質(zhì)量審查LPA-逐層過程管理(LPC)中英文

LayeredProcessControl(LPC)

逐層過程管理(LPC)1WhatAreLayeredProcessControl?什么是逐層過程管理?TherearetwoTypesofLayeredProcessControl:有兩種逐層過程管理:

ProcessControlAudits過程控制審核Error&MistakeProofingVerificationAudits防錯(cuò)防誤驗(yàn)證審核

LayeredProcessControl(LPC)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.逐層過程管理(LPC)是由多個(gè)管理層進(jìn)行的系統(tǒng)審核。對關(guān)鍵過程特性進(jìn)行頻繁的審核以驗(yàn)證過程符合性。ThepurposeofLayeredProcessAuditsistoensurecontinuousconformancetherebyimprovingprocessstabilityandfirst-timethroughcapability.逐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。2WhatisaLayeredProcessControl(LPC)?

什么是逐層過程管理（LPC）？LPC’sassurethatdefinedmethodsandworkinstructionsareutilized,problemsolvingsolutionsareheldinplace,andallprocessissuesareidentifiedandquicklycorrected.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。LPCisanongoingsystemofprocesschecksthatverifypropermethods,settings,operatorcraftsmanship,errorproofingdevicesandotherinputsareinplacetoensureadefectfreeproduct.

逐層過程審核是一項(xiàng)持續(xù)的過程檢查系統(tǒng)，用來驗(yàn)證正確的方法、設(shè)置、操作員技能、防錯(cuò)裝置和其他輸入是否到位從而確保產(chǎn)品無缺陷產(chǎn)生。3WhoPerformsLayeredProcessControl?誰執(zhí)行逐層過程管理？

AnybodycanperformaLayeredProcessControl.任何人都能夠執(zhí)行逐層過程管理。Manufacturingmanagementmustowntheprocessandperformaudits.生產(chǎn)管理部門必須領(lǐng)導(dǎo)此程序并執(zhí)行審核。Allmanagers,regardlessoffunction,canbeauditors.

所有經(jīng)理，無論他的職責(zé)是什么，都可以作為審核員。Eachmanagementlevelshouldperformaudits.

每個(gè)管理層都應(yīng)該執(zhí)行審核。ProcessControlControlshallbeperformedoncepershiftbysupervisors.Plantmanagementshallperformtheauditonceperweek.過程控制管理應(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。4CostofNon-ConformancesatVariousPointsDefectfoundat:The Next Endof Final EndUser’sSource Process LineInspection Hand*Veryminor*Scrap *Repair*SignificantRework*3rdPartyContainment *MinorDelay*Containment*AdditionalOperations*PremiumFreight *Rework*Overtime*Administrativecosts*Reschedule*Delayindelivery*WarrantyCostsofWork*Addedinspection*Reputation *Lostmarketshare *LostbusinessNote:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLCEarlyDetection/Prevention5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(gè)流程

生產(chǎn)線末尾

最終檢驗(yàn) 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(shí)間延時(shí) *遏制 *額外操作 *昂貴的運(yùn)輸成本 *返工 *加班 *管理成本 *重訂工作計(jì)劃 *延時(shí)發(fā)貨 *索賠成本

*附加檢驗(yàn)*聲譽(yù) *失去市場份額 *失去業(yè)務(wù)Note:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC早期探測/預(yù)防6LPABenefits逐層過程審核的優(yōu)點(diǎn)Safetyregulations

安全法規(guī)Reinforces加強(qiáng)Facilitates簡化Operatortraining操作員培訓(xùn)Management/operatorinterface

管理/操作員界面Firsttimethroughcapability一次通過率Morale士氣Improves提高Buildvariationbasedonworkstandardization

因?yàn)楣ぷ鞯臉?biāo)準(zhǔn)化而產(chǎn)生的多樣性End-of-lineinspection線尾檢驗(yàn)Partdefects零件缺陷Reduces減少7LPASuccessatKokomoTransmissionPlant

逐層過程審核在KoKoMo變速箱廠的成功運(yùn)用RepairInventoryvsFirstTimeCapabilityvsLPA對比：修理庫存/一次通過率/逐層過程審核18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly周#ofLPAChecks/Week每周LPA檢查次數(shù)556065707580859095100FirstTimeThrough(%)一次通過率（%)KTPNowconducting6700ProcessLayeredAuditChecksKTP目前正執(zhí)行6700逐層過程審核0ProcessLayeredAudits

