Valmet Automotive Quality Management March 2015 PDF
Valmet Automotive Quality Management March 2015 PDF
Valmet Automotive Quality Management March 2015 PDF
Quality Management
March 2015
INTERNAL
Valmet Automotive
March 2015
INTERNAL
Process-oriented
Serial production
Product launch
Valmet Automotive
March 2015
INTERNAL
Quality:
1995
1999
2003
ISO 9001
QS-9000
ISO/TS 16949
Valmet Automotive
March 2015
Environment:
2001
ISO 14001
Safety:
2012
OHSAS 18001
INTERNAL
Quality objectives
The key targets are set and reviewed together
with customer
Valmet Automotive
March 2015
INTERNAL
Valmet Automotive
March 2015
INTERNAL
Quality audits
Process audits
Product audits
COP audits
Valmet Automotive
March 2015
INTERNAL
Management team
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
Production meetings
VA Management reviews
Valmet Automotive
March 2015
Quality assurance in
production
INTERNAL
Quality management
Serial production control
10
Valmet Automotive
March 2015
Quality
management
Customer
requirements
Continuous
improvement
Action plans
Problem solving process
Improvement projects (8D, Six sigma)
Change management
Market feedback process
Control of non-conforming products
Process
definitions
Quality control
&
measurements
Product audit
Quality control points
End of line tests
Material laboratory analysis
Online/offline (3D) mesurings
Control of process parameters
11
Valmet Automotive
March 2015
INTERNAL
INTERNAL
12
Valmet Automotive
March 2015
INTERNAL
13
Valmet Automotive
March 2015
INTERNAL
PFMEA
- New product
- Process change
Control plan
- New product
- Process change
- New control methods
Reaction priority
1. Design change
2. Process change
3. Control
14
Valmet Automotive
March 2015
Operator instructions
- New product
- Process change
- New control methods
Results/feedback
- Production
- Final audit
- Customers
INTERNAL
Quality Audit
Body
EC
Inspection
Primer
Inspection
Top coat
Inspection
Final Insp.
Paint
LM 2
Inspection
ECOS
LM 1
Inspection
Diagnosis
Delivery
check
Body shop
Roller test
Wheel &
Light
alignment
Paint shop
Water
test
offline
Diagnosis
Paint
Inspection
Underbody
check
LM 3
Inspection
ECOS
Assembly shop
Test drive
ECOS
Product Audit
15
Valmet Automotive
March 2015
INTERNAL
KESKILATTIALINJA
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Ksnhitsaus visuaalinen
tarkastus
Ksnhitsaus momenttitarkastus
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus
Laserhitsaus - VISIR
VIIMEISTELYLINJA
Visuaalinen pintalaatutarkastus
Ovien pulttien momenttitarkastus
Luukkujen sovitemittaus
Hitsaamon laadunmittaus (LM)
KORILINJA
InLine Mittaaminen
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
16
ETUPLINJA
TAKAPLINJA
OffLine mittaus
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Liimauksen visuaalinen tarkastus
OffLine mittaus
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
OnLine liimakamerajrjestelm
Liimauksen visuaalinen tarkastus
Lyhytkaarihitsaus visuaalinen
tarkastus
Lyhytkaarihitsaus
momenttitarkastus
Valmet Automotive
March 2015
SIS- JA ULKOSIVULINJAT
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus
LUUKKULINJA
Valssauksen visuaalinen
tarkastus
OffLine Mittaaminen
Adaptiivinen hitsausvalvonta
Ultrani hitsauslaaduntarkastus
Liimauksen visuaalinen tarkastus
Visuaalinen pintalaatutarkastus
Laserjuottamisen visuaalinen
tarkastus
INTERNAL
= OffLine measuring
= InLine measuring
= Fit&flush measuring
ZB Radeinbau LI
ZB Radeinbau VST RE
005A01L
ZB Radeinbau VO LI ZB Lngstrger LI
002R01
001R01
ZB Stirnwand
010A01
ZB Fahrertr LI
530
ZB Fondtr LI
530
ZB Rckwandtr
570
ZB Radeinbau VST LI
005A01R
560
530
ZB Motorhaube
ZB Fahrertr RE
530
320A
ZB Lngstrger VST HI LI
305A01L
Quertrger LI
Lngstrger IN OB VO RE
003R01
ZB Vorbau Lngstrger IN OB VO LI
025
003L01
ZB Seitenwand IN RE
410L
ZB Seitenwand AU RE
ZB Fondtr RE
ZB Seitenwand AU VST RE
425R
435R
325A
Quertrger RE
ZB Heckboden
340
ZB Z2.1
ZB Unterbau
630
ZB Z2.3
790
745
325A
ZB Lngstrger VST HI RE
305A01R
ZB Radeinbau RE
320A
17
Valmet Automotive
245
ZB Hauptboden
March 2015
410R
425L
ZB Seitenwand IN LI
ZB Seitenwand AU LI
435L
ZB Seitenwand AU VST LI
CONFIDENTIAL
INTERNAL
Degreasing Degreasing
spray
dip
Rinse
spray
Rinse
dip
Rinse
spray
Sealing
Sealing
touch-up
Robot
sealing
Robot sealing/
SAM
Manual
sealing
Passivation
spray
Rinse
dip
Rinse
spray
EC
BS surface
touch-up
EC
oven
DIW Rinse
spray
UF Rinse
dip
UF Rinse
dip
UF Rinse
spray
Cathodic
immersion
EC touch-up
(dry)
Audit
1
Masking
station
Flash-off
Manual
ESTA
Back-up Flash-off
spraying application
Off-line
repair
Back-up
Robot
clear coat
Primer
oven
Audit
2
Clear coat
Top coat
oven
Manual
wiping
Recip.
