MagnaChina-LayeredAuditSession-Chineseversion

1、分層審核過(guò)程分層審核過(guò)程DateAuthor2Disclosure or duplication without consent is prohibited分層分層 審核的目的審核的目的u Reduce the number of non-conformances to existing procedures Reduce the number of non-conformances to existing procedures and policiesand policies減少對(duì)現(xiàn)行程序和政策的不符合項(xiàng)減少對(duì)現(xiàn)行程序和政策的不符合項(xiàng)u Increase the frequency at w

2、hich various levels of management Increase the frequency at which various levels of management perform auditsperform audits增加各管理層面的審核頻率增加各管理層面的審核頻率u Remove roadblocks to correcting unsatisfactory itemsRemove roadblocks to correcting unsatisfactory items去除障礙以糾去除障礙以糾正不滿意項(xiàng)正不滿意項(xiàng)u Standardize types of it

3、ems audited / checked by plant personnelStandardize types of items audited / checked by plant personnel標(biāo)標(biāo)準(zhǔn)類型項(xiàng)目的審核準(zhǔn)類型項(xiàng)目的審核/ /檢查由工廠人員執(zhí)行檢查由工廠人員執(zhí)行. .DateAuthor3Disclosure or duplication without consent is prohibited什么是分層審核什么是分層審核? ?u Conducted by various levels of plant leadershipConducted by various le

4、vels of plant leadership由工廠各層級(jí)的由工廠各層級(jí)的領(lǐng)導(dǎo)團(tuán)隊(duì)執(zhí)行領(lǐng)導(dǎo)團(tuán)隊(duì)執(zhí)行 Typically conducted by first line personnel 典型上由第一線人員執(zhí)行u An audit to assure non-conformances to the quality system are An audit to assure non-conformances to the quality system are identified and correctedidentified and corrected一個(gè)確保識(shí)別和糾正不符合質(zhì)量體系的審核一

5、個(gè)確保識(shí)別和糾正不符合質(zhì)量體系的審核 Supporting personnel from various functions支持人員來(lái)自各個(gè)功能 Middle and upper plant management工廠管理中層和上層u Covers the entire manufacturing facilityCovers the entire manufacturing facility覆蓋整個(gè)制造工廠覆蓋整個(gè)制造工廠 Departments部門Shipping and Receiving出貨和收貨Maintenance維修Fabrication加工Assembly裝配 Areas區(qū)域 S

6、hifts班次DateAuthor4Disclosure or duplication without consent is prohibited如何實(shí)行分層審核如何實(shí)行分層審核 u Review documentationReview documentation檢討文件檢討文件 Work instructions作業(yè)指導(dǎo)書 Standardized work標(biāo)準(zhǔn)化工作 Routings路徑 Control plans控制計(jì)劃 Standardized changeover instructions標(biāo)準(zhǔn)化切換指令u Observe department activitiesObserve de

7、partment activities觀察部門活動(dòng)觀察部門活動(dòng)u Observe workplace organizationObserve workplace organization觀察工作場(chǎng)所組織安排觀察工作場(chǎng)所組織安排u Document actual data / dates found during auditDocument actual data / dates found during audit文件實(shí)際數(shù)據(jù)文件實(shí)際數(shù)據(jù)/ /審核期間發(fā)現(xiàn)的數(shù)據(jù)審核期間發(fā)現(xiàn)的數(shù)據(jù) Dates of incoming material (FIFO verification)來(lái)料數(shù)據(jù)(先進(jìn)先出驗(yàn)證

8、) Date and / or time of last Control Plan check數(shù)據(jù)和/或上次控制計(jì)劃?rùn)z查的時(shí)間u Interview manufacturing personnelInterview manufacturing personnel和制造人員面談和制造人員面談 Do NOT adversely affect:勿被反過(guò)來(lái)影響: Safety安全 Quality質(zhì)量 Production生產(chǎn)DateAuthor5Disclosure or duplication without consent is prohibited分層審核檢查表分層審核檢查表-溝通溝通u Int

