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1、There are two Types of Layered Process Audits: 有兩種分層過(guò)程審核有兩種分層過(guò)程審核: Process Control Audits 過(guò)程控制審核過(guò)程控制審核 Error & Mistake Proofing Verification Audits 防錯(cuò)防誤驗(yàn)證審核防錯(cuò)防誤驗(yàn)證審核Layered Process Audits (LPA) are a system of audits performed by multiple Layered Process Audits (LPA) are a system of audits perfor
2、med by multiple levels of management. Key process characteristics are audited frequently to levels of management. Key process characteristics are audited frequently to verify process conformance. verify process conformance. 分層過(guò)程審核分層過(guò)程審核(LPA)(LPA)是一種標(biāo)準(zhǔn)化的審核是一種標(biāo)準(zhǔn)化的審核, ,在組織的所有層面上定期在組織的所有層面上定期, ,經(jīng)常實(shí)施經(jīng)常實(shí)施
3、, ,由多個(gè)管理由多個(gè)管理層進(jìn)行的系統(tǒng)審核。對(duì)關(guān)鍵過(guò)程特性進(jìn)行頻繁的審核以驗(yàn)證過(guò)程符合性。層進(jìn)行的系統(tǒng)審核。對(duì)關(guān)鍵過(guò)程特性進(jìn)行頻繁的審核以驗(yàn)證過(guò)程符合性。The purpose of Layered Process Audits is to ensure continuous conformance The purpose of Layered Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. ther
4、eby improving process stability and first-time through capability. 分層過(guò)程審核的目的是確保持續(xù)的符合性,從而提高過(guò)程穩(wěn)定性和一次通過(guò)率。分層過(guò)程審核的目的是確保持續(xù)的符合性,從而提高過(guò)程穩(wěn)定性和一次通過(guò)率。LPAs assure that defined methods and work instructions are utilized, problem solving solutions are held in place, and all process issues are identified and quickly
5、 corrected.分層過(guò)程審核確保使用固定的方法和操作說(shuō)明, 確保使用問(wèn)題解決方案, 所有過(guò)程問(wèn)題都被識(shí)別并被迅速糾正。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. 分層過(guò)程審核是一項(xiàng)持續(xù)的過(guò)程檢查系統(tǒng), 用來(lái)驗(yàn)證正確的方法、 設(shè)置、 操作員技能、防錯(cuò)裝置和其
6、他輸入是否到位從而確保產(chǎn)品無(wú)缺陷產(chǎn)生。 Anybody can perform a Layered Process Audit. 任何人都能夠執(zhí)行分層過(guò)程審核。 Manufacturing management must own the process and perform audits. 生產(chǎn)管理部門(mén)必須領(lǐng)導(dǎo)此程序并執(zhí)行審核。 All managers, regardless of function, can be auditors. 所有經(jīng)理,無(wú)論他的職責(zé)是什么, 都可以作為審核員。 Each management level should perform audits. 每個(gè)管理層都應(yīng)
7、該執(zhí)行審核。Process Control Audits shall be performed once per shift by supervisors. Plant management shall perform the audit once per week.過(guò)程控制審核過(guò)程控制審核應(yīng)該在每班生產(chǎn)時(shí)由車間主管進(jìn)行一次審核。工廠管理應(yīng)該在每周執(zhí)行一次審核。Error & Mistake Proofing Verification audits shall be conducted once per shift. Only qualified employees shall per
8、form Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usually qualified.防錯(cuò)防誤驗(yàn)證審核防錯(cuò)防誤驗(yàn)證審核應(yīng)該在每班生產(chǎn)執(zhí)行一次。由具備資格的人員進(jìn)行防錯(cuò)防誤驗(yàn)證審核。 建立、維護(hù)或質(zhì)量審核員通常是具備資格的人員。SQAPSafety regulations 安全法規(guī)安全法規(guī)Reinforces加強(qiáng)加強(qiáng)Facilitates簡(jiǎn)化簡(jiǎn)化Operator training 操作員培訓(xùn)操作員培訓(xùn)Management/operator interfac
9、e 管理管理/操作員界面操作員界面First time through capability 一次通過(guò)率一次通過(guò)率Morale 士氣士氣Improves提高提高Build variation based on work standardization 因?yàn)楣ぷ鞯臉?biāo)準(zhǔn)化而產(chǎn)生的多樣性因?yàn)楣ぷ鞯臉?biāo)準(zhǔn)化而產(chǎn)生的多樣性End-of-line inspection 線尾檢驗(yàn)線尾檢驗(yàn)Part defects 零件缺陷零件缺陷Reduces減少減少18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0
