1、Pass Through Characteristics Pass Through Characteristics Management(Management(传递特性的管理）传递特性的管理）FoA Supplier DevelopmentFoA Supplier DevelopmentFord Motor CompanyFord Motor CompanyWhat is Pass Through Characteristics?（什么是传递特性）Pass Through Characteristics are those internal and external supplied char
2、acteristics with potential fit or function issues that will not get 100%detected within a production assembly and test area(essentially anywhere verifiable within a plant.)Quality defects are therefore at risk of being“Passed Through”to our customers.传递特性就是那些内部或者外部供应产品的特性的潜在的或运行的问题在生产装配和检测时（车间内部任何一个
3、能做验证的）没有被100%的识别，因此就存在质量缺陷被“传递”到我们的客户那里的风险。Pass Through Characteristic Management(传递特性的管理）Proper fit assures the mating part(s)will assemble properly when required,i.e.bores and bosses are present,located to print,with good threads,etc.配套件装配时需要有适当的试验证明，Functionality assures the component is 100%full
4、y functional over its entire operating range,i.e.for a sensor,thermostat,or pump assembly purchased and installed in assembly.PTC SCOPE AT(PTC SCOPE AT(传递特性的定义范围）传递特性的定义范围）Analyze all T and TR final line stations for possible component,hardware,and installation failure modes and their current detect
5、ion.Develop short and long-term corrective action plans for high-risk issues that may affect our customers.分析所有的T和TR由于可能存在的组成和装配失败的样件以及当前的检测方式。针对可能影响到我们的客户的高风险问题开展短期和长期的整改活动计划。GOALGOAL（目标）（目标）Reduce T and TR warranty.减少T和TR的依据 Line Technicians 生产线上的技术人员 Process Engineers 工艺工程师 Controls Engineers管理工程
6、师 Quality Engineers质量工程师 Quality Technicians质量技术员 Supplier Quality供应商的质量 Quality Manager质量经理PROJECT TEAMPROJECT TEAM（攻关小组）（攻关小组）CONTROL PHASESHORT TERM CORRECTIVE ACTIONSIMPROVE PHASECONTROL PHASELONG TERM CORRECTIVE ACTIONSIMPROVE PHASEALLOCATE RESOURCESIMPROVE PHASEPRIORITIZE FAILURE MODESANALYZE
7、PHASEANALYZE FAILURE MODES MEASURE AND ANALYZE PHASESDATA ENTRY INTO EXCEL MATRIXMEASURE PHASEINDIVIDUAL STATION REVIEWMEASURE PHASEPTC PROCESS FLOWPTC PROCESS FLOW传递特性的工艺流程传递特性的工艺流程个别工位的评审（测量个别工位的评审（测量阶段）阶段）分析失效模式（测量和分析失效模式（测量和分析阶段）分析阶段）判定失效模式的优先次判定失效模式的优先次序（分析阶段）序（分析阶段）分配资源（改进阶段）分配资源（改进阶段）临时措施临时措施
8、（改进阶（改进阶段）段）永久性措施永久性措施（改进阶段）（改进阶段）控制阶段控制阶段12345678910111213141516ABCSTATION:40Kit or Part Number/Descriptions1 Manual one-way clutch2 Wave SpringCan this component be INSTALLED IMPROPERLY?Yes NoYes No How?(ie.Upside Down,Backwards)Wrong HeightCockedIs there a method for DETECTING mis-assemblies?Yes
9、No N/AYes No N/AWhere or What Station?Missing is not detected at Sta.#43 or 47,wrong height is caught at#43Sta.#40If this component is LEFT OUT,can it be detected?Yes NoYes NoWhere or What Station?Sta.#43Can a SIMILAR BUT WRONG component be installed?Yes NoYes No If so,can it be detected?Where?Can t
10、his component be installed in the WRONG MODEL?Yes NoYes No If so,can it be detected?Where?Can we install a DAMAGED component?Yes NoYes No If so,can it be detected?Where?Broken with parts inside detected at Sta.#47 Missing bearings and springs not.Sta.#43Are there installation tools required?Yes NoYe
11、s NoAre they used?Yes No N/AYes No N/A12345678910111213141516DE3 Friction/Steel Plates4 Pressure PlateYes NoYes NoSteel on bottom(upside down)Cocked/not in groovesYes No N/AYes No N/ANo DetectionSta.#43Yes NoYes NoSta.#43Sta.#43Yes NoYes NoThick/Thin pressure plates have no known detection(4 vs.5 pl
12、ate design)Can detect thick/thin at Sta.#43Yes NoYes NoSame as aboveSame as aboveYes NoYes NoBent-Sta.#43,cracked plate-no detectionSta.#43Yes NoYes NoYes No N/AYes No N/AINDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW个别工位的评审个别工位的评审INDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW个别工位的评审个别工位的评审D
