Il forum sulla Qualità di QualitiAmo

[2p71828]

vedi alessio

1) abbiamo la brutta abitudine di dare le linee di montaggio o parte di esse in outsourcing
2) a parte il caso dei pezzi fuori tolleranza (campionatura prototipale per rispettare il time to market) l'APQP favorisce queste situazioni paradossali:
al momento della campionatura iniziale tutti sono al centro della tolleranza e poi sono dolori
3) avere dei campioni al limite della tolleranza è praticamente impossibile a meno che non sia un pezzo di tornitura, nessuno fa una verifica a progetto di cosa possa accadere con pezzi al limite (grande vantaggio dell'outsourcing è che basta tanta carta di certificazione) e via verso nuove avventure

nel caso dell'outsourcing c'è poi il problema che se vuoi una modifica, ammesso anche che sia teoricamente possibile (vedi argomentazioni sopra) devi rintracciare il fornitore ammesso che esista ancora etc

[Stregatto]

Zancky ma figurati se mi riferisco a te! Era solo una battuta generale, rivolta a tutti e a nessuno in particolare. E poi lo so bene che sei una bestiaccia, non c'è bisogno che me lo ricordi.

[diangel_al]

per farci del male, e comprendere quanto sia complesso implementare la lean in produzione, riporto le best practice definite dall'APQC nella produzione di autoveicoli (vedrete la parola Kanban 1 volta sola, per il resto MPS e MRP, tanto odiati dai "lean thinkers").
PCF (APQC) AUTOMOTIVE PUNTO 4 Build Vehicle and Logistics (12724):
4.1 Procure materials and services (10216)
4.1.1 Develop sourcing strategies (10277)
4.1.1.1 Plan for production part approval process
(12501)
4.1.1.2 Re-analyze global spend (12502)
4.1.1.3 Plan for supplier collaboration (12503)
4.1.1.4 Create vendor evaluation and monitor plan
(12504)
4.1.1.5 Create negotiating leveraging factors (12505)
4.1.1.6 Evaluate supplier capabilities (12506)
4.1.1.7 Manage bidding events (12507)
4.1.1.8 Planning for purchase order processing (12508)
4.1.2 Select suppliers and develop/maintain contracts
(10278)
4.1.2.1 Select suppliers (10288)
4.1.2.2 Certify and validate suppliers (10289)
4.1.2.3 Negotiate contracts (10290)
4.1.3 Order materials and services (10279)
4.1.3.1 Process/Review requisitions (10292)
4.1.3.2 Approve requisitions (10293)
4.1.3.3 Solicit/Track vendor quotes (10294)
4.1.3.4 Create/Distribute purchase orders (10295)
4.1.3.5 Expedite orders and satisfy inquiries (10296)
4.1.3.6 Record receipt of goods (10297)
4.1.3.7 Research/Resolve exceptions (10298)
4.1.4 Appraise and develop suppliers (10280)
4.1.4.1 Monitor/Manage supplier information (10299)
4.1.4.2 Prepare/Analyze procurement and vendor
performance (10300)
4.1.4.3 Support inventory and production processes
(10301)
4.1.4.4 Monitor quality of product delivered (10302)
4.1.5 Manage inventory (12509)
4.1.5.1 Publish current inventory status and gross
demand (12510)
4.1.5.2 Monitor inventory and simulate replenishment
(12511)
4.1.5.3 Publish planned receipts schedules (12512)
4.1.5.4 Plan for post goods receipt, transmit GR
references and update inventory (12513)
4.1.6 Plan for inbound parts (12514)
4.1.6.1 Inbound processing and receipt confirmation
(12515)
4.1.6.2 Create warehousing and storage plan (12516)
4.1.6.3 Inventory and warehouse management
analytics (12517)
4.1.6.4 Transportation analytics (12518)
4.1.7 Evaluate vendor and continue monitoring (12519)
4.1.7.1 Create vendor evaluation and monitoring plan
(12520)
4.2 Manufacture vehicles (12521)
4.2.1 Produce product (10304)
4.2.1.1 Manage raw material inventory (10310)
4.2.1.2 Execute detailed line schedule (10311)
4.2.1.3 Rerun defective items (10313)
