LPA分層審核精講課件

1、Layered Process Audit 分層過程審核（LPA）Layered Process Audit What Are Layered Process Audit?什么是分層過程審核?Layered Process Audit(LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 分層過程審核(LPA)是由多個管理層進行的系統(tǒng)審核。對關(guān)

2、鍵過程特性進行頻繁的審核以驗證過程符合性。The purpose of Layered Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. 分層過程審核的目的是確保持續(xù)的符合性，從而提高過程穩(wěn)定性和一次通過率。What Are Layered Process AuditWhat is a Layered Process Audit (LPA)? 什么是分層過程審核（LPA）？LPAs assure tha

3、t defined methods and work instructions are utilized, problem solving solutions are held in place, and all process issues are identified and quickly corrected.逐層過程審核確保使用固定的方法和操作說明， 確保使用問題解決方案， 所有過程問題都被識別并被迅速糾正。LPA is an ongoing system of process checks that verify proper methods, settings, operator

4、craftsmanship, error proofing devices and other inputs are in place to ensure a defect free product. 逐層過程審核是一項持續(xù)的過程檢查系統(tǒng)， 用來驗證正確的方法、 設(shè)置、 操作員技能、防錯裝置和其他輸入是否到位從而確保產(chǎn)品無缺陷產(chǎn)生。What is a Layered Process AudiWho Performs Layered Process Audit?誰執(zhí)行分層過程審核？ Anybody can perform a Layered Process Audit. 任何人都能夠執(zhí)行逐層過程

5、管理。 Manufacturing management must own the process and perform audits. 生產(chǎn)管理部門必須領(lǐng)導此程序并執(zhí)行審核。 All managers, regardless of function, can be auditors. 所有經(jīng)理，無論他的職責是什么， 都可以作為審核員。 Each management level should perform audits. 每個管理層都應該執(zhí)行審核。 Layered Process Audit shall be performed once per shift by supervisors

6、. Plant management shall perform the audit once per week.分層過程審核應該在每班生產(chǎn)時由車間主管進行一次審核。工廠管理層應該在每周執(zhí)行一次審核。Who Performs Layered Process ACost of Non-Conformances at Various PointsDefect found at: The Next End of Final End Users Source Process Line Inspection Hand*Very minor *Scrap *Repair *Significant Rewo

7、rk *3rd Party Containment *Minor Delay *Containment *Additional Operations *Premium Freight *Rework *Overtime *Administrative costs *Reschedule *Delay in delivery *Warranty Costs of Work *Added inspection *Reputation *Lost market share *Lost businessNote: Taken from “Layered Process Audits”, The Lum

8、inous Group, LLCEarly Detection / PreventionCost of Non-Conformances at Va在各階段發(fā)生的不符造成的成本在下面階段發(fā)現(xiàn)的缺陷: 貨源 下個流程 生產(chǎn)線末尾 最終檢驗 最終用戶的手里 *非常小 *廢品 *返修 *大的返工 *第三方的遏制 *短時間延時 *遏制 *額外操作 *昂貴的運輸成本 *返工 *加班 *管理成本 *重訂工作計劃 *延時發(fā)貨 *索賠成本 *附加檢驗 *聲譽 *失去市場份額 *失去業(yè)務Note: Taken from “Layered Process Audits”, The Luminous Group,

9、LLC早期探測 / 預防在各階段發(fā)生的不符造成的成本在下面階段發(fā)現(xiàn)的缺陷:早期探測 LPA Benefits 分層過程審核的優(yōu)點Safety regulations 安全法規(guī)Reinforces加強Facilitates簡化Operator training 操作員培訓Management/operator interface 管理/操作員界面First time through capability 一次通過率Morale 士氣Improves提高Build variation based on work standardization 因為工作的標準化而產(chǎn)生的多樣性End-of-line

