your specifications. Right Side Left Side
Reintroducir producto
• Todos las inspecciones del plan de control y pruebas deber ser realizados.;
• El producto removido del flujo de proceso aprobado debe ser reintroducido en el flujo de proceso “en”
o “antes” del punto de remoción.
• El producto reintroducido necesita ser identificado y tener rastreabilidad.
• La mejor práctica sugiere que usted no corra producto más de dos veces.
Página 1 de 1
Retrabajo de piezas con S1 y S2 mal maquinado y Elaborado
Tarea No. Descripción: P23y P36 bajo medida
Fecha de Elaboración 22/09/2011
por:
Antonio Sandoval Motilla
Estandarizado Descripción equipo Numero: Ubicación Tiempo Estimado
Símbolos
Retrabajo Chequeo Sec Mandatoria en
Case A Seguridad Proceso Crítico Sec Mandatoria en el detalle los Pasos Ambiental
Calidad
Descripción de los pasos Detalle del paso (Cómo, Porqué y puntos clave) Diagrama: (Herramientas, partes especiales, PPE, Layout, etc.)
P Sim No
MET Operaciones
Previamente ED&S realizó 2 programas para
1 retrabajar estas piezas únicamente maquinando 3
dichas características con herramienta 5005 y 6010
realizada por el 3 Introducir pieza para retrabajo en operación 50 De manera normal y tal como lo muestra tu HTE
5 Repetir pasos 3, y 4 en operación 60 Una vez la pieza ha sido retrabajada retirarla de la máquina
4
VS Calidad
Descargar pieza probada de conveyor de piezas
1 De manera normal y tal como lo muestra tu HTE
Ok
Verificar de manera visual el correcto maquinado de
2 los barrenos S1 y S2, así como el maquinado del De acuerdo a ayudas visuales de op 50 y 60
P23 y P36
Comprobación
realizada por la 3
Certificar piezas de manera normal checando todas
las demás características críticas y maquinados
De manera normal y tal como lo muestra tu HTE
Estación de
Verificación de
Calidad.
C
FECHAS DEL: AL DEPARTAMENTO: TURNO:
TIPO DE CARACTERISTICA
ACCIÓN CORRECTIVA
(KCDS: PQC, KPC, AQC, Máquina NOMBRE DE MAQUINA/ Op. ACCIONES A VERIFICAR L M M J V S D PLAN DE REACCION
INMEDIATA
etc.)
(COLOCAR PALABRA
DINAMICA O ESTATICA)
W6, W7, Verificar las Maquinas trabajen conforme a la EP-LI-06, Parar la Maquina y retroalimentar al
N/A
R.S. EP-LI-1 Y EP-LI-11 LGT para definir acciones a tomar.
Verificar que en los block's 859 se encuentran limpios los En caso de detectar block's sucios
W6, W7,
N/A pasos de aceite lado asiento a cabeza, asiento a carter y de los drenes de aceite, regranallar
R.S.
crankcase al salir de la màquina. nuevamente el material.
(interno y externo) rastreados en la Reunión de Respuesta Rápida. contribuyen a liberar residuos internos. amarilla y enviar a retrabajo.
Q
maquina.
En caso de que las piezas casting
no se cuelguen como lo indica la
W6, W7, Las piezas casting se cuelgan en los ganchos de la HET. Pare la maquina retroalimente
N/A
R.S. maquina de acuerdo a lo que marca la HET. al operador para que las piezas
sean colgadas como lo indica la
HET.
KPC #1 A
L
L
GCA ALL 01/15/16 EACH STYLE PER DAY - CHECK FOR WELD
IMPERFECTIONS - RECORD RACK NUMBER
KPC #1
GCA ALL 07/23/14 ARE ALL EMBLEMS INSTALLED PROPERLY
C
H DO PANELS MATCH RUN SHEET - COLOR
GEN ALL 07/23/14
E AND STYLE
C
K ARE ALL CHEMICAL BOTTLES AND SAFETY
GEN ALL 07/23/14
S CANS LABELED PEOPERLY
KPC #1 O
M
P
FR SW2 07/23/14
CHECK 6 FASCIA'S PER DAY FOR ZIPPER
BRACKET ALIGNMENT- GO/NOGO GAGE
(Ejemplo)
RECORD RACK #
I
L CHECK PICK LIGHTS FOR PROPER
GEN SW1 08/31/15
Y OPERATION
Reason Legend: W: Warranty; PFA: Process Failure Alert from BG; PQS: Product Quality Standard; PMP: Production Maintenance Partnership; MS: Mandatory Sequence;
GCA: Audit Call; OSO: Operator Sensitive Operation; PQC: Product Quality Characteristics; EL: Electrical (DVT, Static, Etc); H20: Water Leak; MUT: Mutilation; GEN: General;
CO-R: Critical Operation; PCP-R: Process Control Check; FR-R: Fast Response (Required for a minimum of 20 days)
NOTE: "-R" means required check and it cannot be removed
KPC #1 KPC #1
Operator Instructions
Corrective Action
Corrective Action
(Institutionalized)
Lessons Learned
Layered Process
Proof/Detection
Containment -
Standard Work
Implemented
PFMEA / CP
Quality Alert
Breakpoint -
Root Cause
Identified
Validated
Updated
Audits
Error
Reason Legend:
W: Warranty(Garantía);
PQS: Product Quality Standard (Producto de Calidad Estándar);
MS: Mandatory Sequence (Secuencia Obligatoria);
GCA: Audit Call (: llamadas de Auditoría );
PQC: Product Quality Characteristics (Características: de Calidad de
Producto);
KPC: Key Product Characteristic;
GEN: General;
CO-R: Critical Operation (Operación Crítica);
PCP-R: Process Control Check (Verificación de Control de Procesos );
FR-R: Fast Response (Required for a
MISSION:
minimum of 20 days) (Respuesta Topara
Rápida (Requerido be leaders of an enterprise approach to ensure
un mínimo de 20 días)) our suppliers achieve launch and quality excellence.