4.2.1.4 Assess production performance (10314)
4.2.1.5 Repair defective items (12522)
4.2.1.6 Confirm production (12523)
4.2.1.7 Back-flush inventory (12524)
4.2.2 Schedule and perform maintenance (10305)
4.2.2.1 Perform preventive maintenance (12525)
4.2.2.2 Perform corrective maintenance (12526)
4.2.2.3 Analyze and report manufacturing operations
(12527)
4.2.2.4 Obtain, install and maintain equipment (12528)
4.2.2.5 Manage tools/crib (12529)
4.2.2.6 Monitor equipment (12530)
4.2.2.7 Schedule maintenance (12531)
4.2.2.8 Maintain equipment (12532)
4.2.3 Plan master production (12533)
4.2.3.1 Explode Bill Of Material (BOM) for product
structure (12534)
4.2.3.2 Create production planning (12535)
4.2.3.3 Determine cost for products to be built (12536)
4.2.3.4 Import plant supply information (12537)
4.2.3.5 Import plant demand information (12538)
4.2.3.6 Calculate master production schedule (12539)
4.2.3.7 Perform rough-cut capacity planning (12540)
4.2.3.8 Pass master production schedule to MRP
(12541)
4.2.3.9 Integrate master production schedule (12542)
4.2.3.10 Calculate materials requirements plan-MRP
(12543)
4.2.3.11 Allocate production to dealers, distributors
(12544)
4.2.4 Schedule production (12545)
4.2.4.1 Schedule production quantities (12546)
4.2.4.2 Schedule and sequence lines (12547)
4.2.4.3 Schedule line delivery (12548)
4.2.4.4 Generate site level plan (12549)
4.2.4.5 Manage work-in-progress inventory (12550)
4.2.4.6 Generate detail schedule (12551)
4.2.4.7 Communicate schedules with suppliers (12552)
4.2.5 Perform collaborative planning with supplier (12553)
4.2.5.1 Plan for inbound processing and receipt
confirmation (12554)
4.2.5.2 Sequence production line (12555)
4.2.5.3 Implement Kanban (12556)
4.2.5.4 Replenish line based on demand (12557)
4.2.5.5 Manage physical inventory (12558)
4.2.5.6 Dispatch and schedule people and tools
(12559)
4.2.5.7 Manage equipment and parts inventory (12560)
4.2.6 Oversee plant operations (12561)
4.2.6.1 Track production - control / traceability (12562)
4.2.6.2 Track and monitor production parameters
(12563)
4.2.6.3 Assemble and package product (12564)
4.2.6.4 Broadcast messages (12565)
4.2.6.5 Manage alerts (12566)
4.2.6.6 Manage manufacturing order management
(12567)
4.2.6.7 Control flow (12568)
4.3 Manage logistics and warehousing (10219)
4.3.1 Define logistics strategy (10338)
4.3.1.1 Translate customer service requirements into
logistics requirements (10343)
4.3.1.2 Design logistics network (10344)
4.3.1.3 Communicate outsourcing needs (10345)
4.3.1.4 Develop and maintain delivery service policy
(10346)
4.3.1.5 Optimize transportation schedules and costs
(10347)
4.3.1.6 Define key performance measures (10348)
4.3.2 Plan inbound material flow (10339)
4.3.2.1 Plan inbound material receipts (10349)
4.3.2.2 Manage inbound material flow (10350)
4.3.2.3 Monitor inbound delivery performance (10351)
4.3.2.4 Manage flow of returned products (10352)
4.3.3 Operate warehousing (10340)
4.3.3.1 Track inventory deployment (10353)
4.3.3.2 Receive, inspect, and store inbound deliveries
(10354)
4.3.3.3 Track product availability (10355)
4.3.3.4 Pick, pack, and ship product for delivery
(10356)
4.3.3.5 Track inventory accuracy (10357)
4.3.3.6 Track third-party logistics storage and shipping
performance (10358)
4.3.3.7 Manage physical finished goods inventory
(10359)
4.3.4 Operate outbound transportation (10341)
4.3.4.1 Plan, transport, and deliver outbound product
(10360)
4.3.4.2 Track carrier delivery performance (10361)
4.3.4.3 Manage transportation fleet (10362)
4.3.4.4 Process and audit carrier invoices and
documents (10363)