9、erview OperatorsInterview Operators員員工檢討工檢討Awareness of quality issues (formal and informal)質(zhì)量問(wèn)題的意識(shí)(正式和非正式)Knowledge of alarm limits警報(bào)極限的知識(shí)Use of control plans控制計(jì)劃的使用u Verify that quality Verify that quality alerts are postedalerts are posted確認(rèn)確認(rèn)質(zhì)量警告發(fā)布質(zhì)量警告發(fā)布LAYERED AUDIT CHECKLISTLAYERED AUDIT CHECK

10、LISTAUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_ SHIFT:_Process ElementProcess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted for any r

11、ecent WFCCs/quality isssues?Any observations from operator interviews or other input communicated?Workplace Organization & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonconformin

12、g or suspect product identified and placed in a designated area?Are proper containers used?Is material in containment properly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (required by t

13、he Control Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Operator Certification/Standardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan checks m

14、ade at the proper frequency, with the correct sample size and on the correct form?Are product/process checks with in specification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error Proofing

15、 verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are all gages(required by the Control Plan)availble at the workstation? Are the gages numbered, calibrated and mathch the Control Plan? Are significant process events recorded?Containment/ReworkContainment/Rew

16、orkIs containment information documented when the product is nonconforming?Is in-plant rework/teardowns completed per instrctions with proper identification?Are out-of spec conditions recorded and corrective actions documented?P.M.ActivitiesP.M.ActivitiesAre QNPM/TPM activities verified as complete?

17、Section #1-Communication第一部分-溝通DateAuthor6Disclosure or duplication without consent is prohibited分層審核檢查表分層審核檢查表工作現(xiàn)場(chǎng)組織安排和環(huán)境工作現(xiàn)場(chǎng)組織安排和環(huán)境u Check all material Check all material identificationidentification檢查所有材料標(biāo)識(shí)檢查所有材料標(biāo)識(shí)Incoming進(jìn)來(lái)料In-process過(guò)程在制Outgoing出貨Re-work返工Scrap報(bào)廢Containment遏制u Verify material f

18、low (FIFO)Verify material flow (FIFO)確認(rèn)確認(rèn)物流物流( (先進(jìn)先出先進(jìn)先出) )u Verify that proper containers Verify that proper containers are being usedare being used確認(rèn)恰當(dāng)?shù)娜萜鞔_認(rèn)恰當(dāng)?shù)娜萜魇褂檬褂胾 Observe overall Observe overall environmental conditionsenvironmental conditions觀察觀察總體環(huán)境情況總體環(huán)境情況LAYERED AUDIT CHECKLISTLAYERED AUDI

19、T CHECKLISTAUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_ SHIFT:_Process ElementProcess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted fo

20、r any recent WFCCs/quality isssues?Any observations from operator interviews or other input communicated?Workplace Organization & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonco

21、nforming or suspect product identified and placed in a designated area?Are proper containers used?Is material in containment properly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (requir

22、ed by the Control Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Operator Certification/Standardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan c

23、hecks made at the proper frequency, with the correct sample size and on the correct form?Are product/process checks with in specification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error P

24、roofing verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are all gages(required by the Control Plan)availble at the workstation? Are the gages numbered, calibrated and mathch the Control Plan? Are significant process events recorded?Containment/ReworkContainm

25、ent/ReworkIs containment information documented when the product is nonconforming?Is in-plant rework/teardowns completed per instrctions with proper identification?Are out-of spec conditions recorded and corrective actions documented?P.M.ActivitiesP.M.ActivitiesAre QNPM/TPM activities verified as co

26、mplete?Section #2Workplace Organization &Environment第二部分-工作場(chǎng)所組織安排和環(huán)境DateAuthor7Disclosure or duplication without consent is prohibited分層審核檢查表分層審核檢查表設(shè)置設(shè)置u Confirm that current Confirm that current setup documentation setup documentation was usedwas used確認(rèn)現(xiàn)行的設(shè)置確認(rèn)現(xiàn)行的設(shè)置文件被使用文件被使用u Make sure that Mak

27、e sure that changeover instructions changeover instructions were usedwere used確保切換指令的確保切換指令的使用使用u Verify that control plan Verify that control plan requirements are requirements are followedfollowed確認(rèn)控制計(jì)劃要求確認(rèn)控制計(jì)劃要求被執(zhí)行被執(zhí)行Error Proofing / Gauging / Masters used防錯(cuò)/儀表/標(biāo)準(zhǔn)樣件使用Visual aids available有視覺(jué)器具Cor