NOTE: "-R" means required check and it cannot be removed
(significa verificación requerida y que no se puede ser removida)
Basado en Calidad: ejemplo de pregunta usada en cada fase de Resolución de Problemas
Operator Instructions
Corrective Action
Corrective Action
(Institutionalized)
Lessons Learned
Layered Process
Proof/Detection
Containment -
Standard Work
Implemented
PFMEA / CP
Quality Alert
Breakpoint -
Root Cause
Identified
Validated
Updated
Audits
Error
Contención:
• La Alerta de Calidad es colocada (Estación dee Documentación:
Verificación(VS) y operación) • El trabajo estandarizado ha sido actualizado
• Método de inspección claramente definido • El Plan de Control de Proceso ha sido actualizado
• La Gente está capacitada y siguen el método de • PFMEA ha sido actualizado
inspección • La forma PTR ha sido usada (BIQS 14)
• Las partes aprobadas son identificadas y • Extrapolación realizada apropiadamente
almacenadas apropiadamente
• Los registros están actualizados (ejem. : I-Chart)
Verify that a reaction plan is available in the event of error proofing device
failure and is understood by the team member.
Error)
LISTADO MAESTRO DE DISPOSITIVOS A PRUEBA DE ERROR REV. No. FECHA REV.
7 Enero 2013
2 4
3
5
MISSION: To be leaders of an enterprise approach to ensure
our suppliers achieve launch and quality excellence. 6
Control de Calibradores /Gage Control
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Gage Calibration / Measurement System Analysis Evidence Gage R&R and certifications are completed on time per local
procedure.
Gage capability (e.g. gage R&R, bias, linearity, stability, etc.) of
BIQS -7 monitoring and measuring equipment is determined and the Check that no gages are past due for calibration.
equipment is certified/calibrated at a scheduled frequency.
Write down 3 gage numbers at random and verify they are in the gage control
system and on some calibration schedule.
(Ejemplo)
(Ejemplo)
SI
SI SI
¿El equipo midió una ¿Prueba destructiva Estudio de Precisión y Exactitud
característica variable? Datos Variables
o no replicable? (Cg&Cgk)
NO NO
Datos de
Estudio de variabilidad del sistema
atributos
para datos obtener variables :
R&R
SI B&L
¿Prueba destructiva Siga Control de Equipo de Estabilidad
o no replicable? Medición y Monitoreo
NO
Tip: ¨si todo es verde¨, entonces algo está mal. O bien no se busca
bien o se están haciendo preguntas equivocadas.
(GMM)
Verificar el contenido de
LPA. ¿Es adecuado para
dirigir el cumplimiento de la
MISSION: To be leaders of an enterprise approach to ensure evaluación para procesos
our suppliers achieve launch and quality excellence. estandarizados y
proporcionar instrucción?
¡Una Gran Parte del Papel de un líder es el de
Establecer Sistemas y después VERIFICAR,
VERIFICAR, VERIFICAR!
¿Qué debe ser Verificado??? Revisar los procesos para identificar y
eliminar desperdicio. Hacer mejoras y
revisar de nuevo.
Elementos tales como:
Seguridad
Organización del Lugar de Trabajo
Requerimientos del Cliente - Calidad
Control de Proceso
Trabajo Estandarizado
Las Auditorías Escalonadas son una herramienta efectiva que debe ser usada por todos los
niveles de la organización para realizar revisiones regulares.
Executive
CEO
Managers
Gerentes (Ejemplo)
//Directores
Directors
Cada
Quarterly
cuatrimestre
/
minimum
mínimo
Múltiples Niveles de la
Plant Manager
Gerente de Planta
1 time
1 vez//month
mes
Administración iniciando
con el Líder de Equipo /
Coordinador / Supervisor
Gerentes
Manager
/ Gerencias
/ Engineers
de Soporte
11vez/semana
time/week
Supervisor
Supervisor/ /Líder
TeamdeLeader
Equipo
Daily
Diariamente
/ Weekly
Plant Mgr & Plant Joint High level overview to verify the 1/week
Leadership (may do individual process is working. Coach
or group audits) /Teach lower levels.
Plan de Auditoría –
Niveles Múltiples
(Ejemplo)
100% 47 50
90% 43 43 45
80% 40
70% 35
60% 27 30
24
50% 23 22 25
20 19
40% 20
16 16
14
30% 15
20% 10
10% 5
0% 0
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
% IN COMPLIANCE: 88% 68% 95% 96% 97% 84% 95% 95% 94% 95% 95% 89%
# OF ITEMS ON ASSESSMENT: 20 15 20 30 20 10 20 25 20 20 20 20
# OF ASSESSMENTS 20 9 28 15 20 10 20 20 20 20 20 20
TOTAL # OF ITEMS ASSESSED: 400 135 560 450 400 100 400 500 400 400 400 400
# OF ITEMS IN COMPLIANCE: 353 92 533 434 386 84 380 477 376 381 378 357
NON CONFORMANCES 47 43 27 16 14 16 20 23 24 19 22 43
Programa
de Auditoría
Escalonada
y Estado
•Notifique al Líder de Equipo /Supervisor sobre
problemas identificados.
•La hoja de Contramedidas debe ser actualizada por el
Líder de Equipo /Supervisor, cada vez que un elemento
Contramedida abierto se cierra.
•La hoja de contramedidas deberá ser revisada
semanalmente.
•Periodo de Retención: Máximo 3 meses
Métricos
Mensuales
Formas LPA
Métricos
Anuales
MISSION: To be leaders of an enterprise approach to ensure
our suppliers achieve launch and quality excellence.
Gestión de Cambio
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Verification Station (Final Inspection /CARE / GP12) Confirm that Verification Station (Final Inspection /CARE / GP12) is
implemented per the local requirement.
Final Inspection / GP12 must be conducted on all finished product
prior to shipping. Can be 100% inspection or audit based on risk. Look for point, touch, listen and count inspection methods incorporated into
All items checked in the Verification Station (Final Inspection quality checks. Look for increased quality checks for launch, shut down or
/CARE / GP12) must be included in a check at an upstream based on customer feedback (eg. Fast Response).
station. Quality checks are included in standardized work. Point,
BIQS -13
touch, listen and count inspection methods are incorporated.
Successive Production/Quality checks are increased in case of
high risks such as model launch, pass through components and
characteristics pass through, major changes, shut down or
customer feedback.
DIAGRAMA DE PROCESO
OP 10 OP 20 VS
Retroalimentación hacia (Ejemplo)
adelante
OP 50 OP 40 OP 30
VS CARE / Auditoría de
GP12 Embarque
Retroalimentación
Garantía Cliente Contacto
Vericicaciones en las Estaciones de
La (s) estaciones de Verificación pueden ser colocadas en cualquier lugar del proceso. Verificiación están incluídas en las
Alarma & Escalación debe ser aplicado a cada paso en el proceso. CARE (Insoección
final) /GP-12 debe estar en el sitio al final del proceso verificaciones de estación de flujo
MISSION: To be leaders of an enterprise approach ascendente. to ensure
our suppliers achieve 60
launch and quality excellence.
