valmet automotive quality management march 2015.pdf
TRANSCRIPT
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Valmet AutomotiveQuality Management
March 2015
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Valmet Automotive March 20152
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Valmet Automotive
Management system approvals
Based on the company policies Fulfill the relevant quality,
environmental and safety standards as well as the specific requirements of customer
Process-oriented Core processes
- Product launch - Serial production
The quality system fulfils the following standards
- ISO/TS 16949:2009 (Quality) - ISO 14001:2004 (Environment) - OHSAS 18001:2007 (Safety)
The quality, environmental and safety systems are certified by a third party
March 2015
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Valmet Automotive
Management system approvals
March 20154
Quality:1995 ISO 90011999 QS-90002003 ISO/TS 16949
Environment:2001 ISO 14001
Safety:2012 OHSAS 18001
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Valmet Automotive
Quality objectives
The key targets are set and reviewed together with customer
Internal targets are set by the management based on the key targets
Action plans to achieve the targets Management monitors the achievement of the
targets and improvement plans Company management sets and reviews company-
level improvement projects Process owners set and review process-related
improvement projects
March 20155
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Valmet Automotive
Main process KPIs
FTOK (first time OK rate-%) Product audit (index, defect/car) Delivery accuracy (%) Productivity (h/car)
These main KPIs are base for our bonus-system.
March 20156
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Valmet Automotive
Quality audits System audits (internal)
- Effectiveness of the management system is systematically reviewed
- Management sets the plan and reviews the results and corrective actions
Process audits - To evaluate the effectiveness of the production process
and sub-processes - Based on an audit plan and done by experts from the
production departments - Reviews of audit findings and preventive and corrective
actions are managed by the production departments
Product audits - Performed by the quality department according to the
procedure of customer.- Performance of the product audit is secured with
monitoring audit.
COP audits- Done by authorities from different markets (China, Japan, ...)
March 20157
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Valmet Automotive
Management reviews Quality issues
March 2015
VA Management reviews
Management team - Target setting (goals and objectives)
Production management team
- Customer satisfaction- Follow-up of the target fulfillment- Steering of development projects
- Steering and reviewing the business line's/plant's operations
- Steering of the management system
Local department meetings
- Steering of the plant operations- Steering of continuous improvement projects
- Customer service- Follow-up of the target fulfillment
Production meetings
- Steering of the plant operations - Production conditions
- Customer service- Short term action
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Quality assurance in production
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Valmet Automotive
Quality management
Quality control plan is the basis for the process control supported by work and inspection instructions
Team members on the line are responsible for the assembly and the quality of their work
Separate inspection stations after major production steps Final approval of the cars is performed according to the
standards and procedures
Quality reporting system provides immediate feedback of the quality for corrective actions
March 201510
Serial production control
INTERNAL
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Valmet Automotive
Product audit Quality control points End of line tests Material laboratory analysis Online/offline (3D) mesurings Control of process parameters
Quality assurance plan Quality control plans FMEA Internal quality targets Operational & work instructions Preventive maintenance Production and material planning
Customer quality targets Product specifications Supplier part specifications The standards / Regulations
Management reviews Process audits System audits Quality cost report Quality-committee Quality improvement meetings
Action plans Problem solving process Improvement projects (8D, Six sigma) Change management Market feedback process Control of non-conforming products
Quality assurance during serial production
March 2015
Customer requirements
Process definitions
Quality control &
measurements
Continuous improvement
Quality management
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Valmet Automotive
Quality control stations
The purpose of the control activities is to prevent defects from advancing in the process and to ensure that the quality of the product is acceptable for the next process phase.
The inspections and tests which are carried out during the manufacturing process are documented in the quality control plans. With these inspections and tests the compliance of the product with customer requirements is verified.
