‫‪The products are not‬‬

‫‪conform, I react‬‬
‫!‪immediately‬‬

‫ارديبهشت ماه ‪97‬‬

‫معاونت كيفيت گروه‬

‫‪RENAULT Monitoring Plan‬‬ ‫مديريت تضمين کيفيت گروه‬
‫اداره مهندسي کيفيت و تکوين محصول‬
‫حوزه فرايندهاي بدنه و پرس‬
 ‫مقدمه‬

‫مقدمه ‪:‬‬

‫طرح ريزي کيفي بمنظور استخراج پارامترهاي فرايند ‪ /‬محصول و‪ /‬يا محصول جهت‬
‫کشف هرگونه انحراف قبل از توليد محصول نامنطبق صورت مي گيرد‪.‬‬
‫تتوتتتلي اتتتستتتتاندارد با‬
‫تتدتت مح ص‬
‫تتهتتت تتاهتتت براي تول ي‬
‫اطمينان دائتتميتتت ازکفاتتيتتت کلتتيهتت مشخ ص‬
‫‪ Monitoring Plan‬تضمين مي گردد‪.‬‬
‫مراجع ‪:‬‬

‫‪[1]. RENAULT-NISSAN ANPQP‬‬

‫‪[2]. APQP-PPAP‬‬
‫‪[3]. RENAULT Conformity Convergence Plan Standard 72-09-000/--D‬‬
‫‪[4]. RENAULT HCPP Standard 01-33-301/--C‬‬
‫‪[5]. RENAULT Monitoring Plan DIV Quality Engineering‬‬
‫‪[6]. RENAULT Creating the Monitoring FOPs 74-03-000/--B‬‬
‫‪[7]. Control Plan Quality Guideline Q1020C00‬‬
 ‫شمای طرح ريزي کيفي رنو‬

‫‪ .1‬شماي طرح ريزي کيفي شرکت رنو بر اساس فازهاي مختلف تکوين محصول‬

‫راه اندازي‬ ‫توليد‬ ‫ابزار سازي‬ ‫تکوين جزئيات‬ ‫تکوين کلي‬ ‫امور مقدماتي‬

‫توليد انبوه‬ ‫‪SOP‬‬ ‫شروع ابزارسازي‬ ‫پيش از قرارداد‬

‫تحليل ابعادي ‪-‬‬ ‫تحليل‬ ‫تحليل بر اساس‬

‫استانداردي‬ ‫عملگرهاي فني‬ ‫نيازمندي هاي‬
‫– تکنيکي‬ ‫مشتري‬

‫‪FMEA‬‬

‫‪HCPP‬‬
‫‪Capability‬‬
‫‪Monitoring Plan‬‬ ‫مطالعه قابليت‬ ‫اولويت بندي‬
‫پارامترهاي محصول ‪/‬‬
‫فرايند‬
‫‪Conformity Convergence Plan‬‬
‫حدود کاربرد ‪ :‬فرايند قطعه ساز و ‪OEM‬‬
 ‫زمان بندی طرح ريزي کيفي رنو‬

‫‪ .2‬زمان بندي فعاليت ها در حوزه طرح ريزي کيفي‬

‫در حين طراحي جزئي ) ‪( Detail Design‬‬ ‫(‪a‬‬

‫• ‪FMEA‬‬
‫در حين ابزار سازي ) ‪( Tooling‬‬ ‫(‪b‬‬
‫• ‪....................................HCPP‬‬
‫• مطالعه قابليت ) ‪( Capability‬‬
‫• جاري سازي طرح پايش اوليه )‪( Monitoring Plan‬‬
‫در حين راه اندازي ) ‪( Launching‬‬ ‫(‪c‬‬
‫• ‪FOP-S‬‬
‫• ‪FOP-A‬‬
‫• ‪ FOP-A‬ک‬
‫تتتنتتترلي‬
‫در حين توليد انبوه‬ ‫(‪d‬‬
‫• بروز رساني مدارک مرتبط با طرح پايش ) ‪ FOP-S ،FOP-A‬و ‪ FOP-A‬کنترلي (‬
‫• بروز رساني تجهيزات کنترلي‬
‫• سازماندهي کميته مديريت طرح پايش – هدف بروز رساني تناوب و تعداد نمونه برداري بر‬
‫اساس نتايج‬
 FMEA