0層過程審epairInventory修理庫存FTC一次通過率8LayeredProcessAudit逐層過程審核ProvenSuccessfulInternally內(nèi)部經(jīng)過成功驗(yàn)證ExpandingCollaborationtoourSupplybase加強(qiáng)與我們供應(yīng)商網(wǎng)絡(luò)的合作NotaskingSupplierstodosomethingwearenot

不向供應(yīng)商詢問我們不要的（零件）Lowinvestment–significantqualityreturn低投資–獲得顯著的質(zhì)量回報(bào)9HowdoesanLPAWork?逐層過程審核是如何工作的？PROCESS過程ErrorProofing防錯(cuò)ProcessAudits過程審核CorrectiveActions糾正行動(dòng)PreventionActions預(yù)防行動(dòng)EmployeeWorkshops車間職工ContinuousImprovementInputs持續(xù)改進(jìn)輸入Auditsareconductedregularlybyalllevelsofsupervision各監(jiān)督級定期地進(jìn)行審核Non-conformancesareimmediatelyaddressed立即發(fā)現(xiàn)不符合處LAYEREDPROCESSAUDITSAREPROCESSBASED,NOTPARTBASED.逐層過程審核是基于過程的,而不是基于零件的10DevelopingthePlan制定計(jì)劃FormaLPATeamtoimplementtheauditprocess

成立一個(gè)逐層審核團(tuán)隊(duì)實(shí)施審核DevelopprocedureforLPAProcessandDocumentation

為LPA過程和文件制定程序Developauditchecklist.制訂審核清單BasedonKeyprocesselementsthataffectpartquality

基于影響零件質(zhì)量的關(guān)鍵過程要素Determinewhowillconductaudits.確定誰來執(zhí)行審核。Determineauditfrequencyforeachlevel(ProcessControlAuditandError&MistakeProofingVerificationAudit).為每個(gè)級別（過程控制審核與防錯(cuò)防誤驗(yàn)證審核）確定審核頻次Developamonitoringprocessandreportsformanagementreview.制定一個(gè)監(jiān)控過程并向管理部門匯報(bào)。11IdentifyWheretobeginLPAImplementation

確定從哪里開始實(shí)施LPA

Review回顧:CustomerComplaints,QualityAlerts客戶抱怨，質(zhì)量警告First-TimeThroughdata,ScrapReports一次通過數(shù)據(jù)，廢品報(bào)告KeyCharacteristicsandProcessCapability:Cpk&GageR&R關(guān)鍵特性和過程能力：CPK與檢具R&RPFMEA,ProcessFlowDiagram,ControlPlanPFMEA,過程流程圖，控制計(jì)劃Set-upSheets,WorkInstructions,InspectionInstructions

工藝卡片、作業(yè)指導(dǎo)書、檢驗(yàn)指導(dǎo)書ErrorandMistakeProofing防錯(cuò)防誤QualitySystemAudits,DockAudits,InspectionReports

質(zhì)量體系審核，貨場審核，檢驗(yàn)報(bào)告Reworkinstructions返工指導(dǎo)書

TheAreaofHighestRiskshouldbethefirstareatoimplementtheLayeredProcessAudit最高風(fēng)險(xiǎn)區(qū)域應(yīng)該是實(shí)施逐層過程審核的第一個(gè)區(qū)域ThisareawillalsobeusedasaLessonsLearnedforimplementingtheLayeredProcessAuditacrosstheentiremanufacturingfacility.

此區(qū)域也被用于整個(gè)制造廠學(xué)習(xí)如何實(shí)施逐層審核。Use

Discretion

whenaddingitemstothechecklist

在向檢查表中添加項(xiàng)目的時(shí)候使用判斷力。AudititemsareissuesthatwouldcauseCustomerDissatisfaction.審核項(xiàng)目是那些導(dǎo)致客戶不滿的問題。122XWeek每周兩次AreaManagement區(qū)域管理者1XShift每班一次ProductionSupervisor生產(chǎn)主管1XWeek每周一次PlantManager工廠經(jīng)理LPA-FrequencyPlan逐層過程審核-頻率計(jì)劃

EncouragesManagementInvolvement鼓勵(lì)管理層參與EncouragesOperatorFeedback鼓勵(lì)操作員反饋EstablishesAccountability