After every main process phase agreed product characteristics are inspected in separate internal quality control stations to ensure that these conform to stated specifications
Feedback to production line according to the feedback process
March 2015
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Valmet Automotive
Process follow-up / analysis
Q-targets for each process (body, paint, assembly, material, design) Q-costs are reported at management meetings Problem analysis are done acc. 8D-method Weekly Q-improvement meetings, reporting with 8D Continuous improvement process SixSigma method in use (3 BB at Valmet) Q-Committee monthly meetings 3D measurements (off-line)
- 3 measuring units (DEA and Johansson)- 2 portable measuring units (Faro-arm)
On-line measurements at production line (body)
March 201513
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Valmet Automotive
Reaction priority1. Design change2. Process change3. Control
Production quality assurancePreventive & corrective actions in production phase
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PFMEA- New product- Process change
Flow chart- New product- Process change
Control plan- New product- Process change- New control methods
Results/feedback- Production- Final audit- Customers
Operator instructions- New product- Process change- New control methods
Failure ranking list
March 2015
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Valmet Automotive
OnlineMeasuring
Station
Quality AuditBody
Metal & BodyappearanceInspection
ECInspection
PrimerInspection
Top coatInspection
Cpk-Values / Offline Measuring Station
Body shop Paint shop
ECOSLM 2InspectionECOS
PaintInspection
LM 3Inspection
Watertest
Wheel &Light
alignment
DeliverycheckDiagnosisECOSTest drive
UnderbodycheckDiagnosis
Roller test
Assembly shop
Product Audit
offline
LM 1Inspection
Final Insp.Paint
Production quality assurance
March 201515
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Valmet Automotive
Body shop / Quality conceptMercedes A-class manufacturing
16
ALUSTALINJA
InLine Mittaaminen OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus OnLine liimakamerajrjestelm
ETUPLINJA
OffLine mittaus Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus OnLine liimakamerajrjestelm Liimauksen visuaalinen tarkastus
TAKAPLINJA
OffLine mittaus Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus OnLine liimakamerajrjestelm Liimauksen visuaalinen tarkastus Lyhytkaarihitsaus visuaalinen tarkastus Lyhytkaarihitsausmomenttitarkastus
SIS- JA ULKOSIVULINJAT
OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastusLiimauksen visuaalinen tarkastus Visuaalinen pintalaatutarkastus
VIIMEISTELYLINJA
Visuaalinen pintalaatutarkastus Ovien pulttien momenttitarkastus Luukkujen sovitemittaus Hitsaamon laadunmittaus (LM)
OVILINJA
OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus Liimauksen visuaalinen tarkastus Visuaalinen pintalaatutarkastus Laserhitsaus - VISIR
KORILINJA
InLine Mittaaminen OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus OnLine liimakamerajrjestelm
KESKILATTIALINJA
OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus OnLine liimakamerajrjestelm Ksnhitsaus visuaalinen tarkastusKsnhitsaus momenttitarkastus
LUUKKULINJA
Valssauksen visuaalinen tarkastus OffLine Mittaaminen Adaptiivinen hitsausvalvonta Ultrani hitsauslaaduntarkastus Liimauksen visuaalinen tarkastus Visuaalinen pintalaatutarkastus Laserjuottamisen visuaalinen tarkastus
March 2015
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Valmet Automotive
Body shop / QualityGeometry measuring concept
ZB Heckboden
ZB Vorbau
ZB Hauptboden
ZB Unterbau
ZB Seitenwand IN RE
ZB Seitenwand IN LI ZB Seitenwand AU VST LI
ZB Seitenwand AU VST RE
ZB Fahrertr RE
ZB Fahrertr LI ZB Fondtr LI
ZB Fondtr RE
ZB Rckwandtr
ZB Z2.3ZB Z2.1
ZB Radeinbau VST RE ZB Stirnwand ZB Radeinbau VST LIZB Radeinbau LI
ZB Lngstrger VST HI LI
Quertrger LI
Quertrger RE
ZB Lngstrger VST HI RE
ZB Radeinbau RE
ZB Seitenwand AU LI
ZB Seitenwand AU RE
