johnson controls automotive seat

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康康康康康康康 Kangqiao Seating Assembly Plant 工工工工 Plant Profile 康康康康 Plant Brief 康康 Safety 康康 Manufacturing 康康 Logistic 康康 Quality 康康 Engineering 康康康康 Continuous Improvement

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Apresentação de uma empresa chinesa que fabirca bancos para a GM na China

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Page 1: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

工厂概况 Plant Brief

安全 Safety

生产 Manufacturing

物流 Logistic

质量 Quality

工程 Engineering

持续改进 Continuous Improvement

Page 2: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

工厂大事记 Plant Events

工厂组织位置 Plant Position

客户 Customer

主要产品 Main Products

工厂平面布置 Plant Layout

工厂 09 年目标 Plant ’09 Objective

相关数据 Relevant Data

组织机构 Organization

工厂概况 Plant Brief

Page 3: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile工厂大事记 Plant Events

•1998年 4 月, SGM 座椅装配厂成立 Apr. 1998, SGM JIT Plant establishment

•1999年 4月 22 日开始向上海通用供应座椅总成Apr.22 , 1999, Starting supply seats assembly to SGM

•2002年 12 月荣获 JCI 奥林匹克质量金奖Dec. 2002, awarded JCI Olympic Quality Gold Medal

•2004年 10 月工厂易地康花路厂区Oct. 2004,Plant move to Kanghua Road Site

•2007年 4月 SGM 座椅总装厂更名为康桥座椅总装厂Apr. 2007, SGM JIT Plant renamed Kangqiao Seating Assembly Plant

•2008年 12 月被上海通用连续第 10 次评为年度优秀供应商(第四次最佳)Dec. 2008, the 10th SGM excellent supplier of the Year consecutively( the 4th Best )

Page 4: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

上海延锋江森座椅有限公司SYFJC

烟台座椅总装厂Yantai SGM JIT

安亭座椅总装厂Anting seating

盐城座椅Yancheng Kia

康桥座椅总装厂Kangqiao Seating

零件面套单元Parts & Trim BU

机械零件厂Mech

南通面套Natong Trim

头枕发泡单元H/R & Foam BU

重庆延锋江森CQYFJC.

广州东风江森GZDFJC.

职能部门Function

工厂组织位置 Plant Position

座椅总装单元Seating BU

南京座椅Nanjin Seating

沈阳座椅Shenyang Seating

发泡Foam

头枕Headrest

武汉公司WH JV GM

江森鹤华MJV

吉翔公司JARC

子公司Sub-companies

Page 5: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile客户 Customer

上海通用 SGM中国通用 China GM福建戴姆勒 Fujian Daimler

Page 6: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile工厂地理位置 Plant

Location

康桥座椅总装厂Kangqiao Seating

上海通用SGM

金桥 Jinqiao

上海 Shanghai

26km

835km福建 Fujian

Page 7: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile主要产品 Main Products

凯越 Excelle

君威 Regal

君越 LaCROSSE

林荫大道 Park Avenue

新君越 Epsilon

Page 8: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile工厂平面布置 Plant Layout

1

4

2 3

主要区域1. 戴姆勒 NCV2 Daimler NCV22. 通用北厂 North Plant3. 通用南厂 South Plant4. 物流存放 Storage

食堂

发泡工厂Foam Plant

空压机

西门

南门

康桥座椅厂KQ Seating

康意

康花路

北 North

Page 9: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile组织机构 Organization

CI 工程师

CI Engineer

人事协调

HR Co.

质量工程师

Quality Engr

生产协调员

Prod. Co.

制造工程师

Manuf. Engr

物料协调员

Matl Co.

检验组长

leader

生产组长

leader

维修工

Maintenance

物料组长 / 文员

leader/clerk

检验员

Inspector

装配工

Assembler

物料工

Material

项目工程师

Pro. Engr

物料工

Matl Handler

维修组长

Leader

工厂经理Plant Mgr

物料经理Matl Mgr

工程经理Eng Mgr

生产经理Prod.Mgr

质量经理Quality Mgr

项目经理 Pro.Mgr

Page 10: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

2008 年质量目标’ 08 Quality Objective

NO

质量指标Quality Measurables

09YFJC 目标09YFJC

objective

09年 YFJC 整椅09 YFJC Seating

09 工厂目标09Plant

objective

1 用户退货率 CUSTOMER RETURN PPM 3.4 0 0

2 用户抱怨率 CUSTOMER CONCERN PPM 18 22 9

3 内部 PPM INTERNAL PPM * 1870 135 200

4 废品率 SCRAP% OF SALES 0.080% 0.006% 0.005%

5净售后索赔 NET WARRANTY (exclusive charge back to suppliers) (元 / 月) 19,250 17,150 4,500