28、rective action for any item found to be out of specification on set-up針對(duì)任何設(shè)置超標(biāo)項(xiàng)的糾正措施All previous stock purged from cell / line所有來(lái)自單元/線先前的閉箱存貨LAYERED AUDIT CHECKLISTLAYERED AUDIT CHECKLISTAUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_ SHIFT:_Process Eleme

29、ntProcess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted for any recent WFCCs/quality isssues?Any observations from operator interviews or other input communicated?Workplace Organizat

30、ion & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonconforming or suspect product identified and placed in a designated area?Are proper containers used?Is material in containment

31、 properly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (required by the Control Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Operator Certification/

32、Standardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan checks made at the proper frequency, with the correct sample size and on the correct form?Are product/process checks with in

33、specification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error Proofing verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are all gages(required by

34、the Control Plan)availble at the workstation? Are the gages numbered, calibrated and mathch the Control Plan? Are significant process events recorded?Containment/ReworkContainment/ReworkIs containment information documented when the product is nonconforming?Is in-plant rework/teardowns completed per

35、 instrctions with proper identification?Are out-of spec conditions recorded and corrective actions documented?P.M.ActivitiesP.M.ActivitiesAre QNPM/TPM activities verified as complete?Section #3-Set-Up第三部分-設(shè)置DateAuthor8Disclosure or duplication without consent is prohibited分層審核檢查表分層審核檢查表-操作工資質(zhì)操作工資質(zhì)/

36、/作業(yè)標(biāo)準(zhǔn)化作業(yè)標(biāo)準(zhǔn)化u Are Operators and Are Operators and Supervisors following Supervisors following standardized work?standardized work?操操作工和主管執(zhí)行標(biāo)準(zhǔn)作作工和主管執(zhí)行標(biāo)準(zhǔn)作業(yè)嗎業(yè)嗎? ?u Are Operators Are Operators certified on the job?certified on the job?操操作工勝任工作嗎作工勝任工作嗎? ? How do you know?你怎么知道?u Are there operators in Are

37、 there operators in training?training?操作工有培訓(xùn)操作工有培訓(xùn)嗎嗎? ? Is there a training plan? ?有培訓(xùn)計(jì)劃嗎有培訓(xùn)計(jì)劃嗎? ? What are the requirements for certification on a job勝任工作的要求是什么?LAYERED AUDIT CHECKLISTLAYERED AUDIT CHECKLISTAUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_

38、 SHIFT:_Process ElementProcess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted for any recent WFCCs/quality isssues?Any observations from operator interviews or other input communicate

39、d?Workplace Organization & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonconforming or suspect product identified and placed in a designated area?Are proper containers used?Is ma

40、terial in containment properly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (required by the Control Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Op

41、erator Certification/Standardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan checks made at the proper frequency, with the correct sample size and on the correct form?Are product/pr

42、ocess checks with in specification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error Proofing verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are a

43、ll gages(required by the Control Plan)availble at the workstation? Are the gages numbered, calibrated and mathch the Control Plan? Are significant process events recorded?Containment/ReworkContainment/ReworkIs containment information documented when the product is nonconforming?Is in-plant rework/te

44、ardowns completed per instrctions with proper identification?Are out-of spec conditions recorded and corrective actions documented?P.M.ActivitiesP.M.ActivitiesAre QNPM/TPM activities verified as complete?Section #4第四部分Operator Certification/Standardized Work操作工資質(zhì)/作業(yè)標(biāo)準(zhǔn)化DateAuthor9Disclosure or duplic

45、ation without consent is prohibited分層審核檢查表分層審核檢查表 - -控制計(jì)劃控制計(jì)劃u Verify required control Verify required control plan checksplan checks驗(yàn)證要求的驗(yàn)證要求的控制計(jì)劃?rùn)z查控制計(jì)劃?rùn)z查 Frequency頻率 Sample size樣本大小 Fixtures / tooling置具/模具 Form形式u Confirm that checks Confirm that checks are within specificationare within specifica