‫ه)ا ( وروديهاو خروجي‬ FMEA .3

‫ را دنبال کند‬Flow Process Chart ‫مي بايست جريان‬

Process Flow PFMEA Control

Chart Process Chart
• Operation Number • Change in
Detection
• Product/Process
Characteristic • Change in
Occurrence
• Incoming Source of • Variation Class
Variation • Change in Severity

Work Design Other Action

Instructions Change
 ‫‪HCPP‬‬

‫‪ HCPP .5‬چيس ‪:‬‬

‫ت‬
‫ابزاري کيفي جهت استفاده در طراحي و تکوين‬
‫تأثير بر‬ ‫عدم انطباق‬ ‫‪ ‬‬
‫مشتري‬ ‫بالقوه‬ ‫‪Gravity‬‬ ‫‪Feasibility‬‬
‫درجه اهميت‬ ‫امکان سنجي‬

‫‪TNC‬‬
‫)‪(NCR‬‬

‫‪Capability Study‬‬
‫مطالعه قابليت‬

‫‪Preliminary‬‬
‫‪Monitoring Plan‬‬

‫طرح پايش اوليه‬

HCPP
 HCPP

Numerical

Attribute
 ‫‪HCPP‬‬

‫‪ .6‬خروجي ‪: HCPP‬‬

‫(‪ a‬بهينه سازي فاز تکوين‬

‫(‪ b‬مطالعه سرمايه گذاري بالقوه و هزينه هاي سربار توليد‬

‫(‪  c‬تعيين سيستماتيک پارامترهايي که مي بايست در طرح پايش اوليه گنجانده شود‬

‫(‪ d‬تعيين پارامترهاي تأثيرگذار بر تنوع فرايند‬

‫(‪ e‬تعديل فرايند ‪ :‬تغيير فرايندهاي ساخت ‪ ،‬تجهيزات و ابزارآلت‬

‫(‪ f‬تعديل محصول ‪ :‬بهينه سازي تلرانس ها ) زنجيره تلرانسي ( و تغيير طرح‬
 Capability

TAG-N Continuous ( Capability ) ‫ مطالعه قابليت‬.7

s
Manufacturing Process:

Not Capable

TAG-P Counting
Capable
one point = one sample

m
LL UL D
The curve represents the NC
7 target : The average number
one point = one sample 6 of defects allowed by parts.
5
D The curve represents 4
the target of NCR. 3 Capable
7
2 N
6
1
5 Example:
4
N: size of sample (number of parts) N = 10 (hood)
3 Capable
2 N D: Number of defects in a sample D = 25 (defects)
1
Example:
N: Size of sample (Number of parts) N = 50 (Welding Points)
D: Number of defects in a sample D = 7 (defects)

TAG-B Binary
 Process Flow Chart ( APQP-PPAP)

PSW .8

PSW Documents

i g n
signs
Contract FMEA

PSSW
Packing
0)
P
Process
W ( K1 CF
n plan Flow
actio AVES
Chart
h
wit
( K5 0) report

f use d Test
re Drawing
PSW CP Report
 Process Control Chart (Conformity Convergence Plan )

‫تتاتتبل تتت تحتتويلدر‬

Conformity Convergence ‫ي ق‬Plan
‫تتلتتم‬
‫مرحله ق‬ Process Control Chart .9
 Global Control Plan Organization

) boxes- 16 ( ‫ دياگرام‬Global Control Plan Organization .10

PRO SPR ‫سازماندهي طرح هاي پايش بر اساس سيستم‬
Level 1 Level 2 Level 3 Level 4

Manufacturing and inspection workstation

• Apply the monitoring operating modes (described in SOS*)
• Apply self-check
• Alert managers in case of anomaly
• Take corrective and preventative action.

Manufacturing EWT**
• Makes sure that the control plans are applied (Workstations observations)
• Audits the product conformity

Workshop or Department Quality

• Check product conformity (end of workshop product audit)
• Processes application (Level 3 process audits)

Plant quality
• Check conformity of finished cars (level 4 product audits).
• Checks that preventive and corrective actions issued from level 1 to 3 control plan are applied and
efficient (Level 4 process audits…).
 Global Control Plan Organization

‫مونتاژ‬
GLOBAL CONTROL PLAN
CAR ASSEMBLY PLANT
Level 1 monitoring Level 2 monitoring Level 3 monitoring Level 4 monitoring
Workstation EWT* Department Plant
Conformity Control Plan
Functional
Product (Monitoring POS**) S&D CSC
Characteristics
monitoring
Sectorial
SDEP
Checkman Product SIW▫
Process related
Product
Self-check Audit S-Aves▫▫
Characteristics
monitoring