6 供货准时率 ON TIME DELIVERY 100% 100% 100%

7 供应商退货率 SUPPLIER PPM * 162 52 90

8 供应商供货率 SUPPLIER DELIVERY 100% 100% 100%

9遏制成本 CONTAINMENT COST (元 /月) 62,000 7,500 2,000

2009 年工厂质量目标’ 09 Plant Quality Objective

Page 11: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile相关数据 Relevant Data

总产量 Production(000)

人员 Employees290

334

Page 12: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile相关数据 Relevant Data

客户Customer

福建戴姆勒 Fujian Daimler

通用南厂 South plant

通用北厂 North Plant

车型Vehicle Model

NCVII NCVIII凯越 / 新君越

Excelle/Epsilon

凯越 / 君越 / 林荫大道

Excelle/LaCROSSE/Park Avenue

品种 Options 2 4 15

最大日产辆份 Max. car-set/day 50 700 600

客户距离 Distance to Customer( km ) 835 26 26

工厂面积 Plant Occupied(M

2 )8700

需求发布提前期 Lead time Weekly 200 mins 130 mins

固定连接客户接受及时需求信息 Fixed Link to customer to receive

JIT demand informationEmail Yes Yes

员工总数 Total Employees 290

Page 13: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

安全检查团队 Safety check team 安全检查计划 Safety patrol plan

安全 Safety

Page 14: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

工程经理Eng. Mgr

人事协调员HR

工程师Engineer

物料协调Malt. Co.

生产助理Prod As.

电工Electrician

生产经理Prod. Mgr

安全检查团队Safety Team

安全 safety

Page 15: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

班组上岗前检查,分层审核 , 记录 .Team inspection before working, LPA and recording人事协调员巡视安全问题,协调解决HR patrolling for safety issue coordination & settlement机修工设备 , 电气检查Beltman making equipment and electrical inspection

检查计划Patrol plan

周检查Weekly

月检查Monthly

日检查Daily

安全 safety

. 一名经理带队巡检,问题及评分报安全科One manger leading weekly safety patrolling

工厂经理带队安全巡检。Plant manger leading Monthly safety patrolling工厂月度会议回顾安全问题Plant Monthly meeting review safety issues

Page 16: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile安全 Safety

beforebefore :: things put at random in things put at random in front of fire rescue equipmentsfront of fire rescue equipments

afterafter:: add block and things add block and things can not be put in front of the can not be put in front of the fire rescue equipmentsfire rescue equipments

Page 17: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile安全 Safety

beforebefore:: rack will incline by the rack will incline by the outside force and cause injureoutside force and cause injure

afterafter:: add clip to fix the rack add clip to fix the rack and add inductiveprobe to and add inductiveprobe to remindremind

Page 18: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

生产线 Production Line

流程 Process

现场操作控制 Operation Control

生产 Manufacturing

Page 19: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

2. 北厂North Plant

3. 南厂South Plant

1.NCV2 Daimler

生产线Production Line

生产 Manufacturing

Page 20: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

流程 Process

汽车主机厂OEM

2. 预装 Pre-assembly

1. 采购purchasing

骨架 Frame 发泡 Foam 面套 Trim 滑道 Track头枕 Headrest

3. 总装Assembly

缓冲库存Buffer

4. 发运Shipping

生产 Manufacturing

Page 21: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

教室培训Classroom

Training

支持改进Support &

Improvement

双向交流Two-way

communication分层过程审核

LPA

自检互检Self Check & Double Check

目视提示Visual Aids

现场培训OJT

作业指导书ODS

员工操作EmployeesOperation

1. 作业要求Op. Requirement

2. 符合性检查Conformance Check

3. 支持与改进Support & Improvement

现场操作控制Operation Control

客户信息Cust. info

评审Audit巡检

Patrol

生产 Manufacturing

Page 22: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

信息流及物流 Information & Material flow

北厂 North Plant

南厂 South Plant

供应链 Supply Chain

物流 Logistic

Page 23: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

通用南厂SGM South

座椅厂Seating Plant

主生产计划Master Plan

采购计划Purchasing Plan

供应商供货 Supplier delivery

配料上线Material loading

日订单Daily PO

客户周计划转交Customer Weekly Forecast transferring

材料接收Matl. Receiving

装配Building

发运Shipping

拉动配料Pull preparing

排序信息接收Sequence Info receiving

供应商备料生产

Supplier Matl. prepare & prod.