10、316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 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(guò)率(一次通過(guò)率(%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正執(zhí)行6700 逐層過(guò)程審核0 Process Layered Audits 0層過(guò)程審epair Inventory修理
11、庫(kù)存FTC一次通過(guò)率Repair Inventory vs First Time Capability vs LPA對(duì)比:對(duì)比: 修理庫(kù)存修理庫(kù)存/一次通過(guò)率一次通過(guò)率/逐層過(guò)程審核逐層過(guò)程審核PROCESS過(guò)程過(guò)程ErrorProofing 防錯(cuò)防錯(cuò) Process Audits 過(guò)程審核過(guò)程審核CorrectiveActions 糾正行動(dòng)糾正行動(dòng)PreventionActions 預(yù)防行動(dòng)預(yù)防行動(dòng)EmployeeWorkshops 車間職工車間職工ContinuousImprovementInputs 持續(xù)改進(jìn)輸入持續(xù)改進(jìn)輸入Audits are conducted regularly b
12、y all levels of supervision 各監(jiān)督級(jí)定期地進(jìn)行審核各監(jiān)督級(jí)定期地進(jìn)行審核Non-conformances are immediately addressed 立即發(fā)現(xiàn)(記錄)不符合處立即發(fā)現(xiàn)(記錄)不符合處LAYERED PROCESSAUDITS ARE PROCESSBASED, NOT PART BASED.分層過(guò)程審核是基于過(guò)程的分層過(guò)程審核是基于過(guò)程的,而不而不是基于零件的是基于零件的確定從哪里開(kāi)始實(shí)施確定從哪里開(kāi)始實(shí)施LPA Review 回顧: Customer Complaints, Quality Alerts 客戶抱怨,質(zhì)量警告 First-Ti
13、me Through data, Scrap Reports 一次通過(guò)數(shù)據(jù),廢品報(bào)告 Key Characteristics and Process Capability: Cpk & Gage R&R 關(guān)鍵特性和過(guò)程能力:CPK與檢具 R&R PFMEA, Process Flow Diagram, Control Plan PFMEA, 過(guò)程流程圖,控制計(jì)劃 Set-up Sheets, Work Instructions, Inspection Instructions 工藝卡片、作業(yè)指導(dǎo)書(shū)、檢驗(yàn)指導(dǎo)書(shū) Error and Mistake Proofing 防錯(cuò)防
14、誤 Quality System Audits, Dock Audits, Inspection Reports 質(zhì)量體系審核,貨場(chǎng)審核,檢驗(yàn)報(bào)告 Rework instructions 返工指導(dǎo)書(shū) The Area of Highest Risk should be the first area to implement the Layered Process Audit 最高風(fēng)險(xiǎn)區(qū)域最高風(fēng)險(xiǎn)區(qū)域應(yīng)該是實(shí)施分層過(guò)程審核的第一個(gè)區(qū)域 This area will also be used as a Lessons Learned for implementing the Layered Pro
15、cess Audit across the entire manufacturing facility. 此區(qū)域也被用于整個(gè)制造廠學(xué)習(xí)如何實(shí)施分層審核。 Use Discretion when adding items to the checklist在向檢查表中添加項(xiàng)目的時(shí)候使用判斷力判斷力。 Audit items are issues that would cause Customer Dissatisfaction. 審核項(xiàng)目是那些導(dǎo)致客戶不滿客戶不滿的問(wèn)題。2 X Week 每周兩次每周兩次Area Management 區(qū)域管理者區(qū)域管理者1 X Shift 每班一次每班一次Pro
16、duction Supervisor 生產(chǎn)主管生產(chǎn)主管1 X Week 每周一次每周一次Plant Manager 工廠經(jīng)理工廠經(jīng)理 Encourages Management Involvement 鼓勵(lì)管理層參與鼓勵(lì)管理層參與 Encourages Operator Feedback 鼓勵(lì)操作員反饋鼓勵(lì)操作員反饋 Establishes Accountability 建立責(zé)任制建立責(zé)任制EXAMPLE: LPA FREQUENCY AND STRUCTURE舉例:舉例: 分層過(guò)程審核頻率與結(jié)構(gòu)分層過(guò)程審核頻率與結(jié)構(gòu)123123123123123123123123123MONXXTUESXX
17、WEDXXTHURXXFRIXXSATXXMONXXTUESXXWEDXXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 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 3X1 10 0PRODUCTION SUPERVISOR WEEKLY LAYERED AUDIT LINE SCHEDULE1 14 4121