46、tion確認(rèn)檢查在規(guī)范之內(nèi)確認(rèn)檢查在規(guī)范之內(nèi)u Make sure that Make sure that reaction plans are reaction plans are being followedbeing followed確保反應(yīng)確保反應(yīng)計(jì)劃的跟蹤計(jì)劃的跟蹤LAYERED AUDIT CHECKLISTLAYERED AUDIT CHECKLISTAUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_ SHIFT:_Process ElementP

47、rocess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted for any recent WFCCs/quality isssues?Any observations from operator interviews or other input communicated?Workplace Organization

48、 & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonconforming or suspect product identified and placed in a designated area?Are proper containers used?Is material in containment pr

49、operly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (required by the Control Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Operator Certification/Sta

50、ndardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan checks made at the proper frequency, with the correct sample size and on the correct form? Are product/process checks with in sp

51、ecification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error Proofing verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are all gages(required by th

52、e Control Plan)availble at the workstation? Are the gages numbered, calibrated and mathch the Control Plan? Are significant process events recorded?Containment/ReworkContainment/ReworkIs containment information documented when the product is nonconforming?Is in-plant rework/teardowns completed per i

53、nstrctions with proper identification?Are out-of spec conditions recorded and corrective actions documented?P.M.ActivitiesP.M.ActivitiesAre QNPM/TPM activities verified as complete?Section #5第五部分Control Plan控制計(jì)劃DateAuthor10Disclosure or duplication without consent is prohibited分層審核檢查表分層審核檢查表-一次通過(guò)率一次

54、通過(guò)率u Is FTQ data being Is FTQ data being collected at all reject collected at all reject points in the system?points in the system?一一次通過(guò)率的數(shù)據(jù)是從系統(tǒng)次通過(guò)率的數(shù)據(jù)是從系統(tǒng)的所有拒收點(diǎn)收集嗎的所有拒收點(diǎn)收集嗎? ?u Are alarm limits Are alarm limits visually displayed?visually displayed?警報(bào)警報(bào)極限有目視化展示嗎極限有目視化展示嗎? ?u Are alarm limits being

55、Are alarm limits being adhered to?adhered to?警報(bào)極限有警報(bào)極限有被遵從嗎被遵從嗎? ? How would you know?你怎么知道?u Is FTQ data posted?Is FTQ data posted?一一次通過(guò)率有否公示次通過(guò)率有否公示? ?u Are rejected parts Are rejected parts properly identified?properly identified?拒拒收件有適當(dāng)標(biāo)識(shí)嗎收件有適當(dāng)標(biāo)識(shí)嗎? ?LAYERED AUDIT CHECKLISTLAYERED AUDIT CHECKLIST

56、AUDITOR:_ DEPT:_ DATE:_AUDITOR:_ DEPT:_ DATE:_LINE/MACHINE/CELL:_ SHIFT:_LINE/MACHINE/CELL:_ SHIFT:_Process ElementProcess ElementY YN NCommentsCommentsDate CorrectedDate CorrectedCommunicationCommunicationAre employees aware of any recent PRRs/quality issues? Is a Quality alert posted for any recen

57、t WFCCs/quality isssues?Any observations from operator interviews or other input communicated?Workplace Organization & EnvironmentWorkplace Organization & EnvironmentIs in-process & outgoing material properly IDd?Any mix or wrong material found in process?Is FIFO used?Is nonconforming or

58、 suspect product identified and placed in a designated area?Are proper containers used?Is material in containment properly identified & segregated?Are working and environmental conditins suitable?Set-UpSet-UpAre Masters being run if required by the Control Plan?Are Visual Aids (required by the C

59、ontrol Plan)available?Is Set-Up current per routing?Are Change Over instructions followed?Operator Certification/Standardized WorkOperator Certification/Standardized WorkAre Operators following standardized work?Are Operators certified on the job?Control PlanControl PlanAre control plan checks made

60、at the proper frequency, with the correct sample size and on the correct form?Are product/process checks with in specification? If not, are reaction plans being followed?First Time QualityFirst Time QualityAre alarm limits being adhered to?Measurement SystemsMeasurement SystemsAre Error Proofing verification checks complete?Are Error Proofing devices, gages and fixtures used properly?Are all gages(requ