Requerimiento BIQS Requerimiento BIQS
Las Verificaciones de calidad están incluidas en el trabajo Las verificaciones de Producción /Calidad sucesivas se incrementan en
estandarizado. Los métodos de inspeccion de contar, escuchar, tocar y caso de alto riesgo, tales como lanzamiento de modelo, componentes
puntear están incorporados. que atraviesan y características que pasan por , grandes cambios, paro
o retroalimentación de los clientes.
(Ejemplo)
Riesgo Alto
• Lanzamiento de Modelo
• Componentes Inspecciones Sucesivas
atravesando • Operaciones de Flujo Protección de
• Características que descendente
Cliente
atraviesan • Estaciones de Verificación
• Cambios Grandes • CARE
• Paro de Planta / Inicio • GP-12
•
Product Quality Standard (PQS) PQS Document # :
PT
Plant: FE. Flint Engine Area Name: 2. Engine
6.FE.I.2.01.04.ULOC
Elementos de Respuesta
Type: I. In Process Category Name 01. Block Machining Product Line :
No Reference #:
Point of use:
04.
ULOC
6. HFV6 Engine Rápida
Item Standard / Frequency Criteria - Sketch
1
Hole #420 Cup Feature: Appearance
plug misaligned Criteria: No visual gap between plug & hole #420
(PCP) Method: Visual
Suspect - Hole #420 Cup Plug Cocked Good - No gap between plug & block
Adición de inspecciones / controles de unas mismas operaciones en las
diferentes estaciones se considera una comprobación sucesiva, y se
deben llevar a cabo a través del trabajo estandarizado; se puede aplicar a
través de las estaciones de verificación y estaciones de trabajo. Esta
inspección adicional ayuda a que el defecto no vaya en flujo descendente
MISSION: To be leaders of an enterprise approach
y ayuda a proteger al cliente.to ensure
our suppliers achieve launch and quality excellence.
PCP = Process Control Plan, EAD = Engineering Ass’y Document, Print, CUST = Customer requirements, Other
This document is uncontrolled when printed, controlled versions are kept electronically.
Master PQS Form Revision Level: 4 PQS Content Revision Level 2012-03-01
(Ejemplo)
DEPARTMENT:
DATE:
REV: 3/13/01
Información de
PRODUCT NONCONFORMANCE:
nuevo
3
Estación de
SORT METHOD (eg. visual, gage, mating part):
2. Rápido!!!:
SORT CRITERIA (clear pass / fail standards):
1a Retroalimentación (Contención)
Y / N = Yes /No (circle one for each question, #2 - #5) *S=Supplier, A=Assembly/Build issue
PRODUCTION RESPONDS
(Completed by the responder)
Corrective Action:
1-Identify Point of Cause Station # ?
Immediate Fix 2-Standardized work followed?
*S Who Breakpoint
What was done with the defective 3-Correct Tools / Fixtures / Error Proofing? Time
A Answered CSN #
Part? 4-Correct Parts?
5-Parts in spec?
6-What did you do to STOP a REPEAT defect from occurring?
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
6:
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
6:
1-Stat #_________
6:
1-Stat #_________
6:
2- Y / N
2- Y / N
2- Y / N
3- Y / N
3- Y / N
3- Y / N
4- Y / N
4- Y / N
4- Y / N
5- Y / N
5- Y / N
5- Y / N
(Ejemplo)
Las Alertas de Calidad colocadas en la operación para
problemas detectados en procesos posteriores.
RETROALIMENTACIÓN
CONTENCIÓN EN CONTENCIÓN EN DE CALIDAD
LA ESTACIÓN LA LÍNEA
DETECCIÓN
PROCESOS
PROCESOS INFORMACIÓN HACIA POSTERIORES
ANTERIORES DELANTE DE CALIDAD CLIENTE
PROVEEDOR
50
45
40
35
30
25
20
Based on 15
10
Count 5
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
A.
1 B.
(Based on Down time and Frequency)
C.
Top three down stations.
A.
2 B.
C.
A.
3 B.
1
Llamada para Ayuda
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Alarm and Escalation Verify that nonconforming material has sufficient alarm limits with escalation.
Nonconforming product has sufficient alarms limits with Confirm that alarms are responded to and the response is documented.
BIQS -16 escalation. Alarms are responded to according to the alarm and
escalation process (reaction plan).
Confirm Visual Standards are updated as a result for the Fast Response
process where required.
Administración Visual
Una proceso en el que los estándares y condiciones
reales llegan a ser visuales rápidamente en el lugar
de trabajo.
Formato
LPA y
estado
SOS
Plan de
JES Proceso
Maestro
Rotación Listal de
de Trabajo herrament
al y PQS
Información Capacitación
de Seguridad
Información
de Calidad
DOCUMENTACIÓN
(Ejemplo)
Terminado
Item Descripción Quién Cuando N/A Si No
1 Actualización de MPP´s y EPL´s
2 Cambio en Ayudas Visuales
3 HET´s y HTE´s
4 Scrolling y/o Diagrama de Hilos
5 Hoja de herramienta Asignada
Organización de Lugar de Trabajo
6 de acuerdo a manual de estandares.
7 Carta de Flexibilidad y JIT
8 Layout
Listado de herramientas y listado de
9 reparaciones
10 Actualización de AMEF´s
MATERIAL
HERRAMIENTAS Y FACILIDADES
Dispositivos a Prueba de Error
1 (llenar formato UAT)
2 HTA eléctrica (llenar formato UAT)
HTA neumática, FRL, toma de aire,
3 Pistola Punteadora,Transformadores
4 KBK´s o estructura
5 Plataformas, Tarimas/Fosas
6 Dispositivos/Equipos/Gages
Topes, marcas en el cable y
7 etiquetas de topes
8 Etiqueta de KPC en tablero
9 Etiqueta Error Proofing en tablero
SEGURIDAD
1 Modificación de MST
2 Cambio de EPP
3 Análisis de Ergonomía
4 Risk Assessment
OTROS
MISSION: To be leaders of an enterprise approach to ensure
1 Actualizacion de Planes de Control
our suppliers achieve launch and quality excellence.