18、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, 在每個(gè)循環(huán)矩陣中第三班生產(chǎn)中沒(méi)有進(jìn)行審核在每個(gè)循環(huán)矩陣中第三班生產(chǎn)中沒(méi)有進(jìn)行審核 不可接受不可接受的狀況的狀況!生產(chǎn)生產(chǎn) 主管周主管周LPA檢查計(jì)劃安排表檢查計(jì)劃安排表SENIO R SUPERVISO R W EEKLY LAYERED AUDIT LINE SCHEDULEQ U AR TER 1Q U AR TER 298
19、751412114109875141211410W EEK 1XW EEK 14XW EEK 2XW EEK 15XW EEK 3XW EEK 16XW EEK 4XW EEK 17XW EEK 5XW EEK 18XW EEK 6XW EEK 19XW EEK 7XW EEK 20XW EEK 8XW EEK 21XW EEK 9XW EEK 22XW EEK 10XW EEK 23XW EEK 11XW EEK 24XW EEK 12XW EEK 25XW EEK 13XW EEK 26XQ U AR TER 3Q U AR TER 498751412114109875141211410W
20、 EEK 27XW EEK 40XW EEK 28XW EEK 41XW EEK 29XW EEK 42XW EEK 30XW EEK 43XW EEK 31XW EEK 44XW EEK 32XW EEK 45XW EEK 33XW EEK 46XW EEK 34XW EEK 47XW EEK 35XW EEK 48XW EEK 36XW EEK 49XW EEK 37XW EEK 50XW EEK 38XW EEK 51XW EEK 39XW EEK 52XPLANNEDCOMPLETEDD AYSXEVER Y LIN E IS AU D ITED EVER Y 9 W EEKSPLAC
21、 E A C H EC K M AR K IN TH E AB O VE B O X FO R AU D ITS C O M PLETED每條線輪流在每9周進(jìn)行一次審核. 在上面表格中, 用差號(hào)標(biāo)明已經(jīng)完成了審核工廠經(jīng)理周工廠經(jīng)理周LPA檢查計(jì)劃安排表檢查計(jì)劃安排表和日期的藍(lán)點(diǎn)措施并實(shí)施一個(gè)糾正行動(dòng)請(qǐng)求.提問(wèn)應(yīng)該包含對(duì)操作、設(shè)備、文件等的完整說(shuō)明。 Reaction to non-conformances must assure immediate response. 對(duì)不符的響應(yīng)速度必須及時(shí)。). Auditors must understand LPA strategy and purpo
22、se. 審核員必須理解LPA策略和目的。 Review checklist and reactions with auditors. 和審核員共同分析檢查清單和反應(yīng)計(jì)劃。 Auditors must know to respond immediately after finding a nonconformance. 審核員必須在發(fā)現(xiàn)一個(gè)不符合時(shí)快速作出響應(yīng)。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV審核員具備執(zhí)行防錯(cuò)防誤驗(yàn)證的資格。 Perform a p
23、ractice audit where appropriate. 在適用的時(shí)候執(zhí)行一次審核實(shí)踐。Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 一旦一旦LPA計(jì)劃得到批準(zhǔn),供應(yīng)商應(yīng)該培訓(xùn)自己的分層過(guò)程審核員計(jì)劃得到批準(zhǔn),供應(yīng)商應(yīng)該培訓(xùn)自己的分層過(guò)程審核員 Explain why the LPA is being implemented. 解釋為什么為什么LPA在被執(zhí)行。 Explain the purpose and benefits of the LPA proce
24、ss. 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(diǎn)執(zhí)行審核時(shí),將LPA活動(dòng)和對(duì)結(jié)果的期望 通知通知給操作工人。 Encourage workforce feedback. 鼓勵(lì)鼓勵(lì)操作工人進(jìn)行反饋。 Communicate LPA results frequently. 經(jīng)常對(duì)LPA的結(jié)果進(jìn)行交流進(jìn)行交流。 Review audit results frequently when startin
25、g process. 在啟動(dòng)程序的時(shí)候經(jīng)常經(jīng)常對(duì)審核結(jié)果進(jìn)行回顧。 Improve audit checklist based on auditor feedback. 根據(jù)審核員的反饋來(lái)改進(jìn)審核檢驗(yàn)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(shí)候逐漸進(jìn)行灌輸,來(lái)按時(shí)完成審核并提供資 源給快速更正行動(dòng)。 During early phas
26、e - Management audits will find problems, but later management audits will find improvements. 在早期- 管理層的審核將發(fā)現(xiàn)問(wèn)題, 但是以后管理層的審核會(huì)發(fā)現(xiàn)(這些問(wèn)題的)改進(jìn)。 - Develop and apply Lessons Learned to improve audit. - 制定并運(yùn)用吸取的教訓(xùn)吸取的教訓(xùn)來(lái)改進(jìn)審核。 Corrective actions shall be documented as required by ISO/TS 更正行動(dòng)應(yīng)該按照ISO/TS的標(biāo)準(zhǔn)進(jìn)行文件記錄. There must be a system to maintain the audit schedule and track completion. 必須有
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