收货Receiving

及时需求信息JIT demand info

客户日周计划Customer Daily & Weekly Forecast

信息流及物流 Information & Material flow

物流 Logistic

Page 24: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

客户Customer

后座排序生产RS Sequencing

前座缓冲FS Buffer

前座拉动生产FS Pull Building

信息流向 Info物流流向 Mtl Flow

拉动 + 缓存 + 排序 pull + buffer +Sequence

北厂 North Plant

物流 Logistic

Page 25: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

客户Customer

拉动排序生产Pull Sequence

Building

及时发运JIT Delivery

信息流向 Info物流流向 Mtl Flow

排序生产发运 Sequence Building & Shipment南厂 South Plant

物流 Logistic

Page 26: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

康桥座椅厂Kangqiao Seating

内部供应商Internal Suppliers

国外供应商Foreign Suppliers

国利Guoli

面套厂 Trim 零件厂 Mech 发泡 Foam

客户 : 福建戴姆勒Customer: Fujian Daimler

市内供应商local suppliers

龙马神Longmaseng

蓬垫厂Awning

其他other

江森云鹤MJV

市外供应商Outbound suppliers

供应链 Supply Chain

客户 :SGM 金桥Customer: Jinqiao SGM

物流 Logistic

Page 27: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

客户快速响应系统 Quick Customer Response System

前期质量工程师指南AQE Roadmap

质量 Quality

Page 28: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile质量 Quality Quick Customer Response System

客户快速响应系统建设

一。交流平台建设

二。信息传递优化

三。推进客户GCA标准

组织结构调整

信息流转流程标准化

信息交流方式标准化

建立质量数据库

客户标准学习

客户标准内部分享

客户标准与客户双向交流

每天质量晨会

每日质量问题视板

客户快速响应系统 Quick Customer Response System

Quick Customer Response

1. Platform construction

Daily meeting

Issue display board

2. Accelerate the information flow

3. Customer criterion popularization

Page 29: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile质量 Quality Quick Customer Response System

Issue list collected after Daily meeting

problem solving checkKey problem communication

report

Page 30: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

检具开发流程

程序与要求

质量术语

客户要求

五大手册集锦

APQP流程

OTS ,PPAP doc.

AQE手册

AQE 岗位

AQE 工作指南提供了大量 AQE 相关要求、标准、流程、文件、参考资料。AQE Roadmap provide a lot of AQE relevant requirements, standards, procedures, documents, references.

质量 Quality

前期质量工程师指南 AQE Roadmap

Page 31: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

座椅功能自动检测系统 Seats automatic function testing system

人机工程改进 Ergonomics Improvement

工程 Engineering

Page 32: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

座椅功能自动检测系统Seats automatic function testing system

工程 Engineering

主动式头枕测试设备Active Headrest Test System

Page 33: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

发展过程 Developing Stages

建立目标 Setup objective

组织资源 Organize resource

发现机会 Find Opportunities

实施改进 Implementing Improvement

持续改进 continuous improvement

Page 34: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

缺陷 ,浪费

--原因显而易见的

偏差,瓶颈

--原因不明

执行不符合要求

凭直觉 按标准流程 创建管理流程 更新流程强化执行

JDI/ 合理化建议

六西格 6sigma

JCMS/ 改善

LPA/Roadmap

稳健设计

新员工多,能力提升压力大

参与设计评估

产品工艺性

防错设计

历程

已有并将继续采用的做法

发展过程 Developing Stages

多方案选择

打算推进的做法

持续改进 continuous improvement

Page 35: Johnson Controls Automotive Seat

康桥座椅总装厂 Kangqiao Seating Assembly Plant

工厂简介Plant Profile

End, thank you!谢谢!