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TCM DISPLAY
BOARD
Display Concept
②
Scrap Change- Change-
TCM Custmoer Gage SU/PY Tool Life Machine Color- Dropped
Andons PQIs Guidelines PMs Recode over Blue over
Keywords Returns Calibration Check / Pit Stop Release coded Tags Parts
Person Light Racks
③ Requirements
④ TCM
Examples
Firewall, QAs Andon lights
PQIs, Cleaning
Standards
Guidelines,
SU/PY form
Gage Cal
stickers
Go/No-Go
masters
PM
Workorders
Pit Stop Lights
Machine
Release Forms
Color-coded
Tags
Scrap/Recode
Cart
Scrap bins
Changeover
Blue Light
Changeover
Racks
Banner design is
14 Qualitätsprinzipien für den Wertstrom
14 Quality Principles for the Value-Stream
Thema/Topic
des/of the Assessment
Reifegrad-Bewertung / Maturity-Evaluation
Basics Maturity
Name Abteilung/Department Rolle/Role
Evaluation form
Name Abteilung/Department Rolle/Role
14 Q-Basics Reifegradbewertung / Maturity Evaluation
1. Kundenbeanstandungen
Customer Complaints
14. Restmengen 3 2. Reissleine
Teilnehmer/Participant
Remaining Items Andon Cord
Reifegrad /
Verantwortlich für das weitere Vorgehen
11. Ausschuss, Nacharbeit 5. Prüfmittel
Maturity
und die Festlegung von Scrap, Rework Test Equipment Level
Verbesserungsaktivitäten
10. Kennzeichnung
6. Check the Checker 2
Labeling
Customer
Returns
11 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
1 Customer Complaints
Requirement What we do?
Customer complaints are communicated within All MOE1 associates have access to the AdP
the production site and displayed at the station website to review customer complaints.
in question. Using problem-solving techniques, Quality Alerts (with the Stop Sign) are placed
they are processed in a fast and systematic on any station that has caused an AdP/MOE1
manner. IPN production sites are promptly responsible failure.
informed.
There is a bi-weekly management review of
- A STOP sign process with all of the 8D the TCM Firewall. The review includes QMM,
elements is displayed on the shop floor. A MFE, MFO, and TEF.
standard review process involving the
production management and quality 0-mile complaint reports are sent to GS-
management takes place. TC/RBU-NA on a bi-weekly basis and to GS-
TC/QMM on a monthly basis.
- The decision to end the STOP sign process
is taken by production management after a The Stop Sign at the station is removed once
review of the measures’ effectiveness. improvement actions are implemented and
verified.
- It is necessary to ensure that customer
complaints are communicated quickly within all
IPN value streams.
Approved:
Quality Assurance Matrix (QAM)
D1 D2 D3 D4 D5 D6 D7 D8
Quality Assurance
Matrix (QAM) is
Complaint Mode
Responsible COMMENTS
Q8 Closed
Q8 Team Leader Most current Status of 8D QC / QI
Total
Score
days to Problem Product Failure description of Last (Internal) QC Created On Q8 Created
close owner Process Step issue Update Notification Entry Date Q8 Date Customer QE Q Basic Failure
CW30: Station in Safe Launch process to be complete CW32.
40 558 MOE1 EHM-GM Q8:Mfg AdP - On/Off Wire Tensile Break Miller CW30 CW25: Station debug. Tooling modification in process before station can be released. G G R R Y R R R n/a 230004549180 12/11/2015 230004583360 1/28/2016 GM Pena
CW21: Vision
CW25: Tooling installed.
sensor Station
installed. in debug.failure rate data before process is released.
Collecting
posted on AdP
40 420 MOE1 EHM-GM Q8:Mfg AdP - Incorrect Weld Ring R. Moore CW25 CW19: New loading tooling on order for field of view issues with camera. G G G Y Y R Y R n/a 230004662537 4/28/2016 230004699386 6/14/2016 GM Pena not relevant
CW6: Tooling
CW25: ordered.
