GP-12 Training (Chinese) (Updated)

2020/2/28GP-12EarlyProductionContainmentThomasGormanGP-12早期生产遏制2020/2/28AStrategyForImplementationWhatisGP-12WhyweneedGP-12HowtoimplementGP-121执行策略什么是GP-12为什么需要GP-12如何执行GP-12VisionStatement目标GP-12isanattempttoprotecttheSupplier,SGM,andtheCustomerfromsurprises2GP-12的目的是尽力避免供应商、SGM以及客户处发生意外的质量事故。GoalandObjectiveThedesiredgoalistohaveaproblemfreelaunchandasmoothprogressionintonormalproductionThedesiredobjectiveisputinplaceextrameasuresinearlyproductionthatwillbeeffectiveinkeepingsupplierproblemsintheirownplant.3目标与目的期望的目标是使问题自然暴露,平稳地进入正常生产阶段。期望的目的是在早期生产阶段,实施额外的检验控制手段，以保证在供应商现场发现并解决质量问题。WhyAreWeTalkingAboutEarlyProduction?为何讨论早期生产？SGMsuffersmoreproblemsatlaunchthanafter在生产初期SGM往往遇到更多的质量问题。learningcurve知识曲线Surprises意外质量事故SuppliersoftenconductpoorAPQP供应商常实施不合格的APQPmerelyapaperexercise仅仅纸上谈兵humanimaginationislimited有限的个人想象limitedtime,variouschanges有限的时间，多样的变化4WhyAreWeTalkingAboutGP-12Today?为何今天讨论GP-12IFsuppliersdoapre-launchcontrolplan:如果供应商制作一份试生产控制计划:itisoftenpoorlythoughtout常常缺乏认真思考。itisreallytheplantheyexpecttorollintonormalproduction实际上他们是想将之应用在正常生产中。itisnotgoodprotectionforSGM这无法向SGM很好地负责。Suppliersareoverlyconfident供应商过度自信supplyothercustomerswithlowerqualitystandards提供较低的质量标准给其他客户。itisdifficulttoseeyourownflaws很难发现自身缺点。5GP-12ScopeGP-12应用范围AppliestoallsuppliersrequiredtousePPAP适用于所有要求使用PPAP的供应商。Usedforpre-productionandproductionrequirementsthatrequirePPAP应用于要求使用PPAP的试生产和批量生产。Carry-overqualityconcernsshouldbeaddressedusingControlledShipping遗留的质量问题应通过控制发运来解决。GP-12DefinitionandPurposeGP-12定义与用途Documenteffortstocontrolprocessesduringstart-upandacceleration在生产启动和加速阶段，过程控制文件化。Qualityissuesthatarisearequicklycontainedatthesupplierslocation在供应商现场迅速遏制所发生的质量问题。Pre-LaunchControlPlan试生产控制计划validateproductioncontrolplan评审生产控制计划GP-12SupplierResponsibilityGP-12供应商职责Establishcontainmentprocess建立遏制流程Identifypersonresponsible确定负责人员DevelopaPre-LaunchControlPlan制定试生产控制计划Developadditionalcontainment制定附加的遏制政策Promptcontainment及时遏制Identificationofequipmentanddevice标明设备及装置UseGP-12forspecifiedperiod指定时期应用GP-12Greendot绿色圆形标签Pre-LaunchControlPlan试生产控制计划Increasedfrequency/samplesize增加频率/样品数量Sub-suppliercontainment分供方遏制Additionofinspection/controlitems附加检验/控制项目Increasedverificationoflabeling增加对标识的检查Enhancementofprocesscontrols,suchaserrorproofing加强过程控制，例如防错Errorproofingvalidationbyintroducingknowndefects通过对已知缺陷的分析确认防错Increasedinvolvementandvisibilityoftopmanagement加强高层管理的参与性与透明度GP-12ExitCriteriaGP-12退出准则SuppliercanexitGP-12if若满足以下条件，供应商可退出GP-12nonon-conformances没有不符合项meetnumberofpieceorperiodoftimerequirement零件数量或生产时间符合要求approvedbySQESQE批准Ifnon-conformancesfound若已发现了不符合项PR/R’sclosedbycustomer客户关闭PR/RControlplanvalidated控制计划得到验证Recommendations建议Makesurepre-launchcontrolplanisakeypartofAPQP确信试生产控制计划是APQP的关键部分appendixA-8附录A-8Clearlydifferentiatebetweenproductioncontrolsandpre-launchcontrols明确区分生产控制与试生产控制alsouseasummarysheet同样使用总结表GP-12reviewsGP-12回顾withfellowSQE与SQE同事withlaunchteam与生产小组成员withGP-12coreperson与GP-12核心成员TreatGP-12likeaControlledShippingcontainment对待GP-12如同控制发运遏制政策6BenefitsofGP-12GP-12的利益WithimprovedGP-12随着改进的GP-12fewerproblemsatourplant更少的问题在生产现场发生atlaunch生产启动时afterlaunch生产启动后Improved改进PFMEA过程失效模式分析errorproofing防错understandingofprocess理解工艺understandingofcontrols理解控制bettersupplierperformance更好的供应商表现lowerPRRcontainmentcosts较低的PRR遏制成本avoidCS1andCS2costs避免一级/二级发运控制成本7SomePracticalSuggestions一些实践建议Develop100%auditandchecklikeaCS1plan实施100%审核以及象一级发运控制计划一样检查checkformissedoperations检查漏加工missingholes,taps,parts漏孔、漏接头、漏零件developfunctionalgages开发功能性检具checkforprocessdamage检查工艺失误reviewoldPRRandqualitydata回顾老的PRR和质量数据Identifycustomerinterfaces确定客户界面SGMandfinalcustomerSGM以及最终客户ClearlyhighlightallGP-12featuresinPre-LaunchControlPlan在试生产控制计划中，清晰地突出所有GP-12要点。Documenteverythingyoufindclearly,andfollow-uptopreventanddetectinnormalprocess仔细记录发现的每个问题，并跟踪以便在正常生产中及时预防和观测同样的问题。MoreSuggestions进一步建议Usetheprovidedchecklist利用所提供的检查清单。Useseparateauditarea,donotdisruptnormalproduction在不影响正常生产的前提下，利用分离的审核区域。Usedisplayboardtopostinstructions,data,andactionplans利用陈列板张贴作业指导书、质量数据及反应计划。Trainauditteam培训审核队伍。SUPPLIER’SWORKSHOP供应商车间PRODUCTIONAREA生产区域GP-12AUDITAREAGP-12审核区域DisplayBoard陈列板ProgressCharts过程图PPHVTrend0.00.51.01.52.02.53.03.5period1period2period3currentperiod9/19/29/39/49/59/89/109/119/129/159/169/179/189/199/229/239/249/259/269/299/30ParetoChart-Top6Issues0.0%0.5%1.0%1.5%2.0%2.5%3.0%Problem1Problem2Problem3Problem4Problem5Problem6period1period2period3currentperiod