建立責(zé)任制13EXAMPLE:LPAFREQUENCYANDSTRUCTURE舉例：逐層過程審核頻率與結(jié)構(gòu)14Example:FrequencyChartComplianceMatrix

forSupervisors舉例:主管執(zhí)行頻次矩陣圖Note:ExampleIllustratesthat3rdShiftNotBeingAuditedPertheRotationMatrix–UnacceptableCondition!注意:例子顯示,在每個(gè)循環(huán)矩陣中第三班生產(chǎn)中沒有進(jìn)行審核–不可接受的狀況!XXXXXX生產(chǎn)主管周LPA檢查計(jì)劃安排表每9天對每條線輪流每班進(jìn)行審核.在你工作的那班中,用差號標(biāo)明已經(jīng)完成了審核.15WeeklyAuditRotation9WeekstoRotateThroughall9ProductionLines周審核循環(huán)9周內(nèi)循環(huán)審核所有9條生產(chǎn)線

PLANTMANAGERExample:FrequencyChartComplianceMatrix

forPlantManager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(jì)劃安排表每條線輪流在每9周進(jìn)行一次審核.在上面表格中,用差號標(biāo)明已經(jīng)完成了審核.16LPAChecklistDevelopment17LPA檢查表的制定18LPAChecklistDevelopment

OPERATION

orPROCESS

LPACHECKLISTQUESTION

CORRECTIVEACTIONRECEIVING

INSPECTION

IfpartsaretaggedwithredNon-ConformanceTag,isthetagcompletewith1)partnumber,2)dateand3)descriptionofthediscrepancy4)disposition?

NotifyReceivingInspectionSupervisor.MOLDING

Verifymachineprocesssettingsarecorrectaspertheset-upsheet.

NotifyMoldingManager.InformQualityInspectortobegincontainment.

Verifythattheoperatorsarecheckingforandremovinganyflashfromedgesofthemoldedpart

NotifyMoldingManager.InformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifythattheoperatorsaredocumentingflashremovalonoperatorinspectionform.

Notifydepartmentsupervisor.HEATSTAKE

Istheoperatorusingthedigitaldial-indicatortocheckthestakeheightofassemblyasperinspectioninstructions?

Notifydepartmentsupervisor.(ErrorDetectiondeviceatnextstationissettorejectnonconformingparts.)

Verifythatthe#2temperaturegagereadsbetween140and150degreesFahrenheit

NotifyareasupervisorandEngineeringManager.InformQualityInspectortobegincontainment.ASSEMBLY

Verifytheoperatorisapplyinggreaseonboththespringandpivotpin

NotifyAssemblySupervisorInformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifyonthreeassembliesthatthepartsarefreeofexcessgreaseandflash.

NotifyAssemblySupervisorInformQualityInspectortobegincontainment.

Verifythatthehandleoperatessmoothlywithoutbindingorsqueak

NotifyAssemblySupervisorInformQualityInspectortobegincontainment.SHIPPING

Usingonepartfromthetopofapackedtray,verifythatthepartnumberstampedonthepartmatchesthepalletlabel

NotifyMaterialsManagerInformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifythatshippinglabeloneachwrappedpallethasabluedotwithinitialsanddate

NotifyMaterialsManagerInformQualityInspectortobegincontainmentandinitiateaC.A.R..19LPA逐層檢驗(yàn)清單的制定

操作或流程

LPA逐層檢驗(yàn)清單提問

糾正行動(dòng)進(jìn)貨檢驗(yàn)

零件是否被貼上了紅色不符合標(biāo)牌,標(biāo)牌是否包括:1)零件號,2)日期,3)不符描述,4)位置?

通知進(jìn)貨檢驗(yàn)主管.造型

確認(rèn)機(jī)器的流程設(shè)置是按照流程過程卡進(jìn)行設(shè)置的.

.通知造型經(jīng)理;通知質(zhì)檢員開始實(shí)施遏制措施.

確認(rèn)操作工人正在檢查并清除成型零件邊緣上的光澤.

通知造型經(jīng)理;通知質(zhì)檢員開始實(shí)施遏制措施并采取一個(gè)C.A.R(糾正行動(dòng)請求).

確認(rèn)操作工人在工位零件檢驗(yàn)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(yàn)要求使用數(shù)字表來檢驗(yàn)樁的高度?

