福特汽车生产制造概论

生產製造概論ByRingoD.L.LinFordLioHoMotorCo.,Ltd.生產製造概論•品質系統•新車上市控制計畫•環境保護•SixSigma•物料規劃與運籌•福特生產系統/工廠工程&維護•顧客滿意品質系統•TotalQualityExcellence–CompanyPolicyLetterNo.1.•BriefHistoryofFLHQualityManagement•QualityArrow(QualityisJob#1)•QS-9000/ISO14001System/QualityOperatingSystem•TGWReduction/VRT/SAQ•TGR/KanoModel(tobecoveredbyKnightindetail)•Define,Measure,Analyze,Improve,Control•Designfor6-Sigma•CommonProblemSolvingLanguage&Tools•HighQuality,HighVelocityImprovementsinBusinessResults•9LeadershipPrinciples•RewardandRecognition•TrainingandFeedback•PartnershipwithUnions,DealersandSuppliers•VehicleQuality(High&LowTime-In-Service)•CustomerSatisfaction•TGW•Warranty•ResidualValue•Sales&ServiceSatisfaction•EliminationofWasteQualityIsJob#1QUALITYLEADERSHIPINITIATIVEEngageAllEmployees6-SIGMADataDrivenDecisionMakingQUALITYOPERATINGSYSTEMPerformancetoStandardsDriveProcessDeliverResultsPlanDoCheckActFordMotorCompanyQOSProductCreationSales&ServiceCertificationSystemFPDSFutureCustomersCurrentCustomersOrdertoDeliverySuppliersLaunchCurrentModelFPS3PillarsofFordQualityIsJob#1StrategyFordLioHoQualityResolutionFlowDiagramRYGRYGRYGRYG1Time&DataMgmt.GGGG2VariabilityReductionVRT/VFGGGGG3ToolVerificationGGGG4IncomingMaterialYG5ProcessControl/Build&InspectionProcessGGGG6RepairSystemYGYG7QualityAcceptanceCriteriaG8WeldSurveillanceG9DimensionalControlG10TorqueAssuranceY11FCPAG12WindNoiseGQOSArea/ElementR/Y/GRatingsVOQOS/QITDArea/ElementsBodyPaintFinalPDA/NOVA-CQOS總表-1/3RYGRYGRYGRYG13Squeak&RattleG14Water(20minutesoak)G15M-10ProgramG16CBT(PDIorFinal)17PIC(ProductInformationCenter)G18QVSQuickVIMSG19ControlPt/TipLevelRR20UltraSonic21AirLeakageTest22JointQualityComm./Mgmt.QualityComm.236-SigmaMethodologyQOSArea/ElementR/Y/GRatingsVOQOS/QITDArea/ElementsBodyPaintFinalPDA/NOVA-CNewQITDArea/ElementsGTBDTBDTBDQOS總表-2/3RYGRYGRYGRYGTime&DataMgmt.GGGGVariabilityReductionVRT/VFGGToolVerificationGIncomingMaterialYProcessControl/Build&InspectionProcessGGRepairSystemGQualityAcceptanceCriteriaGGQOSActivity/ElementR/Y/GRating24252627VOe-QOSElementAPQPMCPVTRec'g/InspQOS總表-3/3新車上市控制計劃課程內容1.製造處“前瞻工程部”新車導入職掌介紹現行車輛生產流程暨製程管制2.新車上市前生產可行性評估及成本分析(feasibilitystudy&costanalysis)3.新車上市之製造計劃(ManufacturingLaunchPlan)4.新車試作階段之流程管制成功大學EMBA經營管理企業永續經營追求永續利潤~由環境保護創造利基•壹、公司簡介•貳、企業永續發展、經營策略•參、利潤與生態雙贏策略•肆、企業公民：整合性產品策略、綠色製造策略•製造流程及污染防治成效說明績效說明•-執行理念與策略•-工廠環境管理現況(綠色生產力)•-執行情形•-具體成效(環保績優獎項)•五、結語QualitylevelWhatisSixsigma?WhyweneedSixsigma?DevelopmentandDeploymentstrategyHowSixsigmamergesintoourdailybusiness?OutlineSigmaLevel與合格率的關係每百萬不良數合格率2308,53769.15%366,80793.32%46,21099.38%523399.98%63.499.99966%SigmaLevel在1.5s的長期偏移量下挑戰—為什麼大多數的企業在3~4Sigma?3sigma4sigma5sigma6sigma大多數的企業能力障礙•沉醉過去的成就(不再挑戰)•靠檢驗及檢修•依賴嘗試錯誤法(經驗)•救火式的解決問題(頭痛醫頭)•缺乏數據•部門間互相的推卸•官大學問大挑戰—超越障礙大多數的企業能力3sigma4sigma5sigma6sigma那些動力可以躍越障礙?•深信我們還有進步的機會•相信方法論•接受挑戰現況•導入新的技術,工具及手法•領導管理階層的態度—改變•實事求是的行為表現障礙我們的機會獲利減少哪一種比較有利??行政,製造,或運輸的成本利潤理論上的成本利潤*COPQ理論上的成本COPQ理論上的成本利潤COPQ*COPQ:CostOfPoorQuality(劣質成本)利潤目標Year20012002CurrentObjProjectsfromS.A.Q12%83%80%GreenBelts188530600GreenBeltprojectsopened29151137GreenBeltprojectsclosed036120ProjectsonhandsperBlackbelt1.23.43BlackBeltprojectsopened218163BlackBeltProjectsclosed443884EachBlackBeltProjectsclosed2.92.24•FordProductionSystemandVision,•MP&LMission,RoleandResponsibility•ModelLine-UpComplexity•ProductionScheduleandRelease•MP&LExteriorandInternalLogistics•CommonMaterialManagementSystemIntroductionofFLHMP&L介紹內容福特生產系統內容大綱1.企業競爭與觀念變革2.福特生產系統之概念3.精實製造基本觀念4.FPS系統介紹與展開5.FPS小組活動6.FPS小組活動推行績效7.結語工廠工程&維護大綱•FTPM定義•ECPL動力上鎖簡介•FTPM系統介紹•TEM(TotalEquipmentManagement)•FRACAS簡介•Q&A顧客滿意•CustomerisJobNo.#1•TGW/TGR/CV-Sales/CV-Services•DelightedCustomers•ConsumerDriven•LifeCycleSatisfaction•Loyalty謝謝