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