2 Actualización de BPD-GSIP
3 Listado de Equipos en GSIP
4 Actualizar DTR
(Ejemplo) (Ejemplo)
No. DE REGISTRO
REGISTRO C - STD - II - 02 - 4
FECHA DE EMISIÓN
Jun-10
HOJA DE INSTRUCCIÓN DE TAREAS REV. No. FECHA REV.
2 Jan-12
PAGINA: 1 DE: 1
Leí, entendí y me comprometo a seguir la Hoja de Instrucción de Tareas
HISTORIAL DE LA TAREA
Problemas de
MISSION: To be leaders of an enterprise approach to ensure
Calidad
our suppliers achieve launch and quality excellence.
Fecha
Estándares Visuales – comunicados /ayuda para diferenciar
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Visual / tactile / audible Standards - Communicated and Team members shall know the content of Visual standards. Interview a
Understood minimum 3 operators. All shall fulfill the requirements.
Visual Standards are clearly communicated to the team member Visual Standards (checking plans) shall be referenced in standardized work
at the workstation and incorporated or referenced in standardized documentation.
BIQS -18 work. Team members are knowledgeable of the Visual
Standards. Confirm that Visual Standards are clearly differentiate good from bad, are
clearly identified as a Product Quality Standard document and are clearly
Visual Standards to help differentiate "Good from Bad" must referenced in the standardized work.
satisfy customer requirements.
(Ejemplo)
(Ejemplo)
WIP containers, racks and bins protect parts from damage. Visual management includes process diagrams, FIFO tools, rotation
schedules, etc.
Preferred storage method is flow through storage or roller racks to promote
FIFO. Dead end storage should be minimized, any use should be justified.
Ask for documented FIFO process for entire plant. Team Members and Team
BIQS -27 Leaders should be able to explain the process. Process should cover material
against the wall, material in flow-thru lanes, material on racks, point-of-use
indirect material areas, part buffers, sub-assembly areas, and overflow areas.
Containers, racks and/or bins used for WIP storage and movement protect the
parts from damage and easily identify the parts as WIP.
WIP is not kept or stored in GM returnable dunnage.
WALL
1 TO LINESIDE/POU
3 FROM DOCK/PRESS
1 TO LINESIDE/POU
B 2 FIFO
3
Retrieve Driver
FROM DOCK/ To Move FIFO
1 PRESS Indicator
C 2 TO LINESIDE/POU
3 FIFO
Bar used to
1 determine which
D 2 TO LINESIDE/POU row to pick next
3 FIFO
1 FIFO
2 FROM DOCK/PRESS
E
3 TO LINESIDE/POU
Este es un ejemplo de una correcta distribución del piso Esas partes se estancarán en la parte de atrás de la
de producción que apoya bien a PEPS (FIFO). fila y quedarán fuera de los criterios obligatorios
PEPS (FIFO)
MISSION: To be leaders of an enterprise de rotación
approach de existencias.
to ensure
our suppliers achieve launch and quality excellence.
Requerimiento BIQS
Los contenedores de material en proceso (WIP), racks y recipientes protegen a las partes de daño.
(Ejemplo)
Protección de Partes Identificación Min. / Máx.
(Ejemplo)
PFMEA Actualizado
(ALL SHADED AREAS MUST BE COMPLETED) CONTACT: EXT. 5-5391 CHECK ANY ITEMS THAT MAY BE APPLICABLE / IMPACTED: RESPONSE DUE DATE:
SAFETY: CONTACT: SIGNATURE:
SECTION 1: BACKGROUND INFORMATION EMERGENCY PPCR? YES NO
GUARDING OTHER WORK-FIT INSTRUCTIONS
IF "YES", GIVE COPY TO QUALITY
MANUFACTURING: CONTACT: SIGNATURE:
PART NAME(S) IMPACTED Manufacturing Process Bypassed? MAINTENANCE MANUFACTURING INSTRUCTIONS PRODUCTION MONITORING
IF "YES", COMPLETE Manufacturing Process MANUFACTURING ENGINEERING: CONTACT: SIGNATURE:
Backup Worksheet (in S:\ECO\FORMS) PROCESS ROUTING PROCESS PARAMETERS GAGE (DRAWING, PLAN)
TOOLING AND DRAWINGS PFMEA CMM (DRAWING, FIXTURES)
YES NO PROCESS CONTROL PLAN MACHINE DRAWINGS (MECH/ELECT) FLOAT SHEETS
ERROR PROOFING GAGE CHECK SHEET PROCESS FLOW DIAGRAM
MODEL YEAR AND APPLICATION TOOLING ENGINEERING: CONTACT: SIGNATURE:
PART #(S) IMPACTED
CUTTING TOOLS & DRAWINGS CNC PART PROGRAM TOOL ROUTING
INDUSTRIAL ENGINEERING: CONTACT: SIGNATURE:
DATE INITIATED MFG. DEPT(S) IMPACTED OPERATION
WORKPLACE LAYOUT ENGINE SEQUENCING SYSTEM JOB INSTRUCTIONS (SWC/SOS/STS/JES)
/ STATION # TAKT TIME / LABOR CONTENT CYCLE TIME (PART TO PART) STANDARDIZED WORK VIDEO
DUNNAGE (INTERNAL & EXTERNAL) ERGONOMICS GAGE/TOOL CHG/COMP. FREQ.
(IF EMERGENCY, TIME ALSO PLANNED CHANGE DATE MATERIAL HANDLING JOB DESIGN (METHOD CHANGE) VISUAL CONTROLS
REQUIRED) ANDON SIGNALING SYSTEM
PLANT ENGINEERING: CONTACT: SIGNATURE:
OPPORTUNITY / PROBLEM STATEMENT:
ELECTRICAL/CONTROLS SOFTWARE WASHER PARAMETERS/CHEMICALS
RELOCATION/REARRANGEMENTS INSTALLATION/REMOVAL COOLANTS/FILTRATION
ENVIRONMENTAL ENGINEERING: FOR QUESTIONS ON ASSESSING ENVIRONMENTAL IMPACT, CONTACT ENVIRONMENTAL ENGINEER.