13、escriptionDescription Review each assembly&repair station 评审每一个装配和返修工位*Identify all parts installed 识别所有的安装部分*Interview techs to determine what quality issues have been observed.技术部门确定已经出现过的质量问题*Review each station during part installation for process related quality issues.评审每一个和质量问题有关的零部件装配工位*Docu
14、ment model complexity,and review QPS sheets and visual factory for effects.*Run tests to verify assumptions运用测试手段去验证假设INDIVIDUAL STATION REVIEWINDIVIDUAL STATION REVIEW个别工位的评审个别工位的评审ResponsibleResponsible Core team:团队核心成员*Quality Manager and Engineer 质量管理人员和工程师*Manufacturing tech“expert”from area 生产
15、技术员*Controls Engineer操作工程师CONTROL PHASESHORT TERM CORRECTIVE ACTIONSIMPROVE PHASECONTROL PHASELONG TERM CORRECTIVE ACTIONSIMPROVE PHASEALLOCATE RESOURCESIMPROVE PHASEPRIORITIZE FAILURE MODESANALYZE PHASEANALYZE FAILURE MODES MEASURE AND ANALYZE PHASESDATA ENTRY INTO EXCEL MATRIXMEASURE PHASEINDIVIDU
16、AL STATION REVIEWMEASURE PHASEPTC PROCESS FLOWPTC PROCESS FLOW传递特性的工艺流程传递特性的工艺流程MATRIX:ASSESS RISK AND PRIORITIZEMATRIX:ASSESS RISK AND PRIORITIZE矩阵图：矩阵图：FAILURE MODESFAILURE MODES 评估失效模式的风险和优先级评估失效模式的风险和优先级HOW IS THIS FAILURE DETECTED?WHAT STATION?Error ProofIn Process at stationIn Process within T
17、eamIn Process After TeamAt Final Test or Leak TestDetection Unknown(less than 100%)No DetectionCurrent Controls,visual inspection,manual gage,auto gage,air test,etc.WHERE IS THIS FAILURE DETECTED?SEVERITY(S)OCCURRENCE(O)DETECTION(D)CRITICALITY(SxO)RPN(SxOxD)HISTORYCOMMENTSCORRECTIVE ACTION PLANSTATI
18、ONPART NUMBER/PROCESS DESCRIPTIONPOTENTIAL FAILURE MODEPOTENTIAL FAILURE EFFECTSARE HANDTOOLS REQUIRED?POTENTIAL CAUSE(S)Final Line station.What is this station supposed to do?Whats the part number(s)?How could this process go wrong?Examples:can the part be installed incorrectly,missing the part,dam
19、aged part,or wrong model?What is the impact to the customer?(next team,VO plant,end customer)This drives severity rating.Are handtools required for installation?Are they used?What could cause this to go wrong?Locate yellow pad incorrectly-shipping stap to transaxleCould result in an assembly plant r
20、eturnYThere are two different locations for yellow pad depending on model-operator errorMissing shipping strapYOperator ErrorLoose bolt that comes with shipping strapCould drop a transaxle resulting in APRYFaulty torque gunStripped bolt,not part of shipping strapCould drop a transaxle resulting in A
21、PRYOperator Error/Faulty torque gunMissing bolt that is not part of shipping strapCould result in dropped transaxle in-house causing scrap or repairYOperator Error301Auto rotate and indexIncomplete rotate and indexStop BuildNMechanical malfunctionMissing kitStop BuildNOperator ErrorMisoriented filte
22、rStop BuildUnofficial toolOperator ErrorDamaged filter-crackedContamination/shift qualityUofficial toolSupplier Issue/installation problemExtra filter grommet from teardownStop BuildUnofficial toolProcess IssueBreak neck of filterContamination/shift qualityUnofficial toolOperator Error/or faulty par
23、tMissing oil filterContamination/shift qualityUnofficial toolOperator ErrorWrong model filter Unknown/no effectUnofficial toolOperator ErrorBroken clip on filterUnknown/no effectUnofficial toolSupplier IssueNo rubber grommet on filterStop Build wherever grommet falls outNSupplier IssueFill tube grom
