Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

• Andon System• Peer – to – Peer Product Confirmation

BODY SHOP FY 12/13

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

Objective

Interface

Concept

• Instill ‘right at the first time’ culture

• Product confirmation

• SOP – Self checking

Peer –to- peer product confirmation

Sub Assy Main Assy Fitting

• Enhance problem solving skill

• Enhance product & process quality ownership among workers

• Quick response to BIW requirement• Product audit

Andon system

1.0 OBJECTIVE

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

2.0 APPROACH

• Appearance• Fitting• Part

variation

External

• Weld nut / hole missing / offset

• Part variation

Internal

• Line stoppage for quality problem

Andon

• New self check methodology

• Confirm peer product before next process

Peer – to – peer

product confirm

Sub Assy line

Main Assy line

Fitting line

Product Confirmation

BIW Area System Station

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

4.0 ANDON SYSTEM CONCEPT

Pull Andon

> Call related group> Discuss containment action> Decide repair – Online / offline

> Investigate root cause > Plan for countermeasure

Repair affected body

Insert

at DL1B

Quality Problem?

LINE ON LINE STOP LINE ON

Preliminaryreport

Problem solvingreport

Certificate of repair

FillingPull station stop string

PIC

Final line Final line & related groups

Related groups Final line & related groups QIT

Interface

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

Process

STAGE #1

Product Confirm

#1Process

Product Confirm

#1

Product Confirm

#2Process

Product Confirm

# X

STAGE #2 LAST STAGE

Place marker tospecified points

Remove marker Place marker tonext specified

points

Remove marker & put in the box

M-LINE

HOLE #1

M-LIN

E

HOLE #1

M-LIN

E

HOLE #2

M-LIN

E

HOLE # X

BOX

Method

• Magnet Marker

• Simple gauge • Bolt / screwProposed Tools• Hole plug

5.0 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

5.1 PEER – TO – PEER PRODUCT CONFIRMATION SYSTEM CONCEPT [CASE STUDY]M-L

INE

M-LINE

M-LINE

M-LINE

M-LINE

M-LINE

M-LINE

M-LINE

M-LIN

E

SPM HOLE

BOX

1

2

3 4

5

Fitting Line• To confirm correct closure

parts (RHS) installed to body• Tool – magnet marker• Date – Mar ‘12 [start]

Rear door #5(Closure)

Fitting #4

Fitting #5 Fitting #8

Fitting #9

Quality Ownership Engagement Program

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Marketing Department

Quality Ownership Engagement Program

BODY ASSEMBLY MAIN PLANT

6.0 IMPLEMENTATION PLAN

NO SYSTEM STATION FOCUSED AREA IMPLEMENTATION STAGE

1 Andon Fitting Line• Final

• Appearance• Major repair• Part variation

Phase 1 – Major repair

2Peer – to – Peer Product Confirmation

Sub Assembly Line• Side Structure• Front End

• Weld nut / hole missing / offset• Part variation• TF rejection

Pilot Project