QUALITY / RELIABILITY:
APPROVED BY:
PRINT NAME
PRINT NAME
SIGN
(LEADER'S GENERAL SUPERVISOR OR SUPERINTENDENT)
THIS AREA IS FOR CUSTOMER (MANUFACTURING) USE ONLY
SIGN
(MANUFACTURING GENERAL SUPERVISOR OR SUPERINTENDENT)
DATE
DATE
• Diseño
• Máquinaria
• Material
• Método
• Medio Ambiente
ENVIRONMENTAL ENGINEERING: FOR QUESTIONS ON ASSESSING ENVIRONMENTAL IMPACT, CONTACT ENVIRONMENTAL ENGINEER.
QUALITY / RELIABILITY:
P PRODUCTION FOLLOWING ANY CHANGE IN PROCESS OR METHOD OF MANUFACTURE. SECTION 4: OTHER INSTRUCTIONS / COMMENTS
P CORRECTION OF A DISCREPANCY ON A PREVIOUSLY SUBMITTED PART.
P PRODUCTION FROM TOOLING AND EQUIPMENT TRANSFERRED TO A DIFFERENT PLANT LOCATION OR FROM AN ADDITIONAL PLANT LOCATION.
P PRODUCTION FOLLOWING REFURBISHMENT OR REARRANGEMENT OF EXISTING TOOLING OR EQUIPMENT.
CHANGE IN SOURCE FOR SUBCONTRACTED PARTS, MATERIALS, DUNNAGE OR SERVICES (e.g. HEAT-TREATING, PLATING, PAINTING, ETC.)
SECTION 5A: TO IMPLEMENT PPAP WARRANT APPROVED (IF APPLIC.)
P THIS AREA IS FOR USE BY CHANGE LEADER'S SUPERVISOR ONLY
P PRODUCT RE-RELEASED AFTER TOOLING HAS BEEN INACTIVE FOR VOLUME PRODUCTION FOR TWELVE MONTHS OR MORE. APPROVED BY: PRINT NAME SIGN DATE
FOLLOWING A CUSTOMER REQUEST TO SUSPEND SHIPMENT DUE TO A SUPPLIER QUALITY CONCERN. (LEADER'S GENERAL SUPERVISOR OR SUPERINTENDENT)
P
THIS AREA IS FOR CUSTOMER (MANUFACTURING) USE ONLY
P PRODUCTION FROM NEW OR MODIFIED TOOLS (EXCEPT PERISHABLE TOOLS), DIES, MOLDS, PATTERNS ... ETC.,
APPROVED BY: PRINT NAME SIGN DATE
INCLUDING ADDITIONAL OR REPLACEMENT TOOLING. (MANUFACTURING GENERAL SUPERVISOR OR SUPERINTENDENT)
APPROVED
6A. IF ANY SIGNATURE CANNOT BE OBTAINED, THE CHANGE PROCESS STOPS. ALL OTHER
1 1. INITIATOR COMPLETES PPCR FORM SECTION 1 AND SELECTS CHANGE LEADER. DEPARTMENTS CONTACTED IN SECTION 3 OF PPCR FORM.XLS MUST BE NOTIFIED OF THE
7 REJECT.
2. CHANGE LEADER COMPLETES SECTION 2. 7. CHANGE LEADER REVIEWS PENDING PROCESS CHANGE WITH HIS/HER GENERAL SUPERVISOR
OR SUPERINTENDENT (SEE SECTION 3 OF PPCR FORM.XLS).
CMP
4 4A 4B 4B. HAS THE PDT/CIT APPROVED OR REJECTED THE CHANGE?
10. CHANGE LEADER RECORDS THE DATE THE PROCESS CHANGE WAS IMPLEMENTED ON THE
10 PPCR FORM (PPCR FORM.XLS) AND ON THE PPCR LOG SHEET (PPCRLOG.XLS, SEE SECTION 5B).
PPCR APPROVED 4C. THE PDT/CIT LEADER NOTIFIES THE CHANGE LEADER OF APPROVAL OR
REJECTION.
5 4C 4D. THE CHANGE PROCESS IS STOPPED. 11. CHANGE LEADER ATTACHES APPLICABLE WORK SHEETS AND FORWARDS COMPLETED PPCR
11 FORM TO GENERAL SUPERVISOR OR SUPERINTENDENT FOR FINAL APPROVAL. SECTION 5B
5. CHANGE LEADER DETERMINES THE APPROPRIATE PERSONS/DEPARTMENTS REQUIRED TO (PPCRLOG.XLS)
IMPLEMENT THE CHANGE AND COMPLETES SECTION 3 OF PPCR FORM.XLS.
REJECTED
6 6A 6. IS CHANGE LEADER ABLE TO OBTAIN APPROVAL SIGNATURES FROM EACH DESIGNATED
DEPARTMENT? 12 12. CHANGE LEADER GIVES ORIGINAL COPY OF FINAL APPROVED PPCR TO MFG ENGINEERING
NOTE Approval is also needed from final customer CLERK.
APPROVED
6A. IF ANY SIGNATURE CANNOT BE OBTAINED, THE CHANGE PROCESS STOPS. ALL OTHER
DEPARTMENTS CONTACTED IN SECTION 3 OF PPCR FORM.XLS MUST BE NOTIFIED OF THE
7 REJECT.
7. CHANGE LEADER REVIEWS PENDING PROCESS CHANGE WITH HIS/HER GENERAL SUPERVISOR
OR SUPERINTENDENT (SEE SECTION 3 OF PPCR FORM.XLS).
8. DOES THE CHANGE LEADER ACQUIRE WRITTEN DIRECTION TO PROCEED WITH CHANGE
STOP
(OTHER INSTRUCTIONS, SECTION 4 PPCRLOG.XLS) FROM HIS/HER GENERAL SUPERVISOR OR
8 8A SUPERINTENDENT, ALONG WITH SIGNATURE (SIGNATURE BLOCK, SECTION 5A OF PPCR FORM)?
8A. IF DIRECTED TO NOT PROCEED, STOP. NOTIFY ALL CONCERNED PARTIES (SECTION 3 OF PPCR
PROCEED FORM.XLS) WITH REASON FOR CHANGE REJECTION.
Parts are contained, stored and clearly identified prior to and Verify that parts are contained, stored and clearly identified prior to and after
after the PTR build and PPAP approval. the PTR build.
Confirm that for changes that require a customer PTR, all customer locations
are notified. Look to see that production breakpoints are recorded.