4.3.4.5 Manage returns; manage reverse logistics
(10342)
4.3.5 Manage returns; manage reverse logistics (10364)
4.3.5.1 Authorize and process returns (10365)
4.3.5.2 Perform reverse logistics (10366)
4.3.5.3 Perform salvage activities (10367)
4.4 Forecast vehicle build and create build plan (12570)
4.4.1 Forecast for manufacturing planning (12571)
4.4.1.1 Create manufacturing demand planning
(12572)
4.4.1.2 Create model-mix planning and sequencing
(12573)
4.4.2 Plan and simulate manufacturing (12574)
4.4.2.1 Complete material requirements planning
(12575)
4.4.2.2 Create processing delivery schedules (12576)
4.4.2.3 Issue purchase orders (12577)
4.4.2.4 Perform rapid requirement planning (12578)
4.4.2.5 Plan production completion and delivery
(12579)
4.4.3 Plan for plant human resource (12580)
4.4.3.1 Identify available resources (12581)
4.4.3.2 Identify additional resources needed and the
additional shifts (12582)
4.4.4 Plan for plant safety (12583)
4.4.4.1 Identify existing safety concerns (12584)
4.4.4.2 Plan for securing the safety concern (12585)
4.4.5 Set targets for manufacturing (12586)
4.4.5.1 Set Engineering Hours per vehicle (EPHV) /
Hours Per Vehicle (HPV) target for each plant
(12587)
4.4.5.2 Set lean objectives by conducting lean events
(12588)
4.4.5.3 Identify compliance to production cell
readiness (12589)
4.4.5.4 Set run-at-rate (12590)
4.4.6 Strategize production (12591)
4.4.6.1 Review production practices (12592)
4.4.6.2 Establish new practices (12593)
4.4.6.3 Develop long range production strategy (12594)
4.4.7 Determine production rules and policies (12595)
4.4.7.1 Define production governance (12596)
4.4.7.2 Oversee manufacturing product (12597)
4.4.7.3 Manage production activities (12598)
4.4.7.4 Assess production performance (12599)
4.5 Validate quality targets (12634)
4.5.1 Validate corporate quality requirements (12600)
4.5.1.1 Propose/define quality targets (12601)
4.5.1.2 Define serviceability index rating (12602)
4.5.1.3 Define vehicle warranty glide path per limits
(12603)
4.5.1.4 Certify/approve production intent racks (12604)
4.5.1.5 Certify/approve
12605)
4.5.2 Validate supplier quality (12606)
4.5.2.1 Complete purchased parts Process Failure
Mode and Effect Analysis - PFMEA (12607)
4.5.2.2 Complete process validation testing (12608)
4.5.2.3 Define/implement product and process error/
mistake proofing (12609)
4.5.2.4 Validate completion of production tools (12610)
4.5.2.5 Complete production part approval process
(PPAP) (key components and modules) (12611)
4.5.2.6 Demonstrate run at rate (12612)
4.5.3 Manage quality (12613)
4.5.3.1 Establish quality targets (12614)
4.5.3.2 Monitor quality (12615)
4.5.3.3 Feedback quality status (12616)
4.5.3.4 Improve quality continuously (12617)
4.6 Production monitoring (12618)
4.6.1 Assess Master Production Schedule (MPS) and
Manufacturing Resource Planning (MRP) performance
(12619)
4.6.1.1 Establish appropriate performance measures
(12620)
4.6.1.2 Establish monitoring frequency (12621)
4.6.1.3 Calculate performance measures (12622)
4.6.1.4 Identify performance trends (12623)
4.6.1.5 Identify issues/problems with performance
(12624)
4.6.1.6 Prepare appropriate reports (12625)
4.6.1.7 Develop action plan to improve performance
(12626)
4.6.2 Assess procurement performance (12627)
4.6.2.1 Establish key performance indicators (metrics)
(12628)
4.6.2.2 Establish monitoring frequency (12629)
4.6.2.3 Calculate performance results (12630)
4.6.2.4 Identify performance trends (12631)
4.6.2.5 Analyze performance benchmark gaps (12632)
4.6.2.6 Generate appropriate reports (12633)
_________________
Buona giornata a tutti.

Alessio