Il concetto di Processo nei modelli di eccellenza Renato Fabbri CUBO Società di Consulenza Aziendale Srl 5 marzo 2010
OBIETTIVO Presentare come sono vissuti i progetti e i processi nell azienda manifatturiera Perché è necessario integrare progetti e processi Come l automotive integra progetto e processo 09/03/2010 2
Il concetto di Processo INPUT OUTPUT Prodotto 09/03/2010 3
Process Management Catena del Valore Core Processes Value Stream Flows Horizontally Enabling Processes Finance Training IT HR Accounting
Processi vs Struttura DG Core Processes Value Stream Flows Horizontally QA Enabling Processes Finance HR Training IT Accounting COM PRD AMM
COME VIENE RACCONTATO IL PROCESSO? Fase 1 del BPR
Diagramma Tartaruga REGOLE VINCOLI INPUT PROCESSO OUTPUT RISORSE STRUMENTI 09/03/2010 7
P diagram: qualcosa in più (FMEA) Variazioni da pezzo a pezzo Sottosistemi confinanti Ambiente Cambiamenti a fine vita Utilizzo del cliente Fattori di disturbo Input Output Fattori di controllo Stati di errore 09/03/2010 8
I macro processi Approvvigionamenti Produzione Distribuzione Fornitore Materiali Documentazione Informazioni Finanziario Cliente
Diversi ruoli del progetto Prodotto standard: si tratta di prodotti il cui ciclo di vita è caratterizzato da una sequenzializzazione definita. In questi casi l azienda è propositiva di soluzioni al mercato Identificazione del fabbisogno Progettazione della soluzione Produzione Vendita Distribuzione Prodotto personalizzato: si tratta di prodotti in cui il ciclo di vita è caratterizzato da una forte sovrapposizione di fasi In questi casi l azienda è trainata dal mercato Identificazione del fabbisogno Progettazione della soluzione Vendita Produzione Installazione e Collaudo
PROCESSO e PROGETTO nell Azienda Manifatturiera Nella struttura funzionale Classica il processo è un male necessario Ciclo Attivo Ciclo Passivo Produzione Il Progetto è un elemento di disturbo, una variabile impazzita dai tempi incerti e risultati imprevedibili Un buon Progetto è frutto del caso e della genialità 09/03/2010 11
AUTOMOTIVE: perché ECCELENZA L eccellenza costa L eccellenza è faticosa L eccellenza è sfuggente 09/03/2010 12
AUTOMOTIVE Project Management Perchè? Costi: 600000 Costo di una Campagna = 16500 x Costo di Progettazione $ 500000 400000 300000 200000 100000 Design Review ($35) Before Part Procurement ($177) Before Assembly ($368) After Assembly Before Shipment ($17000) Reference: American Society for Quality Control Rectification in Market Place ($590000)
AUTOMOTIVE: pechè Project Management 09/03/2010 14
Engineering Phases Concept Program Approval Prototype Phase Launch Phase Job 1 Plan & Define Product Design & Development Prototype Build Process Design & Development Product- & Process Validation Production Feedback Assessment & Corrective Actions t
Milestones Months before Job 1 42 36 33.5 30 25.5 19 14.5 8 4.5 3.25 0 +6 KO SI Vehicle PR CP CC LR LS J1 FS Kick Off Strategic Intent SC Strategic Confirmation PH Proportions & Hardpoints PA Program Approval System Components ST Surface Transfer PT Powertrain Design Complete Product Readiness Confirmation Prototype Change Cut-Off Launch Sign-Off Launch Readiness Job 1 Final Status* * Europe only! 16
Vehicle Time Schedule GPDS (Global Product Development System) Supplier Portal: http://portal.covisint.com Pocket Card: www.gpdsonline.ford.com Training Material: https://web.qpr.ford.com/sta/gpdssupplierengangement.html
Verifica Validazione - Produzione Verifica Validazione Produzione D- FMEA t Operativo P- FMEA CP SPC MSA APQP Documentale PPAP
REQUIREMENTS APQP Elements 1. Sourcing Decision 2. Customer Input Requirements 3. Craftsmanship 4. Design-FMEA 5. Design- & Manufacturing Reviews 6. Design Verification Plan & Report 7. Subcontractor APQP Status status 8. Facilities, Tools & Gauges 9. Prototype Build Control Plan 10. Prototype Builds 11. Drawings & Specifications 12. Team Feasibility Commitment 13. Manufacturing Flowchart 14. Process-FMEA 15. Measurement System Analyses 16. Pre-Launch Control Plan 17. Operator Process Instructions 18. Packaging Specifications 19. Production Trial Run 20. Production Control Plan 21. Preliminary Process Capability Study 22. Production Validation Testing 23. Part Submission Warrant (PSW) PPAP Requirements 1. Design Records 2. Engineering Change Documents 3. Customer Engineering Approval 4. Design-FMEA 5. Process Flowchart 6. Process-FMEA 7. Control Plan 8. Measurement System Analyses 9. Dimensional Results 10. Material- & Performance Test Results 11. Initial Process Capability Study 12. Qualified Laboratory Documentation 13. Appearance Approval Report 14. Sample Production Parts 15. Master Sample 16. Checking Aids 17. Customer Specific Requirements 18. Part Submission Warrant (PSW)