AGENDA
PTR Date
Standardized Communication and Documentation (PTR form)
Build Readiness Reviews
Quality Reviews before and after the change
Reasonable sample size
Identification
Containment and traceability
Resources needed
Assistance needed (areas)
Responsabilidad - Rasic
10
20
30
7 1 in 100
1% 10 failures/day PROBLEM
DETECTION POST 8
Examples : Squeak & rattle track, GCA water test inspection
SINGLE SENSORY CHECK - 100% SUBSEQUENT OPERATION
MANUAL X X
MODERATE DISRUPTION PROCESSING Examples : visual check OR touch, CARE line, functional test (without gauge, not MANUAL X X
- 100% of product reworked off-line automatic), verification station
LOSS of SECONDARY Function ATTRIBUTE GAUGING - SUBSEQUENT OPERATION
-Standard / Procedure is offline repair
- vehicle operable, but comfort / convenience functions
inoperable
6 -Mainline Stopped for 20 Minutes or More
6 2 per thousand
1 in 500
0.2% 2 failures/day
Examples: go/no go, manual torque check, length of socket, click wrench,
functional test (with gauge, not automatic), squeak & rattle track, water test
inspection (100%)
MANUAL X X
- Repair likely to cause collateral damage to nearby parts - Primary
process followed. VARIABLE GAUGING - PERIODIC
Examples : torque audit - once/shift, body leak tester (BLT)
MANUAL X X
PROBLEM
3
PROBLEM VARIABLE GAUGING - SUBSEQUENT OPERATION
0.001%
1 in 100,000 every 5 months DETECTION POST
PROCESSING
6 Examples : auto functional test (such as door closing tool)
MANUAL X X
how many times a particular failure occurs at AUTO LINE STOP - SUBSEQUENT OPERATION
**Direction from Global PFMEA Group: "Only use a 2 if you've never heard of this happening" Examples : scanning (bar code readers), vision system, error proofing tied to the
vehicles (not pick bins) such as pressure mats, limit switches, fixturing or tooling,
AUTO X X
PROBLEM
DETECTION POST
PROCESSING
4 counter, PLC controls.
Nota(GMM)
Durante la revisión del proceso (en
cualquier estación de trabajo) verificar si
existen modos de falla de manejo de
MISSION: To be leaders of an enterprise approach to ensure
material.
our suppliers achieve launch and quality excellence.
Administración de Riesgo
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
PFMEAs - Risk Reduction & Annual Review Look for evidence of monthly cross functional risk reduction reviews focused
on preventing defects from leaving the work station. Confirm action plans for
Monthly RPN risk reduction reviews by product focused on top issues include: 1. Recommended actions, 2. Responsibility, 3. Timing.
preventing defects from leaving the work station are held to drive
continuous improvement. Action plans for top issues must Plant Management shall be included in top risk reporting and approval of
include: 1. Recommended actions, 2. Responsibility, 3. Timing. countermeasures.
BIQS -4 Verify if Reverse PFMEA (On-station reviews) findings are driven back into the
Reverse PFMEA process is in place to identify new potential Process Flow, PFMEA, Control Plan, and Work Instructions as applicable
failure mode in the shop floor Best practice cross functional line site review for RPN reductions
Busque (GMM)
Preguntar por el programa R-PFMEA
Verifique la adhesión al programa
Verifique si el equipo tiene una lista de
verifiación o flujo.
Verifique el estado del plan de acción
En la operación(control visual)
Procedimiento (Ejemplo)
GM – WPO P
En el trabajo estandarizado
KCDS – GMW 15049 (Ejemplo)
Any Fastener with Torque Angle to Yield Specification Global Fastening Team NA
Part Name / Description Supplier/Plant Approval/Date: Customer Quality Approval / Date (if req'd)
Any Fastener with Torque Angle to Yield Specification See assembly plant acceptance document maintained on the M E GA PCP website NA
Supplier / Plant Supplier Code Other Approval / Date (if req'd) Other Approval / Date (if req'd)
Característica Especial
TAY (Torque Angle Yeld) Control = 100% Método de control
Trabajo Estandarizado
Hoja de Verificación de
MISSION: To be leaders of an enterprise approach to ensure Datos de Proceso
our suppliers achieve launch and quality excellence.
Requerimiento BIQS
Los Planes o Plan de reacción que vienen del Plan de Control de Procesos están presentes, son seguidos y eficaces.
Reaction plans
Los Planes de mustdeben
Reacción be present and followed.
estar presentes They
y seguidos. mustincluir
Deben include communication,
comunicación,
Contramedidas
equipment de equipo, contaminación
countermeasures, product de producto y validación
containment para asegurar
and validation quethe
to ensure
Las reacciones
reactions werefueron efectivas,
effective, conforme aplique.
as applicable.
Prototype Pre-Launch X Production Key Contact/Phone Date (Orig) 10/16/2009 Date (Rev) 12 / 19 / 2 0 14
Control
Plan Ef f ect ive D at e: See
Number T o rque A ngle t o Y ie ld ( T A Y ) See PQRS for latest owner information M E GA PC P W eb sit e
Part Number / Latest Change Level Core Team Customer Engineering Approval/Date (if req'd)
Any Fastener with Torque Angle to Yield Specification Global Fastening Team NA
Part Name / Description Supplier/Plant Approval/Date: Customer Quality Approval / Date (if req'd)
TORQUE OPERATION LIGHT REACTION PLAN
Any Fastener with Torque Angle to Yield Specification See assembly plant acceptance document maintained on the M E GA PCP website NA TOOL INDICATOR LIGHTS CONDITION ACTION TO BE TAKEN
Supplier / Plant Supplier Code Other Approval / Date (if req'd) Other Approval / Date (if req'd)
TO BE USED FOR FASTENERS WITH TAY OR TORQUE PLUS ANGLE. ENSURE JOINT IS NOT MIS-ASSEMBLED OR DAMAGED.
OPTION A STRONGLY RECOMMENDED FOR TORQUE ANGLE TO YIELD LOOSEN FASTENER & RE-TIGHTEN OR REPAIR PER PAD.
NOT GREEN BAD RUNDOWN
REPLACE AFTER MAXIMUM OF 2 TIMES FOR TAY OR 5
Torque and Dynamic TIMES FOR NON-TAY UNLESS OTHERWISE SPECIFIED.