10、inspection 線尾檢驗Part defects 零件缺陷Reduces減少LPA Benefits 分層過程審核的優(yōu)點Safety rLPA Success at Kokomo Transmission Plant 逐層過程審核在KoKoMo變速箱廠的成功運用Repair Inventory vs First Time Capability vs LPA對比： 修理庫存/一次通過率/逐層過程審核18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0316-0319-0322-03

11、25-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 周# of LPA Checks / Week每周LPA檢查次數(shù)556065707580859095100First Time Through (%)一次通過率（%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正執(zhí)行6700 分層過程審核0 Process Layered Audits 0層過程審epair Inventory修理庫存FTC一次通過率LPA Success at Koko

12、mo TransmisLayered Process Audit 分層過程審核Proven Successful Internally 內(nèi)部經(jīng)過成功驗證Expanding Collaboration to our Supply base 加強與我們供應商網(wǎng)絡的合作Not asking Suppliers to do something we are not 不向供應商詢問我們不要的（零件） Low investment significant quality return 低投資 獲得顯著的質(zhì)量回報Layered Process Audit 分層過程審核How does an LPA Work

13、? 分層過程審核是如何工作的？PROCESS過程ErrorProofing 防錯 Process Audits 過程審核CorrectiveActions 糾正行動PreventionActions 預防行動EmployeeWorkshops 車間職工ContinuousImprovementInputs 持續(xù)改進輸入Audits are conducted regularly by all levels of supervision 各監(jiān)督級定期地進行審核Non-conformances are immediately addressed 立即發(fā)現(xiàn)不符合處LAYERED PROCESSAUD

14、ITS ARE PROCESSBASED, NOT PART BASED.逐層過程審核是基于過程的,而不是基于零件的How does an LPA Work? 分層過程審核Developing the Plan 制定計劃Form a LPA Team to implement the audit process 成立一個逐層審核團隊 實施審核Develop procedure for LPA Process and Documentation 為LPA過程和文件制定程序Develop audit checklist. 制訂審核清單Based on Key process elements th

15、at affect part quality 基于影響零件質(zhì)量的關(guān)鍵過程要素Determine who will conduct audits. 確定誰來執(zhí)行審核。Determine audit frequency for each level (Process Control Audit and Error & Mistake Proofing Verification Audit). 為每個級別（過程控制審核與防錯防誤驗證審核）確定審核頻次Develop a monitoring process and reports for management review. 制定一個監(jiān)控過程并向管理

16、部門匯報。Developing the Plan 制定計劃Form Identify Where to begin LPA Implementation 確定從哪里開始實施LPA Review 回顧: Customer Complaints, Quality Alerts 客戶抱怨，質(zhì)量警告 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)鍵特性和過程能力：CPK與檢具 R&R PFMEA, Process Flow Di

17、agram, Control Plan PFMEA, 過程流程圖，控制計劃 Set-up Sheets, Work Instructions, Inspection Instructions 工藝卡片、作業(yè)指導書、檢驗指導書 Error and Mistake Proofing 防錯防誤 Quality System Audits, Dock Audits, Inspection Reports 質(zhì)量體系審核，貨場審核，檢驗報告 Rework instructions 返工指導書 The Area of Highest Risk should be the first area to impl

18、ement the Layered Process Audit 最高風險區(qū)域應該是實施逐層過程審核的第一個區(qū)域 This area will also be used as a Lessons Learned for implementing the Layered Process Audit across the entire manufacturing facility. 此區(qū)域也被用于整個制造廠學習如何實施逐層審核。 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。 Audit items are

19、issues that would cause Customer Dissatisfaction. 審核項目是那些導致客戶不滿的問題。Identify Where to begin LPA Im2 X Week 每周兩次Area Management 區(qū)域管理者1 X Shift 每班一次Production Supervisor 生產(chǎn)主管1 X Week 每周一次Plant Manager 工廠經(jīng)理LPA - Frequency Plan 逐層過程審核-頻率計劃 Encourages Management Involvement 鼓勵管理層參與 Encourages Operator Fee

