新工厂管理要求

GlobalCompetitiveSupplyChainCollaboration1新移地工厂（生产线）管理要求BasicRequirementOfNewSupplierPlantSiteChange(ProductionLine)SGMDYPD2010.6.102SGM-DYConfidential-PDSQE主要内容summary一、项目管理Projectmanagement………………………………………3二、厂房及公用动力WorkshopandPublicpower……………………4三、焊接设备Weldingequipment………………………………………6四、工装fixture………………………………………9五、检验设备、工具C/F,Tools………………………………………11六、物流Logistics…………………………………………13七、备品备件SparePart………………………………………15八、定置目视化visualmanagement…………………………………16九、人员配置、培训Workermanagement,training…………………17十、质量控制QualityControl………………………………………19十一、QSB管理提升QSBimprovement………………………………21十二、审核Audit………………………………………223SGM-DYConfidential-PDSQE项目管理Projectmanagement1、供应商移地立项后，供应商需要提前通知上海及东岳采购部，并附买地、规划的详细信息。SuppliershouldinformSQEthedetailsabouttheplantsitechangeplaninadvance.2、供应商要成立跨部门的团队，共同制定移地项目的启动计划。Suppliershouldestablishaninter-departmentworkinggrouptodrawupsitechangeplan3、启动计划要包含新工厂筹备的人、机、料、法、环各方面内容。并对内容分解展开为具体的工作项，设定负责人，和起止时间。Sitechangeplanshouldincludepeople\machine\part\method\environment.Shouldanalysethecontentmakethedetailedworkingitem.Defineresponsibilityperson,schedule.4、项目的主要时间节点，要和SGM新车型launchplan衔接，并且经过了SQE的批准。TimingchartshouldbeaccordingtoModelprojectlaunchplan,alsobeapprovedbySQE5、供应商的管理层，要定期评审移地项目计划的进展，确保节点和质量均达到要求。对关键节点的后延，要及时向SQE汇报，并制定整改措施，交SQE审核。SuppliermanagershouldreviewtheSiteChangePlanregularly,confirmtheactualstatusaccordwiththerequirement,Regardingthekeytimingdelay,itshouldbereportedtoSQE.Andtakeimprovecontainmentatthesametime.4SGM-DYConfidential-PDSQE厂房、公用动力-workshopandpublicpower1、厂房设施和结构要满足冲压、焊接生产的生产要求。ThestructureofworkshopshouldmeetthePress,Weldingproductionrequirement.2、厂房主要包含生产、仓储两大区域，面积要经过测算，能满足最高合同产能（MCR）的生产要求，和最低3天安全库存的仓储要求。Theproductionandstorageareashouldbemeasuredexactly,shouldsatisfyetheMCRrequirement,satisfythe3dayssafetystorerequirement.3、对公用动力（水、气、电）要求：requirementaboutPublicPower.►冷却水系统要能够保证一定的水温、水压以及流量，要有外循环水冷却系统，如风冷式冷却塔，控制一级管路冷却水温度要低于30℃，进水、回水管路要保证0.2Mpa压差。Coolingwatershouldkeeptemperaturestated,Thepressdifferenceofenterandreturnpipekeep0.2Mpa.►冷却水系统要有水过滤装置，在主管路和设备终端前都需要加装。要求对水质定期软化处理。Coolingwatersystemshouldincludefiltrationequipment,Thewatershouldbeintenerateregularly.►冷却水系统要有防尘装置。Theremustbedustproofequipmentinthecoolingwatersystem.5SGM-DYConfidential-PDSQE►为避免冬季低温上冻（-13℃），水泵房到车间的室外管路需做好保温处理，要求设计为室内走管。在冬季非生产时启动水泵强制水循环。ToavoidthewaterfreezinginWinter,Thepipesshouldmakeheatpreservation,Keepwatercirculateatshutdowntimeinwinter.►要保持冷却水系统稳定的水压，需加装可自行启动的备用水泵。hydraulicpressureshouldkeepsteadybystandbywaterpump.►管路要有目视化的标识，区分一、二、三级进水和回水管路。