010A01005A01L 005A01R
025
305A01L
305A01R
570
630
245
340
320A
320A
325A
325A
425L 435L410R
410L 425R
435R
790745
530
530
530
530
ZB Radeinbau VO LI ZB Lngstrger LI
Lngstrger IN OB VO LI Lngstrger IN OB VO RE
ZB Radeinbau VO RE ZB Lngstrger RE002R01002L01001L01 001R01
003R01 003L01
= OffLine measuring= InLine measuring= Fit&flush measuring
March 2015
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ZB Motorhaube
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Valmet Automotive
Paint shop process description and Quality controlsCONFIDENTIAL
Degreasingspray
Degreasingspray
Degreasingdip
Degreasingdip
RinsesprayRinsespray
Activationdip
Activationdip
Phosphatedip
Phosphatedip
Rinsedip
Rinsedip
RinsesprayRinsespray
Passivationspray
Passivationspray
Rinsedip
Rinsedip
RinsesprayRinsespray
EC ovenEC oven
DIW Rinsespray
DIW Rinsespray
UF Rinsedip
UF Rinsedip
UF Rinsedip
UF Rinsedip
UF Rinsespray
UF Rinsespray
CathodicimmersionCathodic
immersionRobot sealing/
SAMRobot sealing/
SAMManualsealingManualsealing
Sealing oven
Sealing oven
EC touch-up (dry)
EC touch-up (dry)
Off-linerepair
Off-linerepair
ManualwipingManualwiping
ManualsprayingManualspraying
ESTAapplication
ESTAapplication Back-upBack-up Flash-offFlash-off
Primeroven
Primeroven
Primer touch-up(Moist)
Primer touch-up(Moist)
Top coatoven
Top coatoven Flash-offFlash-off Back-upBack-up
Robotclear coat
Robotclear coat
Heatedflash-offHeatedflash-off
Recip.base coat
Recip.base coat
ESTAbase coat
ESTAbase coat
Manualbase coatManual
base coatManualwipingManualwiping
FinishingFinishing RatingOK / NOK
RatingOK / NOK
NOK lineNOK line
OK lineOK line
Spot repairSpot repair
SandingrerunnersSandingrerunners
To generalassembly
Frombodyshop
Audit2
Audit4
Audit1
Audit3
Pre-treatment
ECSealing
Base coat (WB)
Primer surfacer (WB)
Cavitytreatment
CavitytreatmentControlControl
Masking station
Masking station
Phosphatespray
Phosphatespray
RobotsealingRobotsealing
Sealing touch-upSealing touch-up
Clear coat
Off-linerepair
Off-linerepair
BS surface touch-up
BS surface touch-up
Cavity treatment
oven
Cavity treatment
oven
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March 201518
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Valmet Automotive19
Quality concept Paint ShopPRETREATMENT
Random sample min 1 body/shift
Phosphate surface quality Phosphate coating weight EC surface quality EC layer thickness EC roughness
SEALING & SAM
Line check - All vehicles
Robot seams position Robot seams completeness
Quality Audit 1 (Random sample min 1 body/shift ) Body shop surface quality EC surface quality (body & paint) Seam sealant positioning Seam sealant completeness Seam sealant leak tightness Seam sealant optical appearance SAM positioning SAM completeness SAM film thickness
EC TOUCH-UP
Line check - All vehicles
EC surface quality SAM completeness Visible area seam sealant
KPIs-FTOK % EC-Quality Audit 1
PRIMER
Line check - All vehicles
Masking tape completeness Primer coat surface quality
Quality Audit 2(Random sample min 1 body/shift ) EC touch up quality Visible area seam sealant appearance Primer coat surface quality (body & paint) Masking tape positioning Masking tape completeness
KPIs-FTOK % Primer- Quality Audit 2
TOP COAT
Line check- All vehicles
Top coat surface quality Top coat appearance
Quality Audit 3 (Random sample min 1 body/shift)
Primer touch up quality Top coat surface quality (body & paint) Visual color assessment Colorimetry Film thickness (EC, primer coat, base coat and clear coat)
KPIs-FTOK % Top coat-- Quality Audit 3
PAINT SHOP FINISH
Line check - All vehicles
Top coat finishing quality
Quality Audit 4(Random sample min 1 body/shift)
Orange peel (LW, SW, DOI) Cavity wax completeness Optical appearance of the seam sealant in the visible area SAM completeness Paint surface defects Body shop surface quality
KPIs-FTOK % Paint Shop Finish-Quality Audit 4
March 2015
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Valmet Automotive
OS
TSE
NSOR
CAB
INET R.C.
