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 description 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
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