20、dback 鼓勵操作員反饋 Establishes Accountability 建立責任制2 X Week 每周兩次Area ManagemenEXAMPLE: LPA FREQUENCY AND STRUCTURE舉例： 逐層過程審核頻率與結(jié)構(gòu)EXAMPLE: LPA FREQUENCY AND STRExample: Frequency Chart Compliance Matrixfor Supervisors 舉例: 主管執(zhí)行頻次矩陣圖Note: Example Illustrates that 3rd Shift Not Being Audited Per the Rotation

21、 Matrix Unacceptable Condition!注意: 例子顯示, 在每個循環(huán)矩陣中第三班生產(chǎn)中沒有進行審核 不可接受的狀況!XXXXXX生產(chǎn) 主管周LPA檢查計劃安排表每9天對每條線輪流每班進行審核. 在你工作的那班中,用差號標明已經(jīng)完成了審核.Example: Frequency Chart ComplWeekly Audit Rotation9 Weeks to Rotate Throughall 9 Production Lines周審核循環(huán)9周內(nèi)循環(huán)審核所有9條生產(chǎn)線 PLANT MANAGERExample: Frequency Chart Compliance Ma

22、trixfor Plant Manager 舉例: 工廠經(jīng)理執(zhí)行頻次矩陣圖工廠經(jīng)理周LPA檢查計劃安排表每條線輪流在每9周進行一次審核. 在上面表格中, 用差號標明已經(jīng)完成了審核.Weekly Audit Rotation PLANLPA Checklist DevelopmentLPA Checklist DevelopmentLPA 檢查表的制定LPA 檢查表的制定LPA Checklist Development OPERATIONor PROCESSLPA CHECKLIST QUESTIONCORRECTIVE ACTIONRECEIVING INSPECTIONIf parts a

23、re tagged with red Non-Conformance Tag, is the tag complete with 1) part number, 2) date and 3) description of the discrepancy 4) disposition?Notify Receiving Inspection Supervisor.MOLDINGVerify machine process settings are correct as per the set-up sheet. Notify Molding Manager. Inform Quality Insp

24、ector to begin containment.Verify that the operators are checking for and removing any flash from edges of the molded partNotify Molding Manager. Inform Quality Inspector to begin containment and initiate a C.A.R.Verify that the operators are documenting flash removal on operator inspection form. No

25、tify department supervisor.HEAT STAKEIs the operator using the digital dial-indicator to check the stake height of assembly as per inspection instructions? Notify department supervisor.(Error Detection device at next station is set to reject nonconforming parts.)Verify that the #2 temperature gage r

26、eads between 140 and 150 degrees FahrenheitNotify area supervisor and Engineering Manager. Inform Quality Inspector to begin containment.ASSEMBLYVerify the operator is applying grease on both the spring and pivot pinNotify Assembly Supervisor Inform Quality Inspector to begin containment and initiat

27、e a C.A.R.Verify on three assemblies that the parts are free of excess grease and flash.Notify Assembly Supervisor Inform Quality Inspector to begin containment.Verify that the handle operates smoothly without binding or squeakNotify Assembly Supervisor Inform Quality Inspector to begin containment.

28、SHIPPINGUsing one part from the top of a packed tray, verify that the part number stamped on the part matches the pallet labelNotify Materials Manager Inform Quality Inspector to begin containment and initiate a C.A.R.Verify that shipping label on each wrapped pallet has a blue dot with initials and

29、 dateNotify Materials Manager Inform Quality Inspector to begin containment and initiate a C.A.R.LPA Checklist Development OPELPA 逐層檢驗清單的制定 操作或流程LPA 逐層檢驗清單提問糾正行動進貨檢驗零件是否被貼上了紅色不符合標牌, 標牌是否包括:1) 零件號, 2) 日期, 3) 不符描述, 4) 位置?通知進貨檢驗主管.造 型確認機器的流程設(shè)置是按照流程過程卡進行設(shè)置的.通知造型經(jīng)理; 通知質(zhì)檢員開始實施遏制措 施.確認操作工人正在檢查并清除成型零件邊緣上的光澤

