LPA逐層工藝審查簡述

1、SQAP供應(yīng)商質(zhì)量保證程序供應(yīng)商質(zhì)量保證程序ISO/ TS 16949 DaimlerChrysler Customer Specific Requirements 戴姆勒戴姆勒-克萊斯勒用戶特別要求克萊斯勒用戶特別要求 New section under Internal Audits 正對新章節(jié)進行內(nèi)部審查正對新章節(jié)進行內(nèi)部審查 Effective 7/01/04 for Powertrain & Component Plants suppliers; 對傳動系及其零部件的供應(yīng)商于對傳動系及其零部件的供應(yīng)商于7/01/04日開始執(zhí)行；日開始執(zhí)行；1/1/05 for all rem

2、aining suppliers 對所有其余的供應(yīng)商于對所有其余的供應(yīng)商于1/1/05年開始執(zhí)行年開始執(zhí)行Posted on AIAG, IAOB, and QMS web sites 在在AIAG， IAOB， 和和QMS網(wǎng)站上發(fā)布網(wǎng)站上發(fā)布Letter mailed to all suppliers 信函已經(jīng)發(fā)給了所有的供應(yīng)商信函已經(jīng)發(fā)給了所有的供應(yīng)商SQAPThere are two Types of Layered Process Audits: 有兩種逐層過程審查有兩種逐層過程審查: Process Control Audits 過程控制審核過程控制審核 Error & Mi

3、stake Proofing Verification Audits 防錯防誤驗證審核防錯防誤驗證審核Layered Process Audits (LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 逐層過程審查(LPA)是由多個管理層進行的系統(tǒng)審查。對關(guān)鍵程序特征進行經(jīng)常性的審核來確認過程性能。The purpose of Layered

4、 Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. 逐層過程審查的目的是確保連續(xù)性能，從而改善過程穩(wěn)定和一次通過率。SQAPLPAs assure that defined methods and work instructions are utilized, problem solving solutions are held in place, and all process issues are

5、identified and quickly corrected.逐層過程審查確保被選擇的方法和工作指令被運用， 確保問題解決方案在使用中， 所有工藝問題都被確定并被迅速更正。LPA is an ongoing system of process checks that verify proper methods, settings, operator craftsmanship, error proofing devices and other inputs are in place to ensure a defect free product. 逐層過程審查是一項持續(xù)的工藝檢驗系統(tǒng)， 用

6、來驗證正確的方法、 設(shè)置、 操作員技能、防錯措施和其他確保避免次品產(chǎn)生的辦法。SQAP Anybody can perform a Layered Process Audit. 任何人都能夠執(zhí)行逐層過程審查。 Manufacturing management must own the process and perform audits. 制造管理部門必須擁有此程序并執(zhí)行審查。 All managers, regardless of function, can be auditors. 所有經(jīng)理，無論他的職責(zé)是什么， 都可以作為審查員。 Each management level should

7、 perform audits. 每個管理層都應(yīng)該執(zhí)行審查。Process Control Audits shall be performed once per shift by supervisors. Plant management shall perform the audit once per week.過程控制審查過程控制審查應(yīng)該在每班生產(chǎn)時由車間主管進行一次審查。工廠管理應(yīng)該在每周執(zhí)行一次審查。Error & Mistake Proofing Verification audits shall be conducted once per shift. Only quali

8、fied employees shall perform Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usually qualified.防錯防誤確認審查防錯防誤確認審查應(yīng)該在每班生產(chǎn)執(zhí)行一次。僅僅應(yīng)該由具備資格的人員進行防錯防誤確認審查。 建立、維護或質(zhì)量審查員通常是具備資格的人員。SQAPSQAPSQAPSafety regulations 安全法規(guī)安全法規(guī)Reinforces加強加強Facilitates簡化簡化Operator training 操作

9、員培訓(xùn)操作員培訓(xùn)Management/operator interface 管理管理/操作員界面操作員界面First time through capability 一次通過率一次通過率Morale 士氣士氣Improves提高提高Build variation based on work standardization 因為工作的標準化而產(chǎn)生的多樣性因為工作的標準化而產(chǎn)生的多樣性End-of-line inspection 線尾檢驗線尾檢驗Part defects 零件缺陷零件缺陷Reduces減少減少SQAPRepair Inventory vs First Time Capability

10、 vs LPA對比：對比： 修理庫存修理庫存/一次通過率一次通過率/逐層工藝審查逐層工藝審查18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 周周# of LPA Checks / Week每周每周LPA檢查次數(shù)檢查次數(shù)556065707580859095100First Time Through (%)一次通過率（一次通過率（%)KTP

