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1、2023/3/7,GP-12 Early Production Containment,Thomas Gorman,GP-12早期生产遏制,2023/3/7,A Strategy For Implementation,What is GP-12Why we need GP-12How to implement GP-12,1,执行策略,什么是GP-12,为什么需要GP-12,如何执行GP-12,Vision Statement 目标,GP-12 is an attempt to protect the Supplier,SGM,and the Customer from surprises,2
2、,GP-12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 Objective,The desired goal is to have a problem free launch and a smooth progression into normal productionThe desired objective is put in place extra measures in early production that will be effective in keeping supplier problems in their own plant.,3,
3、目标与目的,期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？,SGM suffers more problems at launch than after 在生产初期SGM往往遇到更多的质量问题。learning curve 知识曲线Surprises 意外质量事故Suppliers often conduct poor APQP 供应商常实施不合格的APQPmerely a paper
4、exercise 仅仅纸上谈兵human imagination is limited 有限的个人想象limited time,various changes 有限的时间，多样的变化,4,Why Are We Talking About GP-12 Today?为何今天讨论GP-12,IF suppliers do a pre-launch control plan:如果供应商制作一份试生产控制计划:it is often poorly thought out 常常缺乏认真思考。it is really the plan they expect to roll into normal prod
5、uction 实际上他们是想将之应用在正常生产中。it is not good protection for SGM 这无法向SGM很好地负责。Suppliers are overly confident 供应商过度自信supply other customers with lower quality standards提供较低的质量标准给其他客户。it is difficult to see your own flaws 很难发现自身缺点。,5,GP-12 Scope GP-12应用范围,Applies to all suppliers required to use PPAP适用于所有要求
6、使用PPAP的供应商。Used 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。Carry-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,Document efforts to control processes during start-up and accelerat
7、ion 在生产启动和加速阶段，过程控制文件化。Quality 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。Pre-Launch Control Plan试生产控制计划validate production control plan评审生产控制计划,GP-12 Supplier Responsibility GP-12供应商职责,Establish containment process建立遏制流程Identify person responsible确定负责人员Devel
8、op a Pre-Launch Control Plan制定试生产控制计划Develop additional containment制定附加的遏制政策Prompt containment 及时遏制Identification of equipment and device标明设备及装置Use GP-12 for specified period指定时期应用GP-12Green 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,Increased frequency/sample size 增加频率/
9、样品数量Sub-supplier containment 分供方遏制Addition of inspection/control items 附加检验/控制项目Increased verification of labeling 增加对标识的检查Enhancement of process controls,such as error proofing加强过程控制，例如防错Error proofing validation by introducing known defects通过对已知缺陷的分析确认防错Increased involvement and visibility of top
10、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,Supplier can exit GP-12 if若满足以下条件，供应商可退出GP-12no non-conformances 没有不符合项meet number of piece or period of time requirement零件数量或生产时间符合要求approved by SQESQE批准If non-conformances found若已发现了不符合项PR/Rs closed by customer客户关闭PR/RControl plan validated控制计
11、划得到验证,Recommendations 建议,Make 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appendix A-8 附录A-8Clearly differentiate between production controls and pre-launch controls 明确区分生产控制与试生产控制also use a summary sheet 同样使用总结表GP-12 reviews GP-12 回顾with fellow SQE 与SQE同事with launch team 与生
12、产小组成员with GP-12 core person 与GP-12核心成员Treat GP-12 like a Controlled Shipping containment对待GP-12如同控制发运遏制政策,6,Failure Causes CS1,Benefits of GP-12 GP-12的利益,With improved GP-12随着改进的GP-12 fewer problems at our plant更少的问题在生产现场发生at launch 生产启动时after launch 生产启动后Improved 改进PFMEA 过程失效模式分析error proofing 防错un
13、derstanding of process 理解工艺understanding of controls 理解控制better supplier performance 更好的供应商表现lower PRR containment costs较低的PRR遏制成本avoid CS1 and CS2 costs避免一级/二级发运控制成本,7,Some Practical Suggestions 一些实践建议,Develop 100%audit and check like a CS1 plan实施100%审核以及象一级发运控制计划一样检查check for missed operations 检查漏
14、加工missing holes,taps,parts 漏孔、漏接头、漏零件develop functional gages 开发功能性检具check for process damage 检查工艺失误review old PRR and quality data 回顾老的PRR和质量数据Identify customer interfaces 确定客户界面SGM and final customer SGM以及最终客户Clearly highlight all 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。
15、Document 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,Use the provided checklist 利用所提供的检查清单。Use separate audit area,do not disrupt normal production 在不影响正常生产的前提下，利用分离的审核区域。Use 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。Train audit team 培训审核队伍。,SUPPLIERS WORKSHOP供应商车间,PRODUCTION AREA生产区域,GP-12 AUDIT AREAGP-12审核区域,Display Board 陈列板,Progress Charts过程图,