30、.通知造型經(jīng)理; 通知質(zhì)檢員開始實施遏制措施并采取一個C.A.R (糾正行動請求).確認操作工人在工位零件檢驗表上記錄了將光澤清除的行為.通知部門主管熱樁操作員是否按照檢驗要求使用數(shù)字表來檢驗樁的高度? 通知部門主管,(下個工位設(shè)置了錯誤檢測裝置來拒絕不符合零件的通過);確認2號溫度表的讀數(shù)在140到150華氏度之間.通知區(qū)域主管和工程經(jīng)理. 通知質(zhì)檢員采取遏制措施.裝配確認操作工人正在對彈簧和轉(zhuǎn)動梢上添加潤滑油.通知裝配主管;通知質(zhì)檢員開始采取遏制措施并實施一個糾正行動請求.確認在三個總成上, 零件沒有多余的潤滑油和光澤.通知裝配主管; 通知質(zhì)檢員開始采取遏制措施.確認手柄的活動自如且無阻塞

31、或吱吱響通知裝配主管; 通知質(zhì)檢員開始采取遏制措施.運輸從裝滿零件的工位箱中拿出一個零件, 確認貼在這個零件上的零件號與工位箱上的零件號標簽一致.通知材料經(jīng)理; 通知質(zhì)檢員采取遏制措施并實施一個糾正行動請求.確認每個零件包裹托盤上貼著的發(fā)貨標簽上有一個大寫字母和日期的藍點通知材料經(jīng)理; 通知質(zhì)檢員采取遏制措施并實施一個糾正行動請求.LPA 逐層檢驗清單的制定 操作或流程LPA 逐層檢驗清Develop Audit Checklist.制定審核檢查表- Process Control Audit Checklist. 過程控制審核檢查表- Error & Mistake Proofing Ver

32、ification Audit Checklist. 防錯防誤驗證審核檢查表 Consider: 考慮到: Questions must be concise and specific.提問必須簡明具體 Phrase questions so a “no” always indicates a nonconformance. 使用簡單提問, 使用“不”來表明一個不符合. Questions should include complete identification of operation, equipment, documentation, etc 提問應該包含對操作、設(shè)備、文件等的完整說

33、明。 Reaction to non-conformances must assure immediate response. 對不符的響應速度必須及時。Develop Audit Checklist.制定審核檢Making Questions Specific (Example #1) 使問題具體(舉例#1)Initial Question 最初提問: Inspection Log Book: Look and see if the log is being filled outproperly and checks are being made.檢驗記錄書: 檢查記錄是否填寫正確, 同時是

34、否完成了檢驗.Improved Question 改進提問:Inspection Log Book: Verify QAFM250092 is being filled out with date,shift, badge, and initials and checks are being made. (Missing orIncorrect data could result in incorrect units being held in the event ofa containment.)檢驗記錄書: 確認QAFM250092的記錄填寫了日期,班次, 印章, 和大寫字母, 同時檢驗是

35、否已經(jīng)完成.(缺少數(shù)據(jù)或錯誤數(shù)據(jù)可能會將不正確的零件帶入到遏制行動中).What什么 ?How如何 ?Why 為什么?Making Questions Specific (ExaMaking Questions Specific (Example #2)使問題具體(舉例#2)Initial Question 最初提問:Piston Retainer Install: Is the operator applying grease to thegasket? (Absence of grease could result in a gasket failure.)活塞卡環(huán)安裝: 操作員是否正在向