24、met missingNOperator IssueFill tube not seated completelyPotential leakNOperator IssueBlocked end on fill tube grommetNSupplier IssueFill tube grommet from General MotorsCustomer will not be impactedNSupplier IssueMount kit on pallet and install filter and fill tube grommet(black)302Install shipping
25、 strap with included bolt and loose bolt300MATRIX REVIEW-ASSESS CUSTOMER RISKMATRIX REVIEW-ASSESS CUSTOMER RISKDescriptionDescription Enter all data in matrix spreadsheet 将所有的资料数据输入矩阵图*Failure modes determined from station reviews 评审工序存在的失效模式*Potential cause of failure 潜在的可能导致失效*Categorize risk to c
26、ustomer(red,yellow,green)对顾客冒的风险进行分类（红、黄、绿）*Enter all APRs NEs and other warranty 记录所有的APRs、NEs和其他的依据*Rank risk to customer based on FMEA ranking with Severity,Occurrence and Detection*Prioritize where error proofing/controls are needed base on risk to customer(master rank)ResponsibleResponsible Cor
27、e team plus:*Quality review engineer*Resident engineer*Process engineerError ProofIn Process at stationIn Process within TeamIn Process After TeamAt Final Test or Leak TestDetection Unknown(less than 100%)No DetectionXXXXXXXXXXXXXXXXXXXXXWHERE IS THIS FAILURE DETECTED?Red,Yellow,Green ChartRed,Yello
28、w,Green ChartGreenGreenError Proofed orCaught in Sta.Caught in TeamCaught in next teamAt Final Test or AirTestRedRedDetected Less than 100%No DetectionSEVERITY(S)OCCURRENCE(O)DETECTION(D)CRITICALITY(SxO)RPN(SxOxD)KNOWN DEFECTHISTORYMASTER RANKCOMMENTSSee Rating Sheet.1rst priority.See Rating SheetSe
29、e Rating Sheet2nd priority.3rd priority.Defect found on APR,NE,or FQAHistory of NE,APRs,or FQAs associated with this failure mode?(Example:NE 11/12/00)Ranks issue 1-5(5 most severe)based on FMEA Severity and History to determine resource allocation.11515REAR SUN AND DRUM BUSHING WAS SEIZED TO THE FI
30、NAL DRIVE SUN GEARAPR 5/09/013REAR SUN DRUM DIAMETER THAT MATES WITH OWC IS UNDERSIZED,OWC WILL NOT ENGAGE UNTIL HIGH RPMAPR 7/19/013Inner race undersized.NO FORWARDAPR 10/26/01(4),APR 5/29/01#169,APR 7/19/01,APR 7/19/01411111112481REVERSE CLUTCH SNAP RING GROOVE NOT MACHINED CORRECTLY.SNAP RING POP
31、PED OUT.APR#16,APR 9/09/004REVERSE CLUTCH EXTRA SET OF PLATES AND THE CUSHION SPRING WAS MISSINGAPR 8/28/003FRONT CARRIER MISSING LUBE HOLESNE 2/01/200141MISSING T13NE 10/25/2000,NE 3/29/2001,NE 6/06/2001,NE 8/30/20015Rank Risk To CustomerRank Risk To Customer FMEA Ranking Warranty Information Maste
32、r RankCONTROL PHASESHORT TERM CORRECTIVE ACTIONSIMPROVE PHASECONTROL PHASELONG TERM CORRECTIVE ACTIONSIMPROVE PHASEALLOCATE RESOURCESIMPROVE PHASEPRIORITIZE FAILURE MODESANALYZE PHASEANALYZE FAILURE MODES MEASURE AND ANALYZE PHASESDATA ENTRY INTO EXCEL MATRIXMEASURE PHASEINDIVIDUAL STATION REVIEWMEA
33、SURE PHASEPTC PROCESS FLOWPTC PROCESS FLOWCORRECTIVE ACTION PLANSCORRECTIVE ACTION PLANSShort Term ActionsShort Term Actions Create awareness of issue(not sustainable)*Install Pass-Thru signs at high risk stations describing the failure mode to the customer*Alert management to risk Temporary fixes/u
34、pgradesLong Term ActionsLong Term Actions Solicit ideas from manufacturing techs and engineers for error-proofing ideas In-Process Verification Stations(IPVs)CORRECTIVE ACTION PLANSCORRECTIVE ACTION PLANSTarget dateStatusStaStation FunctionObjectivesProposalsBeforeAfterCost To Implement (matl only)P
35、otential SavingsMaster Risk(5 Highest Risk)1/14/02Comp.109Manual backup for Sta.#107,which installs 3 bolts into the chain cover to case and TSS model check.Eliminate missing or mistorqued boltsComp.Used a control box with push buttons and a red/green light.The only information to the operator is O.