base coat
ESTA
base coat
Manual
base coat
Primer
touch-up
(Moist)
Manual
wiping
Off-line
repair
Finishing
Rating
OK / NOK
Audit
3
Control
Cavity
treatment
Cavity
treatment
oven
To
general
assembly
Spot repair
NOK line
18
OK line
Valmet Automotive
March 2015
Sanding
rerunners
Audit
4
INTERNAL
TOP COAT
PRETREATMENT
Quality Audit 3
KPIs
-FTOK % Top coat
-- Quality Audit 3
Quality Audit 1
Quality Audit 4
(Random sample min 1 body/shift)
PRIMER
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
19
Valmet Automotive
March 2015
KPIs
-FTOK % Primer
- Quality Audit 2
EC TOUCH-UP
Audit 1
Quality concept
Assembly shop
INTERNAL
All vehicles
Audit 2
Check:
-Line 1 and IP-preassys most
important and safety-relevant
assemblies
Audit 3
All vehicles
Check:
-Line 2 and Chassispreassys most important
and safety-relevants
assemblies
KPIs
FTOK % & QC
All vehicles
Check:
-Line 3 and doorspreassys most important
and safety-relevants
assemblies
R C
. .
U
N T
I 1
L E
E
C T
R IC C
A B IN
E T
S
R
. C
.
U N
I T
1
E
L E
C R
T C
I C B
A IN
E T
S
R .C
U N IT 2
O S T
E N
S
S O
R
C A
B IN E
T
Process flow
HUOLT O
Process flow
KPIs
FTOK % & QC
KPIs
FTOK % & QC
Rework
Process flow
Water test
All vehicles
Check:
--Leaks- optical
and manually
Process flow
All vehicles
Test Drive
KPIs
FTOK %
5% test track
100%
cobblestone
drive
Check:
-drivability,
functions, noises
KPIs
FTOK %
High pressure
All vehicles
water test
5 % of cars
Roller test
All vehicles
line 7 Q-check
Paint surface
All vehicles
All vehicles
Check:
- All cars
- CPA-focus
points, feedback
from previous
days/weeks
Check:
-damages,
scratches,
assembly marks
defect/car
KPIs
FTOK %
defect/car
20
Valmet Automotive
March 2015
Line 8
Quality
audit
All vehicles
All vehicles
Check:
-drivability,
functions, noises
5 cars a day
Final inspection
Check:
-deliverable
-chassis card OK
-vehicle corresponds the
order
-delivery condition and
cleanliness
-final diagnose
KPIs
FTOK %
defect/car
KPIs
FTOK %
INTERNAL
Valmet Automotive
March 2015
Product Audit
2 cars/day
INTERNAL
Measuring center
22
Valmet Automotive
March 2015
INTERNAL
Portal machines
Other equipment
-
23
Valmet Automotive
March 2015
INTERNAL
Material laboratory
Provides 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
Chemical laboratory
Process baths and sewage water analysis / monitoring
Chemical managements (e.g. VAs MSDS register)
Cooperation together
Authorities
Material suppliers - SQ activities, analysis / testing services
Universities and research centers - e.g.
o Outotec , Research Center material technology and analytical laboratory
o VTT Technical Research Center analytical service (e.g. metal analysis and other problem solving)
24
Valmet Automotive
March 2015
Product quality
INTERNAL
26
Valmet Automotive
March 2015
INTERNAL
Customers
audit process
Prod.
P
Audit
A
Delivery
P
Audit
Independent activity
Random sample 1 %
Final audit
Legal req.,
functions
Optical
27
Valmet Automotive
March 2015
Results
A/B/C-faults
Improvement
potential
Corrective actions
Customer
Internal operations
Suppliers
INTERNAL
Perhaps
Optical
Quality
Improvement
Potential
Statistical
Valmet Automotive
Immediate
Functional
Defects
(Audit, Quality Measuring)
Delivery Block
Defect Analysis / Immediate Actions
Actions
28
Next WS visit
Type of
defect
Defect
weighting
Complaint
March 2015
Rework
Safety
Disturbance
Legal
Test drive
interruption
Customer
reaction
INTERNAL
Defect founder
Defect
1.
1. Defect added to
body, paint or
chassis card
2.
3.
4.
2. Defect stopped,
inspection & repair
3. Analysis +
corrective &
preventive actions
Quality Manager
29
Valmet Automotive
4. Approval and
additional actions if
needed
March 2015
INTERNAL
Market feedback
Car owners
Dealers
Receive, summarise
and inform
(contact person)
Define priority
(task force)
Reporting
30
OEMcustomers
Warranty info
Leasing cars
Test reports
Dealer reports
JD Power
Suppliers
Audits
Valmet Automotive
Reporting
March 2015
Research
companies
Press
Customer satisfaction
INTERNAL
Valmet Automotive
March 2015
Communication
INTERNAL
Reporting/Escalation
Information/Support
Production
management
morning round
Valmet Automotive
07:40 - 08:10
TL+ OPS:
07:10 - 07:40
OPS:
07:00 - 07:05
March 2015
PRD-VP
PRD-D
QS
LOG
SQ
FIN
ENG
PRD-C
M
SV
TL
OPS
Director of Production
Department Director
Quality representant
Logistics
Representant of Supplier Quality
Representant of Finance
Representant of Process Engrg
Representant of Prodn Control
Representant of maintenance
Supervisor of a Prodn area
Teamleader
Operator on a station
Daily at:
09:20-10:00
Participants: PRD-VP, PRD-D, QS, LOG,
FIN, PRD-C, M
Themes:
Volume, Quality, Productivity,
Availability of parts/materials,
Escalation
32
Abbreviations