通知部門主管,(下個(gè)工位設(shè)置了錯(cuò)誤檢測裝置來拒絕不符合零件的通過);

確認(rèn)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(rèn)操作工人正在對彈簧和轉(zhuǎn)動(dòng)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(shí)施一個(gè)糾正行動(dòng)請求.

確認(rèn)在三個(gè)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(rèn)手柄的活動(dòng)自如且無阻塞或吱吱響

通知裝配主管;通知質(zhì)檢員開始采取遏制措施.運(yùn)輸

從裝滿零件的工位箱中拿出一個(gè)零件,確認(rèn)貼在這個(gè)零件上的零件號與工位箱上的零件號標(biāo)簽一致.

通知材料經(jīng)理;通知質(zhì)檢員采取遏制措施并實(shí)施一個(gè)糾正行動(dòng)請求.

確認(rèn)每個(gè)零件包裹托盤上貼著的發(fā)貨標(biāo)簽上有一個(gè)大寫字母和日期的藍(lán)點(diǎn)

通知材料經(jīng)理;通知質(zhì)檢員采取遏制措施并實(shí)施一個(gè)糾正行動(dòng)請求.20DevelopAuditChecklist.

制定審核檢查表-ProcessControlAuditChecklist.過程控制審核檢查表-Error&MistakeProofingVerificationAuditChecklist.防錯(cuò)防誤驗(yàn)證審核檢查表

Consider:考慮到:Questionsmustbeconciseandspecific.提問必須簡明具體Phrasequestionssoa“no”alwaysindicatesanonconformance.使用簡單提問,使用“不”來表明一個(gè)不符合.Questionsshouldincludecompleteidentificationof operation,equipment,documentation,etc…

提問應(yīng)該包含對操作、設(shè)備、文件等的完整說明。Reactiontonon-conformancesmustassureimmediateresponse.對不符的響應(yīng)速度必須及時(shí)。21MakingQuestionsSpecific(Example#1)

使問題具體(舉例#1)InitialQuestion最初提問:InspectionLogBook:Lookandseeifthelogisbeingfilledoutproperlyandchecksarebeingmade.檢驗(yàn)記錄書:檢查記錄是否填寫正確,同時(shí)是否完成了檢驗(yàn).ImprovedQuestion改進(jìn)提問:InspectionLogBook:VerifyQAFM250092isbeingfilledoutwithdate,shift,badge,andinitialsandchecksarebeingmade.(MissingorIncorrectdatacouldresultinincorrectunitsbeingheldintheeventofacontainment.)檢驗(yàn)記錄書:確認(rèn)QAFM250092的記錄填寫了日期,班次,印章,和大寫字母,同時(shí)檢驗(yàn)是否已經(jīng)完成.(缺少數(shù)據(jù)或錯(cuò)誤數(shù)據(jù)可能會將不正確的零件帶入到遏制行動(dòng)中).What什么?How如何?Why為什么?22MakingQuestionsSpecific(Example#2)

使問題具體(舉例#2)InitialQuestion最初提問:PistonRetainerInstall:Istheoperatorapplyinggreasetothegasket?(Absenceofgreasecouldresultinagasketfailure.)活塞卡環(huán)安裝:操作員是否正在向墊圈上加潤滑油?(缺少潤滑油可能導(dǎo)致墊圈失效.)ImprovedQuestion改進(jìn)提問:InspectionLogBook:IstheoperatorusingthegreasedispensertoapplygreasetotheL/Rgasket?(Absenceofgreasecouldresultinamiss-locatedgasketandleaktesterrejectorawarrantyfailure.)檢驗(yàn)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(dǎo)致墊圈錯(cuò)位且在泄漏檢驗(yàn)儀上被拒絕通過,或帶來售后故障.)23CustomerReview&Approval客戶審核與批準(zhǔn)YourCustomershallreview&approveLPAPlanwithsupplier(RequiredonlyforHigh&MediumRiskParts)priortothePSOvisit.Forlowriskparts,suppliersshallapprovetheirownLPAplan.