Pipevisualmanagementshouldbetaken.►对冷却水系统主要参数的控制，尽可能采用防错技术。人工监控的要有点检制度和书面记录。TheparameterofwatersystemshouldbecontrolledbyPOKA-YOKE.►压缩空气压力在气路末端超过0.6Mpa。储气罐、气路末端增加排水装置。Compressairpressureshouldexceedto0.6Mpaintheendpipe,Thedrainageshouldtakenattheend.►对公用动力设备要进行测试，压力容器还要经安监部门验收。Testthepublicpowerequipment,andthepressurevesselshouldbecheckedbysafetysupervisiondepartment厂房、公用动力-workshopandpublicpower6SGM-DYConfidential-PDSQE焊接设备-WeldingEquipment1、为保证焊接可靠性，对复杂总成零件（轮罩、前、后端板、仪表板、仪表板上横梁等）主体工序，要求采用点焊机器人。Toensurethereliabilityofweldingprocess,WerequesttoadoptRobottoweldtheWheelpanel/Dashupper/DashLower.etc,2、高强度钣材零件（纵梁、门槛板等），要求采用点焊机器人。建议配备中频焊机和伺服焊枪，或者有可靠的应对措施，以保证焊接质量。Highstrengthparts,exampleforcarlingpanel,Doorsillpanel,etc,suggestsuppliertoequipintermediatefrequencyweldingsystemandservosystem,orcrediblecontainment.Inordertoensuretheweldingquality.3、功能件、安全件的CO2焊接，要求使用弧焊机器人，建议加装自动清枪器。Functionparts,safetypartsCo2welding,requestuseRobot,suggesttoequipautoclearmachine.4、对薄板接地螺柱焊接，要求采用可靠的拉弧焊设备，并提高人工操作稳定性。推荐使用自动螺柱焊接系统,克服人为因素导致的焊接质量波动.Accordingtothesheetpanelstudwelding,requesttotakecredibleequipment,Recommenduseautostudweldingsystem,inordertocontroltheman-madeaffection5、手工悬挂焊机必须要有焊接电流递增设置，补偿电极帽损耗导致的电流密度的下降。递增到预设点数后焊机会停止焊接，提醒操作人员更换电极帽。Theelectricalcurrentincreasebydegreessystemshouldbetakentotheweldingcontroller.7SGM-DYConfidential-PDSQE焊接设备-WeldingEquipment6、悬挂焊、凸焊、螺柱焊设备均需要加装电子焊接计数器，且悬挂焊计数器要与焊机、或工装联动（通信），以起到可靠防漏焊的效果。Thespotcountershouldbeusedinweldingequipment,itshouldbetterlinkwiththefixture,inordertopreventthespotleaked.7、普通焊枪焊接电缆使用无感通水电缆，一体式焊枪除外。Commonweldingtorchshouldusenoelectromagneticcable,exceptfortheincorporateweldingtorch.8、点焊焊枪要有一定的刚度，在0.45MP气压下，最低压力要能达到350Kgf，焊枪无电极错位。Spotweldingtorchmusthaveenoughintensity,thelowestpressurein0.45MPairpressureshouldachieve350Kgf.9、一把焊枪要选用一套焊接参数，避免用A/B档开关切换，屏蔽A/B档切换功能。Oneweldingtorchshoulduseonesuitofparameter,avoidtouseA/Bshelvestoswitch8SGM-DYConfidential-PDSQE10、焊接参数（点焊、凸焊、拉弧焊）的设置、调整要锁定，只能由焊接工程师、或授权的专人更改。Weldingparametershouldbelocked,onlycanbeadjustedbyprofessionalworkers11、点焊冷却水开关要有防错装置（加装传感器与焊机联动），避免更换电极帽后，操作人员忘记打开冷却水直接焊接，造成批量虚焊。SpotweldingequipmentshouldincludePOKA-YOKEfitting.12、点焊电极帽不允许手工修磨，要求采用在线更换，集中修磨、或在线设备修磨的方式。点焊机器人要求配备电极帽在线自动修磨器。Thepoleshouldbegrindedtogether,SpotRobotmustbegrindedautomatic焊接设备-WeldingEquipment9SGM-DYConfidential-PDSQE工装-Fixture1、焊接工装的设计、制造、使用执行SGM对供应商工装管理要求。Thedesign,manufactureusingofweldingfixtureshouldfollowedtherequestofSGMFixturemanagement.2、工装档案资料要完整，包括工装图纸、数模、垫片记录等。Thefixturerecordshouldbeintegr