Tool Transducer Visual
Secure Angle Specification Limits See Light Reaction
N/A Electric tool 1 N/A TAY and Encoder 100% 100% inspection of
Fastener Specificatio and Fully Driven and Plan tab
and Controller lights
n Limits Seated
(Ejemplo)
Los estudios
Ongoing de capacidad
process de proceso
capability studiesenshall
curso
bedeben ser conducidos
conducted Minimum:mínimo:
Quarterly for
trimestralmente para KPCs y anualmente para PQCs y DRs. Los datos para los estudios de
KPCs and annually for PQCs and DRs. Data for the ongoing process capability
capacidad de proceso en curso debe n ser tomados en una base consistente y racional a
studies shall be taken on a consistent and rational basis through the course of at least
través del curso de al menos un mes. La planta puede decidir incluir características
one month.
estándar. LosPlant mayde
estudios decide to include
capacidad standard
de proceso paracharacteristics.
todos los KPCs y Process
cualquier capability
PQCs y
studies for all KPCs and any PQCs and DRs not meeting the minimum
DRs que no cumplan el mínimo de requerimientos deben tener una plan de acción y ser
requirements
evaluados porshall have an
un equipo de action plancruzadas.
funciones and be evaluated by a cross functional team.
Planes de Control
(USL)
(UCL)
Boletines de Herramientas y Equipo
(LCL)
Monitorear el Proceso (LSL)
MISSION: To be leaders of an enterprise approach to ensure
our suppliers achieve launch and quality excellence.
Revisiones de Capacidad del Equipo de Proceso
Verificaciones periódicas (típicamente mensuales), son realizadas para identificar tendencias y
cambios en la capacidad durante períodos de tiempo.
t
no
S
JE
or
Processes allowed to be By-passed
up
ss
(Ejemplo)
(Unless approved by Local Plant Manager)
ck
pa
Ba
By
Comments
T5 Engine Ass'y Line - Main 1직
- OP70 EUN check & Piston wrong parts check vision O O
- OP110 Crankshaft wrong parts check vision O O
- OP120 Piston damage check E/P O O
- OP140 Main Bearing caps Fastening
- OP150 Conrod caps Fastening
- OP160 TTT Test (Shork block Torque test)
O
O
O
O
O
O
Trabajo Estándar de
- OP170 Oil seal housing sealing X X Line Stop. Bypass Not Allowed
- OP170 Oil seal housing bolts Fastening
- OP180 Oil seal housing gasket check E/P
- OP190 C/Head gasket missing & wrong parts check E/P
O
O
O
O
O
O
Derivación/ Desviación (JES)
T5 Engine Ass'y Line - Main 2직
- OP 220 Cyl.head bolts Fastening O O
- OP 230 Camshaft wrong parts check E/P O O
- OP 270 Tappet recheck E/P O O
- OP 310 Cam caps Fastening O O
(Ejemplo)
No. DE REGISTRO
REGISTRO C-BIQ-MN-QR-05-1
FECHA DE EMISION
HOJA DE REGISTRO PARA PROCESOS
NOV '2006
BYPASS DE MANUFACTURA Rev. No. FECHA REV.
7 May-13
PAGINA: 1 DE: 1
Modo de falla
Procesos en los que se puede aplicar bypass en Planta Departamento / Estación herramienta Comentarios / Herramienta Bypass
original
__________________________
GUO de Operaciones
__________________________
_____________________________________ __________________________
_____________________________________ __________________________
_____________________________________ __________________________
_____________________________________ __________________________
_____________________________________ __________________________
_____________________________________
MISSION: To be leaders of an enterprise approach to ensure
__________________________
_____________________________________ __________________________
Operators trained
PFMEA review /
documentation
Layered Audit
plant internal consecutive number of insert exit date of Bypass, if verification was S/L who was notified: Mel Jones
CSN or PVI #: 2ga12345678 PFMEA Tech? N Joshi
Verification
Bypass RPN
conducted w ith OK result
Action Plan
Bypass situation
Bypass #
LAYERED
Status of
Reason for BYPASS:________________________________________________ T/L Validations of Reactions
scheduled
Restart
AUDIT *
Result
Original Process Bypass restart acc. Bypass Bypass Reactions implemented to Contain/Repair/Confirm (Containment present?)
Failure occurence: (C)ontinuous or (I)ntermittent:
which is bypassed started Action Plan Owner exit date (Initial & record CSN/PVI every 2 hrs.)
1st Hour
Directions: After each step has been completed, please initial. Post form at bypass station. Time
1) Record Bypass on Build ticket 1st/2nd hr. 3rd/4th hr. 5th/6th hr. 7th/8th hr.
G 5 Torque OP 2030 C 6/ 1/ 2008 9/ 13/ 2008 K. Smit h G G G G G G Step BYPASS PREPARATION Initial
1 Verify BYPASS JES approved and posted. (Note: Verify torque is confirmed for all spindles in a bypassed station) Initial 2) 100% Manually Click wrench fastener shown below to XX NM. T/L Initials JD JD JD
Y: Verification of original process ongoing T/L Initials T/L Initials T/L Initials T/L Initials
R: Verification of restart done, NOK result Step BYPASS CONFIRMATION & APPROVAL Initial Initial CSN/PVI # CSN/PVI # CSN/PVI # CSN/PVI #
G: operators are trained 5 Notify lead advisor or superintendent:
R: operators are not trained
(according SOS/JES) G: RPN of Original process in allow able range Name:_______________________________________ Title:____________________________
Y: RPN too high, process needs optimization Bypass Ended Bypass Ended
4th Hour Bypass Ended Date: May 23/2012
R: RPN not evaluated 6 Lead advisor or superintendent verify "BYPASS PREPARATION" steps 1-4 above completed. Time CSN/PVI #: 2ga12345999 S/L notified: Sudesh Kent
Error Proofing back on Prod. Group or Shift Leader Quality Tech/Lead
Date: May 23/2012
G: RPN of Bypass process in allow able range G: Layered Audits conducted, results ok Step BYPASS IMPLEMENTATION Initial Initial line and validated by: Signature: Sudesh K ent Signature: Connie Tuck
Y: RPN too high, process needs optimization Y: deviations found in Layered Audit Both Signature are Mandatory!