UNIT 2
R .C .UN IT 1
ELEC
TRIC
CAB
INETS
HUOLT O
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U NI T 1EL EC TR IC C AB INE TS
Quality conceptAssembly shop
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All vehicles
5 cars a day
defect/car
Quality audit
Check:- All cars- CPA-focus points, feedback from previous days/weeks
defect/car
line 7 Q-check
Audit 1
All vehicles
Check:-Line 1 and IP-preassys most important and safety-relevant assemblies
KPIsFTOK % & QC
Audit 2
All vehicles
Check:-Line 2 and Chassis-preassys most important and safety-relevants assemblies
KPIsFTOK % & QC
Audit 3
All vehicles
Check:-Line 3 and doors-preassys most important and safety-relevants assemblies
KPIsFTOK % & QC
Water test
All vehicles
Check:--Leaks- optical and manually
KPIsFTOK %
Roller test
All vehicles
Check:-drivability, functions, noises
KPIsFTOK %
Paint surface
All vehicles
Check:-damages, scratches, assembly marks
KPIsFTOK %
Test Drive
5% test track100% cobblestone drive
Check:-drivability, functions, noises
KPIsFTOK %
Line 8
All vehicles
Final inspectionCheck:-deliverable-chassis card OK-vehicle corresponds the order-delivery condition and cleanliness-final diagnose
KPIsFTOK %
Process flow
Process flow
Process flow
Process flow
All vehicles
All vehicles
Rework
All vehicles
5 % of cars
defect/car
High pressure water test
March 2015
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Valmet Automotive
Quality Assurance Plan Assembly shop
March 201521
Line 1 Quality Check 100%
Line 2 Quality Check 100%
Line 3 Quality Check 100%
Line 7Q-check defined points (CPA etc.)100%
Water Test 100%
Wheel alignment & Roller Test 100%
Paint surface inspection 100%
Test Drive (test track 5%, cobblestone 100%)
Extra Quality Check 5 cars
High pressure water test 5%Product Audit
2 cars/dayLine 8 100%
INTERNAL
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Valmet Automotive
Measuring center
March 2015
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Valmet Automotive
Measuring center equipment
Coordinate measuring machines (CMM)- Dual arm machine with four movable measuring pallets
Measuring range X=6000 mm, Y=2797 mm, Z=2400 mm- Portal machines
Measuring range X=1500 mm, Y=1500 mm, Z=800 mm Measuring range X=700 mm, Y=450 mm, Z=350 mm
Other equipment- Spring testing gauges- Dial indicator gauge- Block gauges- Pressure calibrators- Length measuring machines
March 2015
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Valmet Automotive
Material laboratoryProvides services to all VAs departments. It gives support for monitoring processes of the paint shop and it helps introducing new materials into production. The laboratory also provides its expertise to different VAs projects as required. The main activities of the material laboratories can be divided following categories
- Surface treatment laboratory Alignment test programs for the new materials Acceptance tests for all base coats and clear coat batches (including e.g. color, mechanical properties) Climate and corrosion tests (e.g. according to VDA-standards)
- Chemical laboratory Process baths and sewage water analysis / monitoring Chemical managements (e.g. VAs MSDS register)
- Metal laboratory / Rubber and plastic laboratory Tensile strength tests, compression stress test (including textiles and plastics) Hardness measurements (Vickers, Brinell, Rockwell, Shore A, Shore D)
- Cooperation together Authorities Material suppliers - SQ activities, analysis / testing services Universities and research centers - e.g.