在PSO訪問前，你們的客戶應(yīng)該與供應(yīng)商一起評審并批準(zhǔn)LPA計(jì)劃。(僅對高風(fēng)險(xiǎn)和中風(fēng)險(xiǎn)零件有此要求)。對于低風(fēng)險(xiǎn)零件，供應(yīng)商應(yīng)該批準(zhǔn)其自己的LPA計(jì)劃。TheLPAPlanshallinclude(ataminimum)LPA計(jì)劃應(yīng)至少包括：LPARoll-OuttimingplanLPA滾動(dòng)計(jì)劃Frequency/Schedule&StructureChart

頻次/計(jì)劃與結(jié)構(gòu)圖AuditorTrainingPlan

審核員培訓(xùn)計(jì)劃Checkliststhatincludeanarea/sectionforenteringimmediatereactionplan(s)

包括實(shí)施迅速反應(yīng)計(jì)劃的區(qū)域/部分的檢查清單Non-conformancecorrectiveactionprocedure

對不符合的更正行動(dòng)程序ScheduleofmanagementreviewsforLPAresultsLPA結(jié)果的管理檢查進(jìn)度ProvisionsforeventualLPAcoverageofallpartsproducedatsupplier’slocation

在供應(yīng)商地點(diǎn)生產(chǎn)的所有零件的最終LPA范圍的規(guī)定24

AuditorsmustunderstandLPAstrategyandpurpose.

審核員必須理解LPA策略和目的。Reviewchecklistandreactionswithauditors.

和審核員共同分析檢查清單和反應(yīng)計(jì)劃。Auditorsmustknowtorespondimmediatelyafterfindinganonconformance.

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)。EMPVAuditorsshallbequalifiedtoperformerror andmistakeproofingverification.EMPV審核員具備執(zhí)行防錯(cuò)防誤驗(yàn)證的資格。Performapracticeauditwhereappropriate.

在適用的時(shí)候執(zhí)行一次審核實(shí)踐。OncetheLPAplanisapproved,theSuppliershalltraintheirLayeredProcessAuditors.一旦LPA計(jì)劃得到批準(zhǔn)，供應(yīng)商應(yīng)該培訓(xùn)自己的逐層過程審核員TrainAuditors培訓(xùn)審核員25

NotifyWorkforce通知操作工人Explainwhy

theLPAisbeingimplemented.

解釋為什么LPA在被執(zhí)行。ExplainthepurposeandbenefitsoftheLPAprocess.

解釋LPA程序的目的和益處。

InformworkforceofLPAactivityandwhattoexpectwhenauditsareperformedintheirworkareas.

當(dāng)在工作地點(diǎn)執(zhí)行審核時(shí)，將LPA活動(dòng)和對結(jié)果的期望

通知給操作工人。

Encourage

workforcefeedback.

鼓勵(lì)操作工人進(jìn)行反饋。

CommunicateLPAresultsfrequently.

經(jīng)常對LPA的結(jié)果進(jìn)行交流。26

BeginAudits開始審核

Reviewauditresultsfrequentlywhenstartingprocess.

在啟動(dòng)程序的時(shí)候經(jīng)常對審核結(jié)果進(jìn)行回顧。

Improveauditchecklistbasedonauditorfeedback.根據(jù)審核員的反饋來改進(jìn)審核檢驗(yàn)表。Managementmustinstilldisciplineearlyintheprocesstocompleteauditsontimeandprovideresourcesforimmediatecorrectiveaction.

管理層必須在程序的早期時(shí)候逐漸進(jìn)行灌輸，來按時(shí)完成審核并提供資源給快速更正行動(dòng)。

Duringearlyphase-Managementauditswillfindproblems,butlatermanagementauditswillfindimprovements.

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(jìn)。 -DevelopandapplyLessonsLearnedtoimproveaudit.-制定并運(yùn)用吸取的教訓(xùn)來改進(jìn)審核。27

CorrectiveactionsshallbedocumentedasrequiredbyISO/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.Theremustbeasystemtomaintaintheauditscheduleandtrackcompletion.

必須有一套系統(tǒng)來保證審核進(jìn)度和跟蹤它的完成.ImprovementsdrivenbytheLPAprocessshallbemeasured,monitored,andreportedtomanagementasperChryslerGroupTSCustomerSpecifics(.1).

通過采用LPA程序而得到的改進(jìn)應(yīng)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（.1）的要求向管理層提供匯報(bào)。DevelopaMonitoringProcessandReportsforManagementReview.制定一個(gè)監(jiān)控流程并為管理層評審提供報(bào)告

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