Otomotiv sanayi ve kalite sistem gerekleri
Başlık çevirisi mevcut değil.
- Tez No: 75530
- Danışmanlar: DOÇ. DR. ALPASLAN FIĞLALI
- Tez Türü: Yüksek Lisans
- Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1998
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Endüstri Mühendisliği Ana Bilim Dalı
- Bilim Dalı: Endüstri Mühendisliği Bilim Dalı
- Sayfa Sayısı: 209
Özet
Gün geçtikçe bilinçlenen tüketiceler, isteklerini fiyat, kalite ve servis açısından en optimum şekilde karşılayan ürünlere yönelmektedirler. Ulaşım ve iletişim sektörlerinde yaşanan hızlı gelişmeler sonucunda globalleşen pazarlar, rekabet şartlarını daha da ağırlaştırmaktadır. Bu şartlara ayak uydurmak zorunda olan üreticiler de her zaman aynı şartlarda ve kalitede üretim gerçekleştirebilmek için, üretimlerini standartlaşma yollarını aramaktadırlar. Üretimlerin standartlaştırılması olarak tanımlayabileceğimiz kaite güvence sistemi kavramı ile, müşteri isteklerini en optimum şekilde karşılayan, sürekli iyileştirme içinde olan kalite yönetim sistemleri tanımlanmaktadır. QS-9000 - Kalite Sistem Gerekleri, özellikle otomotiv sanayine yönelik olarak geliştirilmiş, ISO-9000 tabanlı bir kalite yönetim sistemidir. QS-9000, Ford, General Motors, Chrysler ve 5 kamyon üreticisinin kalite sistem programlarının ortak tek bir doküman altında birleştirmeleri sonucunda oluşturulmuştur. Bu çalışmada, ülkemizde sistem gereklilikleri yeni yeni yerine getirilmeye başlanan,“QS-9000 - Kalite Sistem Gerekleri”kavramı ve içeriği hakkında bilgi verilmek istenmiştir. Beş bölüm olarak hazırlanan bu çalışmanın, ilk bölümünlerinde, kalite kavramları üzerinde durulmuştur. Sonraki bölümde ise QS-9000'in özellikle uygulama sahası olarak tanımlanan Otomotiv Sanayisi ile, bu sanayinin Türkiye'deki durumu değerlendirilecektir. QS-9000 başlığı altında hazırlanan bölümde ise, genel olarak QS-9000 kavramı ve yapısı hakkında bilgiler bulunmaktadır. Bu bölümde ayrıca QS-9000'in içinde yer alan ve uygulamada kullanılan kalite iyileştirme tekniklerinden bazıları hakkında açıklamalar yapılmıştır. Son bölümde ise, QS-9000 kapsamında yer alan bazı tekniklerin otomotiv yan sanayine yönelik üretim yapan bir işletmede uygulama çalışmaları ve işletmenin kalite güvence sistemine dahil edilme faaliyetleri incelenmiştir.
Özet (Çeviri)
Today, as we are approaching the twenty first century, the improvements in technology are apparent in the transportation and communication sectors as in all other sectors. The improvements in these two sectors have lead to a smaller global world market and thus to a severe competition. Therefore, manufactures have started searching for ways to standardize their production in order to obtain the same quality and standards throughout their manufacturing. This study analysis the status of quality control system - which we can idendify as standardization of production - in the automotive sector, a sector with very high competition. The first part of the study provides general information regarding quality concepts. Quality, in general, can be defined as“how well consumers expactations are met”. Because of this, quality is a measure, and can change and improve since it depends upon consumers' expactations. Two factors;. Function or utilization purpose,. Price, should be taken into consideration when determining the quality of a product and/or service. Control, in general terms, is the activities required to fulfill a number of industrial objectives. Quality control, on the other hand, is the series of operations to sustain and improve quality and to continue production at the economic level wherr consumers will be satisfied. While in the traditional perspective the aim is to find defects, the contemporary perspective suggest the creation of a system in which the aim is to prevent defects and thus obtain zero defect. The quality control is defined as the management and technical methods network required to manufacture and deliver products with certain quality standards. Consumer desires, management policies and technological opportunities are the inputs and product design, production prodecures, process control, inspection process, and product quality are the outputs of a quality control system.Quality assurance, represents all planned and systematic activities that need to be implemented in order to met the quality expectations of a product or service. As can be understood from the definition, quality assurance is not only an inspection or quality control activity. A system that is independent of inspection and traditional quality control, that depends on process control reduces the need to inspect and thus produces. Quality in every step of the production will eventually lead to quality assurance. The quality assurance system needs to be implemented and adapted by taking into consideration the sector the company is in. The quality assurance system should be implemented in a system in which,. the system is totally understood and effective,. products and services meet consumer expectations,. preventive approaches are done before problems occur rather than inspecting then after they occur. This project will focuse on the quality assurance systems in automotive sector, a sector with severe competition. Manufacturers we recognize as the“Original Equipment Manufacturer (OEM)”have lead to the creation of a sectoral group that is at least as big as they are. OEM foces their suppliers which has a direct impact on the pricing and quality of their products to manufacture at a specific standard. In the automotive industry,“quality”has become a way of doing business and every level of production reflects a strong