Summary 8Dprovided
of issue completion expected
to TTO 4/7/2017.
with recommendation to close issue as customer
21 152 MOE1 EHM-GM Q8:Mfg AdP:Contamination across TCU lead Pena CW25 responsible since the carbon fiber contamination aligns with clutch material even if it is not clear G R R R R R R 230004831469 11/21/2016 230004919686 3/9/2017 GM Pena
how thatCorrective
CW25: material got into the
actions forshort
MRClocation.
in review with TEF3 and TEF7.
21 90 MOE1 EHM-GM Q8:Mfg AdP - FWD Traceability Ryan CW25 CW20: TRC and MRC developed. To be reviewed with GM 5/17/17 and with BV 5/22/17. G G R R Y R R R 230004964034 4/28/2017 230004972554 5/10/2017 GM Pena
Andons
PQIs
(Process and Quality Instructions)
Guidelines
Process validations are performed to Many critical processes must satisfy control
determine whether target values/tolerances of limits for part to be considered good. If
the defined parameters have been observed. process operates outside of programmed
limits, part will be coded bad and cannot be
Deviations are systematically recorded and processed at subsequent stations.
eliminated.
Gage Calibration
PMs
(Preventive Maintenances)
Duration: .25
Reminders (Insure all gages and tool calibration stickers are current)
Required Tools:
are assigned PM
1. Paint brush (clean the fins)
Verification Process:
Autonomous PM is
1.
Freq.
2. Change Dates:
(Annual)
3.
ISO 14001 INFORMATION
E.g., IMMEDIATELY REPORT ANY SPILLS OF ZESTRON LARGER THAN 5 GALLONS TO
SECURITY AT EXTENSION 8922. carried out by OPs
DESCRIPTION OF WORK TO BE PERFORMED
Tool Life
/ Pit Stop
39 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
8 Tools Management
Requirement What we do?
Each tool has a defined service life; the current Tools are identified in SAP WBS structure and
status must be recognizable. A quality controlled with Crib# system in order to ensure
evaluation must be carried out during removal correct tool are used for correct process.
or disassembly. Tool service life is defined in time-base,
The current service lives of all tools have been quantity-base or condition-base.
recorded. Tool service is controlled with SAP PM
A warning system promptly displays when workorder or Station PLC system.
tools need to be serviced or replaced. When service life is achieved, SAP triggers
Each tool needs to be inspected when techs, or PLC triggers techs/OPs to execute
removed or disassembled to check for defined service work.
damage/ wear and tear. Completion of tool service is tracked by SAP or
In case of deviations, it is necessary to follow PLC/TCAR system.
measures to ensure product quality is Critical product characteristics are verified after
maintained. tool service is complete. (i.e., Destructive
Restart is performed according to clearly testing, Visual inspection)
defined rules (see Principle 9);
the standard is regularly reviewed.
Machine Release
Prosys Welders 1, 2,
Machine Release
Verification Form
Welders Equipment: 3, & 4
Prosys Welders 1, 2,
Do not run production on welder until all verification steps are completed with Time: Date: / /
positive results.