R: RPN not evaluated
8 Record FIRST unit processed in bypass/backup:
R: Layered Audits not conducted
Trace#:_____________________________________ Time:______________________ If bypass continues beyond 3 shifts - start next sheet. Form Revision: May 24/2012
G: all actions w ithin due date 9 Is there suspect material? Yes No If yes, initiate containment checksheet. 5th Hour
Y: actions behind target date Time
R: no action plan available 10 Complete Business Team process to notify succeeding shift.
NOTE: Post the original form at bypass station. Forward a copy of this form to Superintendent/Lead Advisor. Initial
If station is still in bypass at end of shift, next shift MUST initiate new " BYPASS CHECKLIST AND LAYERED AUDIT " form.
Las derivaciones/desviaciones
Signature:_________________________________ Title:_________________________
Initial
12 Verify station placed back into full automatic. Re-evaluated RPN: ______
8th Hour
MISSION: To be leaders of an enterprise approach to ensure 14 Verify tools returned to cabinet: Initial
our suppliers
de Reinicio achieve launch and quality excellence.
9th Hour
15 Approval of Restart of original process Time
2o. Verificación
Authorized Signature:________________________________ Date & Time: ___________
Initial
NOTE: Remove "BYPASS CHECKLIST AND LAYERED AUDIT" from station & forward to Superintendent/Quality Coordinator.
Trabajo Estandarizado
Falla (I)ntermitente o
Liderazgo
Auditoria Escalonada
Operador entrenado
Verificación de
RPN de Bypass
Resultado de
Fecha programada
© Continua
Fecha de
Bypass #
reinicio.
Status
Inicio de para reestablecer
acción
salida de
Proceso Original con bypass Bypass el proceso original Responsable
Bypass
de acuerdo a plan
de acción.
(Example)
Nota: Remover el formato de bypass de proceso de la estación y enviarlo al GUO o Coordinador de Calidad.
LGT Calidad
Paso Sección 4: Es llenado por calidad Proceso Bypass Auditado / Registrado 18a hora
16 Auditar el proceso Bypass para verificar que se haya completado apropiadamente (GUO de Calidad o delegado) Hora
Firma del GUO de Calidad: Fecha y Hora:
LGT Calidad
17 "CHECKLIST DE BYPASS Y AUDITORIA" Completada y llenada en DCC. Firma LGT Calidad
Firma de Calidad: Fecha y Hora:
MISSION: To be leaders of an enterprise approach to ensure 20a hora LGT Calidad
When customer requires sediment control, verify that the supplier adheres to
stated frequencies, maintains trend charting and corrective actions for out-of-
control and out-of-spec points.
Stamping Paint
2. Identificar las fuentes de
contaminación (usar PFMEA)
1. Entender los requerimientos de
contaminación
4. Establecer controles detectivos Assembly Machining
y preventivos
5. Verificar la efectividad de las
acciones
Plastic
Dust
Cotton Cloth
Ferrous chips
Foreign material
Oil
G Y R
MISSION: To be leaders of an enterprise approach to ensure
our suppliers achieve launch and quality excellence.
126
Administración de Flujo de Material
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Shipping Approved Packaging Production intent containers are being used for any build events.
A process is in place to ensure that violations of the requirement are identified
Material is shipped in the designated production container with and corrected.
BIQS -28 proper labeling for regular production and all saleable build
events.
Etiquetado:
Las etiquetas del Contenedor contienen al menos – número de parte,
proveedor, fecha de embarque /fabricación, cantidad, ubicación de
almacenaje u códico d and código de muelle de recibo.
Los requerimientos de etiquetado deben estar establecidos.
Los procesos de etiquetado deben ser efectivos.
El etiquetado de A prueba de error (Error proofing) debe estar
incluído en el diagrama de Flujo, PFMEA y Plan de Control.
Etiquetas con código de Barras son requeridos y usados para eliminar
MISSION: To be leaders of an enterprise approach
oportunidades to ensure
de error.
our suppliers achieve launch and quality excellence.
Mantenimiento
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Maintenance To maintain equipment and tools to the required standard, achieve business
results, and to ensure availability for production.
A planning process that achieves reliability excellence, with
Manufacturing Engineering, Operations and Maintenance working - List of critical spare parts.
together. Comprehensive tasks are developed and delivered - Stock of spare parts: reception / organization / consumption.
that support Total Productive Maintenance. - Conditions of storage.
- Computer aided system.
The spare parts and their storage are managed. - Inventory (take an example of a critical part and verify the robustness of the
The critical parts are identified. inventory).
BIQS -26
- MTTR & MTBF
The maintenance planning must cover machines and tooling, for
preventive maintenance and where applicable the predictive Look for evidence that PM schedule generates work orders and that these are
maintenance should be developed. closed as scheduled must cover machine, toolings and gages.
Look for use of predictive and preventive maintenance, check some
examples.
Look for PM frequencies appropriate to needs.
Proceso de Planeación
Plan de
Mantenimiento
Preventivo
(PM )
Tareas
Equipo del
Plan de MP
(PM)
Herramientas del
El Documento permite: Plan de MP (PM)
• Dar seguimiento a las
operaciones preventivas
• To
MISSION: Identificar la mejora
be leaders del enterprise approach to ensure
of an
plan de mantenimiento
our suppliers achieve launch and quality excellence.
Administración de Proveedores Nivel 1 (Tier Supplier)
BIQS
BIQS Requirement BIQS Calibrator Guidelines (Look For)
Item #
Supply Management Is there a process at all Tiered suppliers for tracking internal and external
issues?
Tier supplier targets are defined and their performance are Do they mandate a Fast Response process be used?
tracked. Do they review how effective their problem solving process is at each Tiered
BIQS -29
Annual Audits are performed, issues found are tracked until supplier?
closed. Are annual Tiered Audit performed? Do they use BIQS 1-13 at a minimum to
Quality Data is used in the sourcing decision process. audit?
Selección de Proveedor
El criterio para convertirse en proveedor abastecedor
Rastreo de Desempeño está definido.
(Ejemplo) Para que la ubicación de proveedor sea elegible para
Lista de Proveedores Aprobados
recibir una nueva adjudicación de negocio debe ya sea
tener:
• Estatus de Abastecedor en la «Lista de Proveedores
Aprobados» (Bid List)
O
• Un Documento firmado que le soporte (ej. Caso de
Negocio de Calidad (Quality Business
Case(QBC)reporte QUAD) con una auditoría
aprobada.
El Departamento de Calidad del Proveedor u
(Ejemplo) organización está completamente involucrada en el
proceso de abastecimiento.
BIQS 18