commitment to achieving consistent quality. In today's business environment,“quality assurance”describes products or services developed in accordance with an established quality management system that effectively meets your customer's needs. The Quality System Requirements (QS 9000) standart is the quality system that has been tailored too the automotive industry. QS-9000 merges the quality programs of Chrysler, Ford, General Motors and various truck manufacturers into one document. This merging process is called“harmonization”and it lets suppliers meet the requirements for each of these companies. The documents replaced by QS-9000 include:. Chrysler's Supplier Quality Assurance Manual,. Ford's Q-101 Quality System Standard and. General Motor's NAO Targets for Excellence,. materials were also received from truck manufacturers. The applicabilityof QS-9000 targets all Tier 1 internal and external suppliers. Tier 1 suppliers are those supliers that provide products and services directly to Chrysler,Ford, General Motors or other OEM (original equipment manufacturer) customers subscribing to this stantard - for example; suppliers of 1) production materials 2) Production or service parts and 3) heat treating, painting, plating or other finishing services. QS-9000 was introduced in September 1994 and was reissued with updated information in February 1995. By now, all applicable supliers should have implemented an effective quality system based on QS-9000 and be self-assessing their compliance. Third - party registration of a supplier's quality system will be required by Chrysler by July 31, 1997, and by General Motors by December 31, 1997, Ford does not require third party registration at this time, but has required self-assessment to QS-9000 since June 1995. Third - party registration involves having a team of external auditors from an RAB- accredited registrar, that has accredited for ISO 9000 assessment activities, verify that your system complies with QS-9000. The basis of QS-9000 is the ISO 9000 series of standards, which establish global requirements for quality management systems. In a similar manner, QS-9000 is a management framework that defines a company's processes and provides for a structured approach to the production of products or services so that a company generates a consistent level of quality. As with ISO 9000, the QS-9000 quality system basically says you must; 1. Define your process - that is, document what you do. 2. Follow the Process - that is, do what you have documented 3. Ensure the process is effective - if not, change your documented processes 4. Record the results of your work and make the results available to customers and auditors. QS-9000 is composed of three sections: 1. ISO 9000 based requirements 2. Sector- Specific Requirements 3. Customer- Specific Requirements. ISO 9000 based requirements are founded on Section 4 of the 1994 version of ISO 9001. The 20 elements of ISO 9001 are included in QS-9000, together with supplemental requirements. Sector- Specific Requirements go beyond ISO 9000 and address three areas within the automotive industry:. Production Part Approval Process. Continuous Improvement. Manufacturing Capabilities.Customer- Specific Requirements are additional standards that Chrysler, Ford, General Motors and truck manufacturers have imposed. Production part approval involves the examination of a new process to ensure that the statistically predicted capability of the process will comply with tolerance requirements. In most cases, the PPAP is used any time a new part is proposed, an old part significantly changed, a customer quality concern is reported and coorrected, the manufacturing process changed, new materials used, and other situations where the capability of the manufacturing process might change. Production part approval process is composed of four sections: 1. Production Part Approval Process (PPAP) 2. Potential Failure Mode and Effects Analysis (FMEA) 3. Advanced Product Planning and Control Plan (APQP) 4. Measurement System Analysis (MSA) A comprehensive continous improvement philosophy is fully deployed throughout company's organization. Company has to lead continuously improves in quality, service and price for all customers. Company identifies opportunities for quality and productivity and implement appropriate improvement projects. Exampels are:. Unscheduled machine downtimes,. Maschine set-up,. Excessive cycle time,. Non value-added use of floor space,. Scrap, rework and repair,. Excessive variation,. Less than 100% first run capability,. Process averages not centered on target values,. Waste of labor and materials,. Excessive cost of non-quality,. Excessive handling or storage,etc. Company has demonstrated knowledge of the following measures and methodologies and uses those that are appropriate: Capability Indices (Cp, CPk ) Control Charts Cumulative Sum Charting (CUSUM) DOE Evolutionary Operation of Processes (EVOP) Cost of quality Value analysis Problem Solving Benchmarking Analysis of motion / Ergonomics Overall equipment effectivenessManufacturing Capabilities has four steps; 1. Facilities, Equipment and Process Planning and Effectiveness 2. Mistake Proofing 3. Tool Design and Fabrication 4. Tooling Management In this project there are the details about these headlines. In the four section of this study there is the information about the practice of the quality assurance system in one company that is the supplier to the automotive sector. The system of this company was investigated and improved according to these knowledge.
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