宝马项目化流程标准全解析（BMW ABC flyer requirement）

ABC flyer/ BMWQMT build phase requirement

宝马的项目流程标准叫做ABC flyer,也叫QMT build phase requirement.为什么叫这么名字，是因为宝马项目的产品零件分为几个阶段：A-samples, B-samples,C-samples, initial-samples.

阶段为： MTBàBBGàPVL/VS0àVS1àVS2àAPàSOP

ABC samples的具体含义请参考下文图片

对于项目的各个阶段标准，最主要的就是MTB和BBG阶段可以提供手工样件prototype, 可以开软模具，此阶段在德国慕尼黑研发FIZ中心装车，主要用于验证设计design.

PVL/VS0阶段一定要量产模具，量产工装，生产产地为中国宝马BBA进行装车。

具体各个阶段的详细标准要求，请看下文解析：

PVL/ VS0:

100% ok parts in terms ofSC/CC, FMK, Gap plan.

100%合格产品，满足特殊特性，重要特性，FMK公差尺寸要求，间隙面差要求。

Tooling:（模具工装）

- All series tools100% ready at tool maker with all functions

所有量产模具和工装要做好，满足所有功能

- Trial out at tool shop T0 – first function test of the tool with parts

模具T0试模满足所有功能要求

- Quality loops (1 – 2) implementation for all tools

质量提升1-2轮对于所有模具

- Trial out at tool shop T1- first part production run with BMW

首次模具T1运行生产邀请BMW

- Further optimization of tooling as necessary

模具进一步优化

- Parts can be produced attool maker for VS0(1)

VS0的零件可以在tool maker进行生产

Production equipments:（生产设备）

- fixtures and assembly supports at series location

工装设备在量产产地

- Series production equipment can be at supplier (prepare Cmk studies)

准备设备的CMK数据研究

- VS(0) parts can be made at equipment supplier

VS0的产品可以在设备厂家生产

(Except some special part families e. g. safety relevant parts)

安全件除外

Checking fixtures/Gauges:（检具）

-100 % ready at tool maker or series location

100%状态的检具在tool maker或者

- CMM machine available at series location

三坐标在量产地投入使用

- 100% measurement of all VS(0) parts according to BMW Messplan

VS0产品要100%满足BMW测量要求

- 100% Significant characteristics/Critical Characteristics measured andconfirmed

100%控制特殊特性和重要特殊

Packaging:（包装）

-Temporary packaging defined and agreed by BMW QMT

临时包装方案经过QMT的批准

- Label requirement according to BBA

标签要求满足要求

Additional preventiveQ-planning activities:（额外的质量规划）

-Validation plan agreement

产品PV验证计划

- PFMEA for all production steps

所有工艺步骤的PFMEA

- Definition of production layout at series location with line balancing

生产工艺布局和线平衡

- Control plan according to component specific key characteristics (SC/CC)

控制计划要根据SC/CC来制定

- Forecast production planning and capacity investigation

生产规划和产能调查

- Supply chain concept and backup plan

供应链concept和应急计划

- Quality loops – as much as possible & as independent as possible

质量提升环

VS1:

Parts quality: （零件质量）

100% ok for dimensions (according to BMW messplan), appearance, functionand SC/CC or gap plan relevant characteristics.

100%满足尺寸，外观，功能SC/CC,间隙面差要求。

Tooling:（模具工装）

- All series tools100% ready at series location

所有模具量产工装，量产产地

(Except tools with graining)（皮纹模具除外）

- Machines for series production are defined

定义系列化生产设备

- Process parameter defined and controlled

过程参数定义可控

- Parts must be produced at series location for VS1

VS1零件一定在量产产地生产

Production equipment:（生产设备）

-Series production equipment at final location

量产设备在最终产地

- Assembly line setup 100% done

装配线100%做好

- Poka Yoke 100% working

防错100%工作

- VS1 must are produced at series location

VS1零件一定在量产产地生产

Checking fixtures/gauges andCMM:（检具和三坐标）

-100 % ready at series location

100%在量产产地做好

- SPC definition and labor capacity ready

定义SPC和劳动力产能

Packaging & logistic:（物流包装方案）

-Use temporary packaging as before

临时包装方案

- Series packaging defined and prototype bin confirmed

量产包装方案确认，箱子确认

- IT connection with BBA/BMW installed and working

与BBA确认EDI的IT连接，用于后续接订单

- JIS/JIT Forecast available

拿到BBA的call offs订单预测

Additional preventiveQ-planning activities:（额外的质量规划）

-Parts flow optimization

工艺流程优化

- Visual management/KPI tracking at Shop floor

建立车间的KPI

- Quality training for all operators according to BMW group

对于所有操作工的质量培训

Standards and specifications

- Problem solving process/reaction time

问题解决和反应时间

VS2:

