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1、GP-12 Early Production ContainmentThomas GormanGP-12早期生产遏制2018/8/16A Strategy For ImplementationWhat is GP-12 Why we need GP-12 How to implement GP-121执行策略什么是GP-12 为什么需要GP-12 如何执行GP-122018/8/16Vision Statement 目标uGP-12 is an attempt to protect the Supplier, SGM, and the Customer from surprises2GP-12
2、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。Goal and ObjectiveuThe desired goal is to have a problem free launch and a smooth progression into normal productionuThe desired objective is put in place extra measures in early production that will be effective in keeping supplier problems in their own plant.3目标与目的期
3、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。Why Are We Talking About Early Production? 为何讨论早期生产？uSGM suffers more problems at launch than after 在生产初期SGM往往遇到更多的质量问题。ulearning curve 知识曲线uSurprises 意外质量事故uSuppliers often conduct poor APQP 供应商常实施不合格的APQPumerely a pape
4、r exercise 仅仅纸上谈兵uhuman imagination is limited 有限的个人想象ulimited time, various changes 有限的时间，多样的变化 4Why Are We Talking About GP-12 Today? 为何今天讨论GP-12uIF suppliers do a pre-launch control plan: 如果供应商制作一份试生产控制计划:uit is often poorly thought out 常常缺乏认真思考。uit is really the plan they expect to roll into nor
5、mal production 实际上他们是想将之应用在正常生产中。uit is not good protection for SGM 这无法向SGM很好地负责。uSuppliers are overly confident 供应商过度自信usupply other customers with lower quality standards 提供较低的质量标准给其他客户。uit is difficult to see your own flaws 很难发现自身缺点。5GP-12 Scope GP-12应用范围uApplies to all suppliers required to use
6、PPAP 适用于所有要求使用PPAP的供应商。uUsed for pre-production and production requirements that require PPAP 应用于要求使用PPAP的试生产和批量生产。uCarry-over quality concerns should be addressed using Controlled Shipping 遗留的质量问题应通过控制发运来解决。GP-12 Definition and Purpose GP-12定义与用途uDocument efforts to control processes during start-u
7、p and acceleration 在生产启动和加速阶段，过程控制文件化。uQuality issues that arise are quickly contained at the suppliers location 在供应商现场迅速遏制所发生的质量问题。uPre-Launch Control Plan 试生产控制计划uvalidate production control plan 评审生产控制计划GP-12 Supplier Responsibility GP-12供应商职责uEstablish containment process建立遏制流程uIdentify person r
8、esponsible确定负责人员uDevelop a Pre-Launch Control Plan 制定试生产控制计划uDevelop additional containment 制定附加的遏制政策uPrompt containment 及时遏制uIdentification of equipment and device 标明设备及装置uUse GP-12 for specified period 指定时期应用GP-12uGreen dot 绿色圆形标签Signed: Senior Manager高级经理 签名Pre-Launch Control Plan 试生产控制计划uIncreas
9、ed frequency / sample size 增加频率/样品数量uSub-supplier containment 分供方遏制uAddition of inspection / control items 附加检验/控制项目uIncreased verification of labeling 增加对标识的检查uEnhancement of process controls, such as error proofing 加强过程控制，例如防错uError proofing validation by introducing known defects 通过对已知缺陷的分析确认防错uI
10、ncreased involvement and visibility of top management 加强高层管理的参与性与透明度GP-12 Exit Criteria GP-12退出准则uSupplier can exit GP-12 if 若满足以下条件，供应商可退出GP-12uno non-conformances 没有不符合项umeet number of piece or period of time requirement 零件数量或生产时间符合要求uapproved by SQE SQE批准uIf non-conformances found 若已发现了不符合项uPR/Rs
11、 closed by customer 客户关闭PR/RuControl plan validated 控制计划得到验证Recommendations 建议uMake sure pre-launch control plan is a key part of APQP 确信试生产控制计划是APQP的关键部分uappendix A-8 附录A-8uClearly differentiate between production controls and pre-launch controls 明确区分生产控制与试生产控制ualso use a summary sheet 同样使用总结表uGP-1
12、2 reviews GP-12 回顾uwith fellow SQE 与SQE同事uwith launch team 与生产小组成员uwith GP-12 core person 与GP-12核心成员uTreat GP-12 like a Controlled Shipping containment 对待GP-12如同控制发运遏制政策6Benefits of GP-12 GP-12的利益uWith improved GP-12 随着改进的GP-12u fewer problems at our plant 更少的问题在生产现场发生uat launch 生产启动时uafter launch 生
13、产启动后uImproved 改进uPFMEA 过程失效模式分析uerror proofing 防错uunderstanding of process 理解工艺uunderstanding of controls 理解控制ubetter supplier performance 更好的供应商表现ulower PRR containment costs 较低的PRR遏制成本uavoid CS1 and CS2 costs 避免一级/二级发运控制成本7Some Practical Suggestions 一些实践建议uDevelop 100% audit and check like a CS1 p
14、lan 实施100%审核以及象一级发运控制计划一样检查ucheck for missed operations 检查漏加工umissing holes, taps, parts 漏孔、漏接头、漏零件udevelop functional gages 开发功能性检具ucheck for process damage 检查工艺失误ureview old PRR and quality data 回顾老的PRR和质量数据uIdentify customer interfaces 确定客户界面uSGM and final customer SGM以及最终客户uClearly highlight all
15、 GP-12 features in Pre-Launch Control Plan在试 生产控制计划中，清晰地突出所有GP-12 要点。uDocument everything you find clearly, and follow-up to prevent and detect in normal process 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。More Suggestions 进一步建议uUse the provided checklist 利用所提供的检查清单。uUse separate audit area, do not disrupt
16、 normal production 在不影响正常生产的前提下，利用分离的审核区域。uUse display board to post instructions, data, and action plans 利用陈列板张贴作业指导书、质量数据及反应计划。uTrain audit team 培训审核队伍。 SUPPLIERS WORKSHOP供应商车间PRODUCTION AREA生产区域GP-12 AUDITAREAGP-12审核区域Display Board 陈列板Progress Charts 过程图Pareto Chart - Top 6 Issues0.0%0.5%1.0%1.5%2.0%2.5%3.0%Problem 1Problem 2Problem 3Problem 4Problem 5Problem 6period 1period 2period 3current period