o Outotec , Research Center material technology and analytical laboratoryo VTT Technical Research Center analytical service (e.g. metal analysis and other problem solving)
March 2015
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Product quality
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Valmet Automotive
Product quality improvement meetings
Product audit- Review of each car daily
Weekly product quality improvement meetings with management- Prio-issues from product audit- Task force teams for selected issues- Problem analysis are done acc. to 8D-method- Reporting with 8D-form
Weekly QM-meeting with all quality managers- Review of the results vs. internal targets and corrective actions
March 201526
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Valmet Automotive
Product audit process
27 March 2015
AuditR&D Prod.Prod. DeliveryDelivery
P
DC
A P
DC
A
Customersaudit process
Monitoring
Results
A/B/C-faults
Improvementpotential
Final audit
Ran
dom
sam
ple
1 %
Legal req., functions
Optical
Independent activity
Corrective actionsCorrective actions operationsCustomerInternal operationsSuppliers
Audit
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Valmet Automotive
Product audit action plan
March 2015
Perhaps Next WS visit Immediate
Disturbance Walk home failureComplaint
Optical Functional
Depends on the repair costs
Customerreaction
Type of defect
Delivery BlockDefect Analysis / Immediate Actions
ReworkStatistical
Actions
Quality Improvement
PotentialDefects
(Audit, Quality Measuring)Defect
weighting
Lega
lTe
st d
rive
inte
rrup
tion
Safe
ty
INTERNAL
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Valmet Automotive
Handling of major and systematic defects
1. Defect added to body, paint or chassis card and issue reported verbally and in written format to the defect source.
2. Defect stopped and inspections & repair activities started. Sampling inspection of 25+25 cars. Delivery stop if defect found from already approved cars.
3. Root cause analysis and corrective actions to prevent the issue happening again. Analysis and actions reported to stakeholders.
4. Solution approval and additional actions if needed. Defect creator informed.
March 201529
Defect
1. Defect added to body, paint or chassis card
Defect founder
Area where the defect was caused
2. Defect stopped, inspection & repair
3. Analysis + corrective & preventive actions
Quality Manager 4. Approval and additional actions if needed
INTERNAL
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Valmet Automotive
Market feedback
30 March 2015
Car owners Dealers OEM-customers
Warranty info Leasing cars Test reports Dealer reports JD Power Suppliers Audits
Researchcompanies
Press
Receive, summarise and inform
(contact person)
Define priority(task force)
Define root causeand responsibility
(task force)
Plan and implementcorrective actions
(responsible)
Verify and approvecorrective actions
(task force)
Reporting Reporting Customer satisfaction
INTERNAL
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Valmet Automotive
Delivery stop process
This process is used, if there would be found a critical defect in the product audit, in the production or in case the legal requirement is not met.
Cars are blocked and deliveries to the harbour and further will be stopped until the corrective actions are done.
The decision for a delivery stop is done by QM / product quality.
By using this process it will be secured that all the possibly affected cars will be checked and reworked before delivery to the customer.
March 2015
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Valmet Automotive
Daily Information Flow at VA Production Depts
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Production management
morning round
Production morning walk
Info
rmat
ion/
Supp
ort
Repo
rtin
g/Es
cala
tion
Daily at: 09:20-10:00 Participants: PRD-VP, PRD-D, QS, LOG,
FIN, PRD-C, MThemes: Volume, Quality, Productivity,
Availability of parts/materials,Escalation
Communication
Daily at: 07:00-08:50 Themes: Volume, Quality,
Productivity, Availability of parts/materials, Escalation
TL+ OPS: 07:10 - 07:40
TL+ SV, ENG: 07:40 - 08:10
SV+ PRD-D, LOG, SQ, M, QS, ENG: 08:20 - 08:50
AbbreviationsPRD-VP Director of Production PRD-D Department Director QS Quality representant LOG Logistics SQ Representant of Supplier Quality FIN Representant of FinanceENG Representant of Process EngrgPRD-C Representant of Prodn ControlM Representant of maintenanceSV Supervisor of a Prodn area TL TeamleaderOPS Operator on a station
OPS: 07:00 - 07:05
March 2015
INTERNAL