Welders 3, & 4
Operator Shift: 1 2 3 4 5
Do not run production on welder until all verification steps are completed with Time: Date: / /
Technician Name / WO#
completed by
Technician Name / WO#
Brief description of repair/maintenance:
Electrode adjustment/replacement
1 4 2
Electrode adjustment/replacement
Weld Head replacement
technician, GL
1 4 2
3 1 4 2 7 8
Weld Head replacement
Weld Controller and/or transformer replacement
3 1 4 2 7 8
1 2 3 4 7 8
Weld Controller and/or transformer replacement
Weld Head Air Pressure Regulator change
1 2 3 4 7 8
verifies results, GL
3 4 2
Line down
Weld Head Air Pressure Regulator change
Arbor Clamp adjust or replacement
3 4 2
5 4 1 2
Arbor Clamp adjust or replacement
Adjustment or replacement any cylinder on the Arbor clamp tooling
- Andon on
5 4 1 2
5 4 1 2
Adjustment or replacement any cylinder on the Arbor clamp tooling
then ONLY GL
6
3 1 4 2
Welder parameter change
3 1 4 2
Release Verifications
restarts the line by
initials
oper tech
initials 1 Visually check the alignment between the top and bottom electrodes, replace electrodes instruction PQI
oper tech 2 Pull automated SPC to check three coils for peel & pull per PQI AI472041 - Do NOT resume production until
1 Visually
3 check
Refer the alignment
to process guidelinebetween
for inputthe top and
values and setup
bottom electrodes,
procedure. replace
Check off onelectrodes instruction
all applicable PQI
parameters in
instructing line
7 Pull
9 automated SPC every hour for four hours to check three coils for peel & pull per PQI AI472041
8 Monitor
10 Vision failures (CNC6 W3/W6) every hour for four hours.
9
10
GL Sign Off for Release:
associates to start.
GL Sign Off for Release:
GL Sign Off for DTA Complete:
Release Signature
GL Sign Off for DTA Complete:
Instructions:
Check box beside item at the top to be done. Verification step to be done by appropriate person and initial. GL to
Instructions:
Check box beside item at the top to be done. Verification step to be done by appropriate person and initial. GL to
Restart
- Andon
turned off
Color-coded Tags
Scrap Recode
Person
51 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
11 Scrap / Rework
Requirement What we do?
The handling of rejected parts and those to be Rework processes are generally not allowed.
reworked is clearly regulated. Those that are in the control plan.
As a basic rule, rework has to be avoided and NOK parts (Scraps) are held and coded in a
is only permissible if a respective procedure manner that prevents unintended usage.
exists. If containment actions outside of normal
If rework is permitted the following conditions processes are initiated, the concession
must be met: an FMEA and a control plan for process is used.
reassembly and reintroduction exist, Risk is assessed for containment actions.
rework takes place on the original assembly
line,
rework is limited in time.
If the rework process is permanently required,
this must be transferred to a standard process
that is approval by GB/QM.
Scrap must be disposed of in line with the
standard and unauthorized further use of these
products must be prevented (for example, by
destroying them.)
Dropped Parts
Change-over
Blue Light
59 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
13 Correct Product
Requirement What we do?
Only the correct product may be provided for Components for multiple part types are not
removal and assembly. generally stored on the line at the same time.
Only the correct product may be available to Change over process is standardized to
the associate at the time of assembly. replace correct parts being presented to the
All other variants or versions that are stored at affected stations.
the assembly station must not be accessible to Change-Over Blue Light initiates and indicates
the employee. change over in progress.
It is furthermore necessary to ensure, across Incorrect components are blocked. Only
the entire logistics chain, that only the correct correct component is accessible by operators.
product is retrieved or available. Incorrect components are also detected by
Poka-Yoke (Error Proof).
Change-over
Racks
63 Internal | Gasoline Systems | AdP/MOE1.2 | 4/5/2016
© 2016 Robert Bosch LLC and affiliates. All rights reserved.
TCM Value Stream
14 Remaining Items
Requirement What we do?
The handling of remaining items/ quantities is Standards are in place to handle remaining
clearly regulated. items in accordance with these criteria.
Remaining quantities must be clearly labeled Remaining parts are labeled with Green Tag.
and stored securely (using the accompanying Lot/Date code and process information are
card/on the correct shelf). documented on the tag in order to sustain
The “First In, First Out” principle must be FIFO.
observed. Remaining parts are stored in Change-Over
Close attention must be paid to ensure tidiness Racks designated by each line and process.
and cleanliness as the goods have yet to be Change-Over Racks are designed to protect
placed in the final packaging. parts during handling and storage.
Maximum storage times must not be Part exceeded maximum storage time is
exceeded. processed according to standardized
The quantity of remaining items must be taken procedure.
into consideration with regard to engineering
change requests.