REQUIREMENTS APQP Elements PPAP Requirements Supplier Engagement Process 1. Sourcing Decision 2. Customer Input Requirements 3. 1. Craftsmanship Sourcing Decision 4. 2. Design-FMEA Customer Input Requirements 3. 5. Design- Craftsmanship & Manufacturing / Appearance Reviews Approval 6. Design Report Verification Plan & Report 4. 7. Subcontractor Design-FMEA APQP Status status 5. 8. Facilities, Design- & Tools Manufacturing & Gauges Reviews 9. 6. Prototype Design Verification Build Control Plan & Plan Report / 10. Material- Prototype & Builds Performance Test Results 11. 7. Drawings Subcontractor & Specifications APQP Status 12. 8. Team Facilities, Feasibility Tools & Commitment Gauges 13. 9. Manufacturing Prototype Build Flowchart Control Plan 14. 10. Process-FMEA Prototype Builds 15. 11. Measurement Drawings & Specifications System Analyses / Design Records 16. 12. Pre-Launch Engineering Control Change Plan Documents 13. 17. Team Operator Feasibility Process Commitments Instructions / Customer 18. Engineering Packaging Specifications Approval 14. 19. Manufacturing Production Trial Process Run Flowchart 20. 15. Production Process-FMEA Control Plan 21. 16. Preliminary Measurement Process System Capability Analyses Study 22. Production Validation Testing 23. Part Submission Warrant (PSW) 1. Design Records 2. Engineering Change Documents 17. 3. Customer Qualified Laboratory Engineering Documentation Approval 18. 4. Design-FMEA Checking Aids 19. 5. Pre-Launch Process Flowchart Control Plan 20. 6. Process-FMEA Operator Instructions 21. 7. Control Packaging Plan Specifications 22. 8. Measurement Production Trial System Run Analyses 23. 9. Dimensional Production Control Results Plan 10. 24. Material- dimensional & Performance Results Test Results 11. 25. Initial Process Capability Study 26. 12. Production Qualified Laboratory Validation Documentation Testing 13. 27. Appearance Part Submission Approval Warrant Report (PSW) 28. 14. Bulk Sample Material Production Requirements Parts 29. 15. Sample Master Sample Parts 30. 16. Master Checking Sample Aids 31. 17. Record Customer of Compliance Specific Requirements 18. Part Submission Warrant (PSW)
Il team APQP -PPAP Global Product Development System PD Supplier STA Purch. Plant MP&L Approccio di Team Una sola voce Migliore Utilizzo delle risorse
Quality Requirements No. Requirement Lead Target Deliverables 3 Craftsmanship / Appearance Approval Report PD Product Development <TT> Tooling Trial 6. Appearance Approval Report (AAR) approved <PP> Pilot Production 7. colour harmony assessment completed
Quality Requirements No. Requirement Lead Target Deliverables 10 Prototype Builds PD Product Development <FDJ> Final Data Judgement 21. all prototype tool orders addressed to suppliers <FDJ> Final Data Judgement 22. prototype parts are ordered <FDJ> Final Data Judgement 23. prototype parts are 100% specification conform
48 Key Deliverables APQP/PPAP Element Lead Due* Deliverables 1. Sourcing decision Buyer <PTCC> 1. Required Sourcing Agreement Signed <PA> <FDJ> <PA> 2. Required Supplier Commercial & Program Agreements Signed 3. All Production Tool Orders Issued to Suppliers 4. Final Mix, Maximum Weekly Volume Communicated and Agreed 2. Customer input requirements PD <PA> 5. Program Expectations Cascaded to Suppliers 3. Craftsmanship/ appearance approval report PD <TT> 6. AAR Approved <PP> 4. DFMEA PD <PA> 8. DFMEA Completed <PA> 7. Color Changes Completed Supporting Color Harmony 9. Special Characteristics Cascaded to Suppliers 5. Design/manufacturing reviews PD/STA <PP> 10. Quality Issues Closed and Effective 6. DVP&R material, performance test results PD <TT> 11. DV Testing Complete 7. Subcontractor APQP status STA <FDJ> 12. Sub-supplier PPAP Timing Plan Completed <TT> <MP1> 13. Sub-supplier PPAP Phase 1 (or equivalent) Completed 14. Sub-supplier PPAP Phase 3 (or equivalent) Completed
Reporting Process: 31 APQP/ PPAP Elements 48 Deliverables (minimum 1 per element) 217 Expectations Element Status Section è strutturata gerarchicamente in : 1. APQP/PPAP Elements 2. Deliverables 3. Expectations
Reporting Process: Element Status
Fine