Premise:（前提）

- VS2 parts have to be produced from official BMW processSeries (PZS)!

- Target is to reach PZS green right first time!!!

VS2零件一定要产于PZS审核

目标是一次性到达PZS审核绿色状态

Parts quality: （零件质量）

100% ok for dimensions (according to BMW messplan), appearance,

function and SC/CC or gap plan relevant characteristics.

100%满足尺寸，测量，外观，功能，SC/CC，面差缝隙要求。

Process Series (PZS):（PZS过程审核）

- All tools and equipment are ready

所有的工装模具做好

- All processes from incoming until shipment are linked

所有的过程从来料检验到发货链接在一起

- Quantity: one shift production!

数量：一个班次生产

- Adjustment of the production plan accordingly

可以适当调整生产计划

- Dummy call off for JIS/JIT is needed when the real call off is notenough

如果正式的call offs订单不足，通过创建Dummy order来做PZS审核

- Targets have to be reached (right first time, scrap rate, rework rate,internal PPM, tact time etc)

目标满足（一次性通过率，报废率，返工率，内部PPM,节拍等）

- Quality standard/mindset/knowledge for all operators at all processsteps 100% given

质量标准，意识，知识要灌输到100%工艺步骤中去

- All produced parts should be checked 100% in terms of dimensions,functions and

appearance Ppk ≥ 1.67

所有生产的零件要百检，满足尺寸，功能，外观，PPK大于1.67

- Series packaging available for PZS parts

量产包装对于PZS的零件

- Traceability established and documented

追溯系统建立起来并且文件存档

- Safety stock management

建立安全库存

AP/SOP:

Further steps:

Process series Follow up:

PZS后续问题的跟踪

- Status follow up with actions and timing

后续问题的跟踪和时间节点

- Define next process checks if needed

如果必要定义后续的过程审核

- All required documentations and reports have to be provided to BMW QMTand relevant persons

所有需求的文件要提交给BMW QMT

- Preparation of ISIR yellow status in the RMT/IPQ system

ISIR yellow状态的文件要提交到BMW IPQ系统

- Release ISIR status yellow by QMT (part payment of the tools!)

QMT放行yellow状态的ISIR(部分付款模具)

- Further training of operators and quality persons

进一步培训操作者和质量人员

SOP+ 3months ramp up：

Ramp up and stabilization:（爬坡和稳定化过程）

- Documentation of SPC data for all component special characteristics

数据记录SPC对于SC特性

- Long term process capability has to be reached to Cpk ≥ 1.33

CPK大于1.33

- By deviations additional quality gates with clear deion must beinstalled.

如果有偏差需要建立额外的质量门

Second/Third shiftimplementation:（实施第二和第三班次）

- Hiring qualified operators in suitable time window

出示招聘计划

- Set up training program and follow up

培训计划

- Process checks with 2. or 3. Shift

过程审核第二和第三个班次

- Final BMW process series PZS for new shifts

新的班次的PZS审核

ISIR1 (Production release):

- Providing the Cpk data to BMW QMT

提供CPK数据给QMT

- Release ISIR green status by QMT (rest payment of the tools!)

QMT放行ISIR绿色状态（模具剩余部分的付款）

Series activities:（系列化生产活动）

- Phase out of project teams

项目组退出

- 8D report, PPM monitoring, internal PPM monitoring

8D报告，PPM监控，内部PPM监控

- Additional quality gates for ramp up: GP12, BMW specific q-Gates etc…

爬坡的额外质量门：GP12,特殊质量门等

- Sub supplier monitoring with escalation activities

下级供应商监控和升级活动