New Model Develop and Launch Control Plan (????????)

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New Model Develop and Launch Control
Plan(????????)

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• Dec. 27, 2002

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1. ??? ????? ????????.
2. ?????????????
3. ????????????????? (feasibility study cost
   analysis)
4. ????????? (Manufacturing Launch Plan)
5. ???????????

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New Model Launch Organization and Function
Introduction Advanced Engineering Department

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SIX SIGMA
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????????????????????,??? http//www.ford.com.tw
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Current Vehicle AssemblyFlow Chart / Process
Control

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PBS
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?? . Metrostar?????????(VCATS)

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????? (Trim Line)
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?????? (Final Line)
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??????? (FAI / CAI)
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??? Metrostar ?????????
1. VCATS ??GEM , HEC , RCM ?PCM ???????
a. GEM (Generic Electric Module)
???????????? ?????????????????????(double
locking, RCsingle door
unlocking, alarm system)? b. HEC (Hybrid
Electronic Cluster) ?????? ?????????ABS?????????
(seat belt indication, ABS
warning light)? c. RCM (Restraints Control
Module)???????? ??????????(airbag system
driver passenger airbags?
side curtain airbags)? d. PCM (Powertrain
Control Module)????????? ????????????????(tire
size, gear ratio)?
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5c ???? (?? / ??? / ?? / ???/ ???)
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Overall New Model Launch Process Flow
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?????????????????
. ?????? . ??????/?? (Facility Tooling)
(Packaging / Vanning) . ????? .
??/???? (Layout Study) (Budget Working
Std.) . ???? (Material Planning Logistic)
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(b)
Product Investigation Letter Reply Of MFG.

• Subject
• Program Assumption from PIL content Model / Body
  style / Exterior / Interior / Powertrain /
  Chassis /
• 
  Features / Cycle plan volume
  Mix../ Job1 date
• 3) Assumption of Mfg
• 1. Line speed design
• 2. Layout
• 3. Assy Level
• 4. Powertrain
• 5. Prove out build plan TTO / CP2 /
  1PP / FEU / C/B
• 6. BWS Increase / decrease
• 7. Facility Tooling cost
• 8. Launch expense
• PS Manufacturing FT (Capitalized)
  Launch expense
• . Body construction
  1.
  Program engineering
• . Paint
  
  a. Overtime b. Sample Car
• . Trim / Chassis / Final
  c.
  Early warning vehicle gasoline
• . Engine assembly
  d.
  Travel expense e. Assistance engineer
• . MPL
  2.
  Preactivation

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???????????

• Launch cross functional team set up
• Develop Launch timing each stage
• Define prove out cars of each pilot production
• Develop facility / tooling / product validation
  plan
• Develop logistic / packaging / vanning plan
• Set up APQP control timing plan
• . Process Flow Chart .
  Control Plan
• . Measurement system analysis . PFMEA
• . Statistic process control .
  Process Sheet

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(I)-1
Launch Quality Operating System (LQOS) Abstract
1. The goal of Launch Quality Operating System
(QOS) is to ensure a flawless, measurable and
consistent launch practice. Its from 9 key
sources (as diagram shows) and supported by both
measurable and deliverables metrics.
2. In order to achieve the above goal, a
standardized LQOS manual is necessary. This
manual defines the basic standards, methods, and
procedures in the Launch Cycle beginning at the
ltSIgt milestones through PostltJ1gt.
3. This document contains 98 key sections
supported by numerous standards, procedures,
guidelines and information to drive deployment
for implementation of the 2002 and beyond model
years.
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???????????

• Cross function team weekly meeting review all
  the issues from PP
• . Sub-committee ( Body / Engine / Trink Final)
• . AE meeting (Manufacturing)
  
• NOVA-C (Vehicle Quality Review) (FCPA)
• Early warning drive test (Dura issue feedback)
• Readiness sign off for confirmation build
• Batch review sign off for master production

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Golden Brain Award
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(P)
NOVA-C AUDIT
MODEL SERIAL NUMBER
AUDIT DATE COLOR
ENGINE BUILD
DATE DOOR
TRANSMISSION AUDITOR
1 2 Avg.
1 2 Avg.
1. AXLE
8.
SQUEAKS / RATTLES ???

???? 2. BODY
9. STEERING HANDLING
ENTERIOR MOULDING

?????? ??????? 3. BRAILES
10. TEMPERATURE CONTROL ??
???? 4.
ELECTRICAL
11. TRANSMISSION ACCESSORY????
??? 5. ENGINE
12. WATER LEAKS ??
?? 6. EXTERIOR PAINT
13. WIND NOISE ????
?? 7. INTERIOR TRIM
SCORE TOTAL ????

VISAL ??
FUNCTIONAL ??
9.090 OF CUSTOMER WILL COMPLAIN 1.010 OF CUSTOMER WILL COMPLAIN
5.050 OF CUSTOMER WILL COMPLAIN 0.11 OF CUSTOMER WILL COMPLAIN
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