11、Now conducting 6700 Process Layered Audit ChecksKTP目前正執(zhí)行6700 逐層工藝審查0 Process Layered Audits 0層工藝審epair Inventory修理庫存FTC一次通過率SQAPSQAPPROCESS工藝工藝(過程過程/程序程序)ErrorProofing 防錯防錯 Process Audits 工藝審查工藝審查CorrectiveActions 糾正行動糾正行動PreventionActions 預(yù)防行動預(yù)防行動EmployeeWorkshops 車間職工車間職工ContinuousImp

12、rovementInputs 持續(xù)改進輸入持續(xù)改進輸入Audits are conducted regularly by all levels of supervision 各各監(jiān)督級定期地進行審查監(jiān)督級定期地進行審查Non-conformances are immediately addressed 立即發(fā)現(xiàn)不符合處立即發(fā)現(xiàn)不符合處LAYERED PROCESSAUDITS ARE PROCESSBASED, NOT PART BASED.逐層過程審查是基于逐層過程審查是基于程序程序的的,而不而不是基于零件的是基于零件的SQAPSQAP確定從哪里開始實施確定從哪里開始實施LPA審查審查 Re

13、view 審查: Customer Complaints, Quality Alerts 客戶抱怨，質(zhì)量預(yù)警 First-Time Through data, Scrap Reports 一次通過數(shù)據(jù)，廢品報告 Key Characteristics and Process Capability: Cpk & Gage R&R 關(guān)鍵特征和過程能力：CPK與R&R PFMEA, Process Flow Diagram, Control Plan PFMEA，工藝流程圖，控制計劃 Set-up Sheets, Work Instructions, Inspection I

14、nstructions 制定表格、操作指導(dǎo)書、檢驗指導(dǎo)書 Error and Mistake Proofing 防錯防誤 Quality System Audits, Dock Audits, Inspection Reports 質(zhì)量系統(tǒng)審查，貨場審查，檢驗記錄 Rework instructions 返工指導(dǎo)書 The Area of Highest Risk should be the first area to implement the Layered Process Audit 最高風(fēng)險區(qū)域最高風(fēng)險區(qū)域應(yīng)該是實施逐層過程審核的第一個區(qū)域 This area will also be

15、 used as a Lessons Learned for implementing the Layered Process Audit across the entire manufacturing facility. 此區(qū)域也可以被作為整個制造廠學(xué)習(xí)如何實施逐層審核的用途。 Use Discretion when adding items to the checklist 在向檢查表中添加項目的時候使用判斷力判斷力。 Audit items are issues that would cause Customer Dissatisfaction. 審查項目是那些導(dǎo)致客戶不滿客戶不滿的問題

16、。SQAP2 X Week 每周兩次每周兩次Area Management 區(qū)域主任區(qū)域主任1 X Shift 每班一次每班一次Production Supervisor 生產(chǎn)主管生產(chǎn)主管1 X Week 每周一次每周一次Plant Manager 車間主任車間主任 Encourages Management Involvement 鼓勵參與管理鼓勵參與管理 Encourages Operator Feedback 鼓勵操作員反饋鼓勵操作員反饋 Establishes Accountability 建立責(zé)任制建立責(zé)任制SQAPEXAMPLE: LPA FREQUENCY AND STRUCTU

17、RE舉例：舉例： 逐層工藝審查頻率與結(jié)構(gòu)逐層工藝審查頻率與結(jié)構(gòu)SQAP123123123123123123123123123MONXXTUESXXWEDXXTHURXXFRIXXSATXXMONXXTUESXXWEDXXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 1XEVERY LINE IS AUDITED ACROSS EACH SHIFT EVERY 9 DAYS IN ROTATIONSHIFT 2XPLACE A CHECK MARK IN THE ABOVE BOX FOR YOUR SHIFT FOR AUDITS COMPLETEDSHIFT 3

18、X1 10 0PRODUCTION SUPERVISOR WEEKLY LAYERED AUDIT LINE SCHEDULE1 14 4121 11 149 987 75Note: Example Illustrates that 3rd Shift Not Being Audited Per the Rotation Matrix Unacceptable Condition!注意注意: 例子顯示例子顯示, 在第三班生產(chǎn)中沒有進行審查在第三班生產(chǎn)中沒有進行審查 不可接受的條件不可接受的條件!XXXXXX生產(chǎn)生產(chǎn) 主管周主管周LPA檢查計劃安排表檢查計劃安排表每每9天對每條線輪流每班進行審查