Process
Poka Yoke monitoring
Parameter
monitoring Maintenance

Level 3 Level 4
Process Workstation
Criteria Process Process Audit
Observation
monitoring Audit Procedure
Audit
 Global Control Plan Organization

GLOBAL CONTROL PLAN ‫بدنه‬

Body shop activities
Level 1 monitoring Level 2 monitoring Level 3 monitoring Level 4 monitoring
Workstation EWT* Department Plant

Functional
Product
Characteristics
monitoring
•
•
VIN number
1D geometry
S&D CSC

Sectorial
SDEP
Checkman Self-check
Process related
Product (manual welding) (manual welding) TCT Audit SIW▫
Characteristics
monitoring • 3D geometry
S-Aves▫▫
• Mastic and sealants dimension
• pot and MIG welding pull-off
strength
Process
Parameter
• Welding gun parameters Around 30
monitoring Poka Yoke monitoring monitoring
POS
Maintenance
Process
Criteria Level 3 Level 4
Workstation
monitoring
Process Process Audit
Observation
Audit Procedure
Audit
 Global Control Plan Organization

GLOBAL CONTROL PLAN ‫رنگ‬

Paint shop activities
Level 1 monitoring Level 2 monitoring Level 3 monitoring Level 4 monitoring
Workstation EWT* Department Plant

Functional
S&D CSC
• Process check
Product • Different layers and paint • Corrosion test
Characteristics aspect • DOI, Gloss
SDEP
• Sealants leakiness
monitoring
Sectorial
Checkman Self-check SIW▫
Process related (manual sealant) (manual sealant) TCP Audit
Product S-Aves▫▫
Characteristics • Sealants dimensional conformity
monitoring • Different layers thickness

•
Around 32
Surface treatment facilities
Process parameters, monitoring
• Cataphoresis facilities parameters
Parameter • Cocking cabin temperature POS
monitoring
Maintenance

Level 3 Level 4
Process Workstation
Criteria Process Process Audit
Observation
monitoring Audit Procedure
Audit
 Global Control Plan Organization

Fit ability
GLOBAL CONTROL PLAN
TCF activities
Level 1 monitoring Level 2 monitoring Level 3 monitoring Level 4 monitoring
Workstation EWT* Department Plant

Functional • Wheel alignment

• 1D geometry • Parking break test
Product • Head lamp • Heights and
Characteristics • Wheel alignment masses
monitoring • Car leakages Sectorial • Noise intrusion
Checkman Self-check Platform S&D CSC
Process related Audit
Product
• Torque monitoring
SDEP
Characteristics
monitoring
•
•
Glass gluing
Glass position
SIW▫
• Air conditioning filling parameters Around 41 S-Aves▫▫
• Engine coolant filling parameters
Process monitoring
Parameter Poka Yoke monitoring POS
monitoring
Maintenance

Level 3 Level 4
Process Workstation
Criteria Process Process Audit
Observation
monitoring Audit Procedure
Audit
 Monitoring Plan