36、墊圈上加潤滑油? (缺少潤滑油可能導致墊圈失效.)Improved Question 改進提問:Inspection Log Book: Is the operator using the greasedispenser to apply grease to the L/R gasket? (Absence of grease could result in a miss-located gasket and leak testerreject or a warranty failure.)檢驗記錄書: 操作員是否正在使用油嘴向左后墊圈上加潤滑油? (缺少潤滑油可能導致墊圈錯位且在泄漏檢驗儀上

37、被拒絕通過, 或帶來售后故障.)Making Questions Specific (ExaCustomer Review & Approval 客戶審核與批準Your Customer shall review & approve LPA Plan with supplier (Required only for High & Medium Risk Parts) prior to the PSO visit. For low risk parts, suppliers shall approve their own LPA plan. 在PSO訪問前， 你們的客戶應該與供應商一起評審并批準

38、LPA計劃。(僅對高風險和中風險零件有此要求)。 對于低風險零件， 供應商應該批準其自己的LPA計劃。The LPA Plan shall include (at a minimum) LPA計劃應至少包括：LPA Roll-Out timing plan LPA滾動計劃Frequency/Schedule & Structure Chart 頻次/計劃與結(jié)構(gòu)圖Auditor Training Plan 審核員培訓計劃Checklists that include an area/section for entering immediate reaction plan(s) 包括實施迅速反應計

39、劃的區(qū)域/部分的檢查清單Non-conformance corrective action procedure 對不符合的更正行動程序Schedule of management reviews for LPA results LPA結(jié)果的管理檢查進度Provisions for eventual LPA coverage of all parts produced at suppliers location 在供應商地點生產(chǎn)的所有零件的最終LPA范圍的規(guī)定Customer Review & Approval 客戶 Auditors must understand LPA strategy a

40、nd purpose. 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計劃。 Auditors must know to respond immediately after finding a nonconformance. 審核員必須在發(fā)現(xiàn)一個不符合時快速作出響應。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV審核員具備執(zhí)行防錯防誤驗證的資格。 Per

41、form a practice audit where appropriate. 在適用的時候執(zhí)行一次審核實踐。Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 一旦LPA計劃得到批準，供應商應該培訓自己的逐層過程審核員Train Auditors 培訓審核員Once the LPA plan is approved, Notify Workforce 通知操作工人 Explain why the LPA is being implemented. 解釋為什么LPA在被

42、執(zhí)行。 Explain the purpose and benefits of the LPA process. 解釋LPA程序的目的和益處。 Inform workforce of LPA activity and what to expect when audits are performed in their work areas. 當在工作地點執(zhí)行審核時，將LPA活動和對結(jié)果的期望 通知給操作工人。 Encourage workforce feedback. 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。 N

43、otify Workforce 通知操作工 Begin Audits 開始審核 Review audit results frequently when starting process. 在啟動程序的時候經(jīng)常對審核結(jié)果進行回顧。 Improve audit checklist based on auditor feedback. 根據(jù)審核員的反饋來改進審核檢驗表。 Management must instill discipline early in the process to complete audits on time and provide resources for immedi

44、ate corrective action. 管理層必須在程序的早期時候逐漸進行灌輸，來按時完成審核并提供資 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- 管理層的審核將發(fā)現(xiàn)問題， 但是以后管理層的審核會發(fā)現(xiàn)改 進。 - Develop and apply Lessons Learned to improve audit. - 制定并運用吸取的教訓來改進審核。 Begin Audits 開始

45、審核 Corrective actions shall be documented as required by ISO/TS 更正行動應該按照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)來保證審核進度和跟蹤它的完成. Improvements driven by the LPA process shall be measured, monitored, and reported to management as per Chrysler Group TS Customer Specifics (4.2.1.9.1). 通過采用LPA程序而得到的改進應該是可以被測量、監(jiān)測的，并能夠按照克萊斯勒TS客戶規(guī)范（4.2.1.9.1）的要求向管理層提供匯報。Develop a Monitoring Process and Reports for Management Review.制定一個監(jiān)控流程并為管理層評