19、天對每條線輪流每班進行審查. 在你工作的那班中在你工作的那班中,用差號標明已經(jīng)完成了審查用差號標明已經(jīng)完成了審查.SQAPSENIOR SUPERVISOR WEEKLY LAYERED AUDIT LINE SCHEDULEQUARTER 1QUARTER 2987514 12 11410987514 12 11410WEEK 1XWEEK 14XWEEK 2XWEEK 15XWEEK 3XWEEK 16XWEEK 4XWEEK 17XWEEK 5XWEEK 18XWEEK 6XWEEK 19XWEEK 7XWEEK 20XWEEK 8XWEEK 21XWEEK 9XWEEK 22XWEEK

20、 10XWEEK 23XWEEK 11XWEEK 24XWEEK 12XWEEK 25XWEEK 13XWEEK 26XQUARTER 3QUARTER 4987514 12 11410987514 12 11410WEEK 27XWEEK 40XWEEK 28XWEEK 41XWEEK 29XWEEK 42XWEEK 30XWEEK 43XWEEK 31XWEEK 44XWEEK 32XWEEK 45XWEEK 33XWEEK 46XWEEK 34XWEEK 47XWEEK 35XWEEK 48XWEEK 36XWEEK 49XWEEK 37XWEEK 50XWEEK 38XWEEK 51X

21、WEEK 39XWEEK 52XPLANNEDCOMPLETEDDAYSXEVERY LINE IS AUDITED EVERY 9 WEEKSPLACE A CHECK MARK IN THE ABOVE BOX FOR AUDITS COMPLETED PLANT MANAGER工廠經(jīng)理周工廠經(jīng)理周LPA檢查計劃安排表檢查計劃安排表每條線輪流在每每條線輪流在每9周進行一次審查周進行一次審查. 在上面表格中在上面表格中, 用差號標明已經(jīng)完成了審查用差號標明已經(jīng)完成了審查.SQAPSQAPSQAPSQAPSQAPSQAPSQAPSQAPSQAP Auditors must understand

22、 LPA strategy and purpose. 審查員必須理解LPA策略和目的。 Review checklist and reactions with auditors. 和審查員共同分析檢查清單和反應(yīng)。 Auditors must know to respond immediately after finding a nonconformance. 審查員必須在發(fā)現(xiàn)一個不符時快速作出響應(yīng)。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV審查員應(yīng)該為具有資

23、格的人士來執(zhí)行防錯防誤確認。 Perform a practice audit where appropriate. 在適用的時候執(zhí)行一次審查實踐。Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 一旦一旦LPA計劃得到批準，供應(yīng)商應(yīng)該培訓(xùn)自己的逐層工藝審查員計劃得到批準，供應(yīng)商應(yīng)該培訓(xùn)自己的逐層工藝審查員SQAP Explain why the LPA is being implemented. 解釋為什么為什么LPA在被執(zhí)行。 Explain the purpose

24、 and benefits of the LPA process. 解釋LPA程序的目的和益處益處。 Inform workforce of LPA activity and what to expect when audits are performed in their work areas. 當(dāng)在工作地點執(zhí)行審查時，將LPA活動和對結(jié)果的期望 通知通知給操作工人。 Encourage workforce feedback. 鼓勵鼓勵操作工人進行反饋。 Communicate LPA results frequently. 經(jīng)常對LPA的結(jié)果進行交流進行交流。SQAP Review aud

25、it results frequently when starting process. 在啟動程序的時候經(jīng)常經(jīng)常對審查結(jié)果進行檢查。 Improve audit checklist based on auditor feedback. 根據(jù)審查員的反饋來改善審查檢驗表。 Management must instill discipline early in the process to complete audits on time and provide resources for immediate corrective action. 管理層必須在程序的早期時候逐漸進行灌輸，來按時完成

26、審查并提供資 源給快速更正行動。 During early phase - Management audits will find problems, but later management audits will find improvements. 在早期- 管理層的審查將發(fā)現(xiàn)問題， 但是以后管理層的審查會發(fā)現(xiàn)改 進。 - Develop and apply Lessons Learned to improve audit. - 制定并運用吸取的教訓(xùn)吸取的教訓(xùn)來改進審查。 SQAP Corrective actions shall be documented as required by ISO/TS 更正行動應(yīng)該按照ISO/TS的標準進行文件記錄. There must be a system to maintain the audit schedule and track completion. 必須有一套系統(tǒng)來保證審查進度和跟蹤它的完成. Improvements driven by the LPA process shall be measured, mo