36、K or not O.K to build-no info.on which bolt needs torque.No logic to prevent releasing the pallet without torque of any/all bolts or stud.Also,wrong torque may be achieved due to tray malfuction.Pallets cannot be released unless torque is achieved on any/all bolts.Installed 3 new green lights at top
37、 indicate which and how many bolts need to be torqued.Lights go out when achieved.Also repaired socket to torque correlation.Included in costs for station#13If caught in-house results in 12 teardowns/yr or$1917.00/yr or APRs$20,400.Depends on degree of leak2Logged in 1/15/02Complete and in tryout350
38、-1/2Sta.#350 Manual install chain cover plug,TSS plug,C-clip,(1)cooler fitting plug and bulkhead plugEnsure Chain Cover plug is installed.Add elec.Eye after Sta.#350,just before index station to detect presence of plugManual install of Chain Cover Plug.Plug is at back of transaxle,so is never seen v
39、isually for check of presence.Elec.Eye senses transaxle presence first and then detects chain cover plug presence$1000.EstimateMultiple NE with estimated value of$12,500./yr5 Low Trans.Fluid,water 12/20/01Comp.73Backup station installs bolts for O.D.servo coverEnsure all 3 bolts installed and torque
40、d prior to release of palletComp.Used a control box with push buttons and 1 red light(not O.K.to build)and 1 green light(O.K.to build).A pallet could be released without achieving torque on any/all bolts.Added 3 torque lights and changed logic so that individual torques must be completed prior to pa
41、llet releaseModified existing equipment with materials in-houseInverted delta item-could result in APRs Rated 4 based on safety8/1/01Comp.99Install 4 accummulator springs and chain cover gasketAdd detection for spring on sideComp.Spring could fall over and be detected as there,depending on orientati
42、on when on-side.Recalibrated cylinder and George Gery added verification to test to detect spring on sideNoneF.Q.A resulting in teardown=$150.00/yr21/14/02Comp.372 CCheck TRS switch,install orange TRS cap Cost SavingsComp.TRS dust cap had O ring to protect from water damaging switch.Eliminated O rin
43、g no longer required due to process changes 2 years agoNone14 cents per plug or$77,000/yr.N.A.BACKUP STATION#109COMPLETE STATIONCOMPLETE STATIONSHOWS TORQUE REJECT SHOWS TORQUE REJECT CLOSEUP OF STATIONCLOSEUP OF STATIONTORQUE ACHIEVED,TORQUE ACHIEVED,LIGHT OUT.PALLET LIGHT OUT.PALLET WILL NOW RELEA
44、SEWILL NOW RELEASEStation#350 1/2Station#350 1/2SENSOR TO DETECT PRESENCESENSOR TO DETECT PRESENCE OF TRANSAXLE OF TRANSAXLESENSOR TO DETECTSENSOR TO DETECTCHAIN COVER PLUGCHAIN COVER PLUGCHAIN COVER PLUGCHAIN COVER PLUGControl Plan will consist ofControl Plan will consist of:Updating dynamic contro
45、l plansStatistical process control chartsFMEA(Living Document)CONTROL PLANCONTROL PLANMachined Part ExampleMachined Part ExampleKEYS TO REPLICATIONKEYS TO REPLICATIONMethodologyMethodology*Work backward(final assy.to machining)*Test assumptions*Review no more than 5 stations per day*Streamline paperwork*Dedicated area to complete matrix reviewPeoplePeople*Involve as many Mfg.Techs as possible*Consistent core team led by Black Belt*Maintenance involvement early in process*Develop reward system