Group Caracteristic Method

‫ش (طرح‬
) ‫تتت اپتتي‬
Equipment & how to control Frequency
Monitoring Plan .11
Who do what FOP No FOS No
Selfcontrol 100% by operator DO: Prod,operator (Level 1)
Visual - Manual (based on check list) ……………….. All FOS -A
(Spot Welds,Sealant & Mig &…) 1/shift by foreman Check: Prod,foreman (Level 2)
1 BODY/ 4 Weeks
Destructive VISUAL,CALLIPER, … Quality,Prod operator(Level 3) STS DES 203 SAL90TDS03
1OPENING PANELS SET /4 Week
SPOT WELDING 1 Time / 20 Body
Non destructive Control by Hammer,Chisel & VISUAL 3 points / GUN Prod ,operator (Level 1) STS TND 202 SAL90TTND02
TBD Layout
1 Time / 20 Body
3 Studs / GUN
Non destructive (300&301) CONTROL BY Plastic Hammer Prod,operator (Level 1) STF GFM600 SAL90TTND04
(Same as Spot weld Frequency)
TBD Layout
100% of studs
Non destructive (300&301) CONTROL BY PULL FORCE TESTER(Astech) Quality STF GFM600 SAL90TTND04
1 unit /shift
1 Time / 20 Body
Non destructive 3 Studs / GUN
STUD WELDING CONTROL BY Plastic Hammer Prod,operator (Level 1) STF GFM600 SAL90TTND04
(GROUND) (Same as Spot weld Frequency)
TBD Layout
Non destructive 100 % of Ground studs
Torqumeter Quality STF GFM600 SAL 90 TTND04
(GROUND) 1unit /Shift
Destructive 100 % of Ground studs STF GMA700
CONTROL BY TORQUE WRENCH Quality SAL90TDSR02
(GROUNDING STUD) 1 time /4weeks STF GFM600
Product Control
100 % of studs STF GMA700
Destructive (STUD 300&301) VISUAL,CALLIPER, … Quality SAL90TDSR04
1 time /4weeks STF GFM600
Destructive VISUAL,CALLIPER,… 1 BODY/ 4weeks Quality STS MIG 100 SAL 90TDSR05
100% Welding Beads( for appearance)
Non destructive VISUAL Prod,operator (Level 1) STS MIG 100 SAL90 TTND03
MIG WELDING Non destructive GAUGE 3 Beads/ equipment (length) Prod,operator (Level 1) STS MIG 100 SAL90 TTND03
100% Welding Beads( for lengh& APP)
Non destructive VISUAL&GAUGE 1 body/shift Quality STS MIG 100 SAL90 TTND03

1 BODY WITH PANEL/4weeks

Sealant(MASTIC) Destructive Drill,SCALEXOR Quality STM DES 200 SAL90 TDSR05
(AFTER SEALING)
1 Time / 20 Body
Control by Rubber&metallic Hammer&chisel 3 Screw & Nut / GUN
Non destructive(nut &Screw) Prod,operator (Level 1) STF EV2 500 SAL 90 TTND 01
(visual manual ) (Same as Spot weld Frequency)
TBD Layout
Screws / Nuts Control by Rubber&metallic Hammer&chisel 100%Screw
Non destructive(Nut & Screw) Quality STF EV2 500 SAL 90 TTND 01
(visual manual ) 3Unit/ Shift
100%Nuts
Non destructive(Square Nut) Control by Torque wrench Quality STF EV2 500 SAL 90 TTND 05
1Unit/ Shift
Destructive Hammer ,Cotter ,Pipe 1 BODY/ 4weeks QUALITY STF EV2 500 SAL90 TTDSR 01
Hemming measure (thickness) micrometer 1set/week QUALITY STGEPS100 SAL90TPSR04
Self Maint. Control before starting production 1 / Shift Prod,operator (Level 1)
Spot Welding
Projection Welding Current Parameters once / 2weeks Maintenance
Measures STS CPS 403 SAL90TPSR02
Force of Tips(tecna) once/ month Quality
Process Control
CURRENT PARAMETERS
MIG WELDING Measure and read Wire speed once / week Prod STS MIG 100 SAL 90 TPSR03
gas flow
Sealant(MASTIC) Read spec. on the station Temperature,Preasure,Viscosity, Expiry date 1 Time / Shift Quality STM SPS 100 SAL 90TPSR01
Functional points & Dimentional Points(Body & 5 Bodies/2 Weeks
Geometry 3D support + CMM machine CMM members STG M3D 100 SAL90 TGVF01
Moving Parts) 5 Sets Moving part/2 Weeks
1D TCT Gap & Flushness , Gap clearance Control by: comparator, Special tapper gage , Tampons, Magnets and Load weights for doors 1 Body/Shift Quality STG GVF 100 SAL 90 TG3D01
1D TCT Gap & Flushness , Gap clearance Control by: comparator, Special tapper gage, Magnets and Load weights for doors & MES System 100% Prod (Level 1)
Aspect conformity Aspect surface body Conformity Product Visual & MES System 100% Prod (Level 1)
 Monitoring Plan Basic Elements

Monitoring Plan ‫اجزاي اصلي‬

INSPECT Control (measure, assess( at defined
frequency, the conformity of product
characteristics or process parameters, with
adapted measurement processes
Use simple decision tools for the inspector
DECIDE (control charts,…( to discover the deviations
and the non-conformities

Applied efficient reaction modes

ACT

Control devices are the eyes of the Monitoring

plan…
Standard gauges - - - - - - - - - - - - - è to more perfect
… we must systems
trust them
… they must be suitable, approved and calibrated…
 ‫مقدمه‬

‫با تشکر از حسن توجه شما‪ ‬‬