LPA分层审核精讲课件.ppt

1、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.分层过程审核(LPA)是由多个管理层进行的系统审核。对关键过程特性进行频繁的审核以验证过程符合性。The purpose of Layered Process Audits is to ensure continuous conformance ther

2、eby improving process stability and first-time through capability.分层过程审核的目的是确保持续的符合性，从而提高过程稳定性和一次通过率。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 corrected.逐层过程审核确保使用固定的方法和操作说明，确保使用问题

3、解决方案，所有过程问题都被识别并被迅速纠正。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.逐层过程审核是一项持续的过程检查系统，用来验证正确的方法、设置、操作员技能、防错装置和其他输入是否到位从而确保产品无缺陷产生。Anybody can perform a Layere

4、d Process Audit.任何人都能够执行逐层过程管理。Manufacturing management must own the process and perform audits.生产管理部门必须领导此程序并执行审核。All managers,regardless of function,can be auditors.所有经理，无论他的职责是什么，都可以作为审核员。Each management level should perform audits.每个管理层都应该执行审核。Layered Process Audit shall be performed once per sh

5、ift by supervisors.Plant management shall perform the audit once per week.分层过程审核应该在每班生产时由车间主管进行一次审核。工厂管理层应该在每周执行一次审核。Safety regulations 安全法规安全法规Reinforces加强加强Facilitates简化简化Operator training 操作员培训操作员培训Management/operator interface 管理管理/操作员界面操作员界面First time through capability 一次通过率一次通过率Morale 士气士气Imp

6、roves提高提高Build variation based on work standardization 因为工作的标准化而产生的多样性因为工作的标准化而产生的多样性End-of-line inspection 线尾检验线尾检验Part defects 零件缺陷零件缺陷Reduces减少减少Repair Inventory vs First Time Capability vs LPA对比：对比：修理库存修理库存/一次通过率一次通过率/逐层过程审核逐层过程审核18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-

7、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检查次数检查次数556065707580859095100First Time Through(%)一次通过率（一次通过率（%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正执行6700 分层过程审核0 Process Layered Audits 0层过程审核18001805400Repair

8、Inventory修理库存FTC一次通过率PROCESS过程过程ErrorProofing 防错防错 Process Audits 过程审核过程审核CorrectiveActions 纠正行动纠正行动PreventionActions 预防行动预防行动EmployeeWorkshops 车间职工车间职工ContinuousImprovementInputs 持续改进输入持续改进输入Audits are conducted regularly by all levels of supervision 各各监督级定期地进行审核监督级定期地进行审核Non-conformances are immed

9、iately addressed 立即发现不符合处立即发现不符合处LAYERED PROCESSAUDITS ARE PROCESSBASED,NOT PART BASED.逐层过程审核是基于过程的逐层过程审核是基于过程的,而不而不是基于零件的是基于零件的确定从哪里开始实施确定从哪里开始实施LPA Review 回顾:Customer Complaints,Quality Alerts 客户抱怨，质量警告 First-Time Through data,Scrap Reports 一次通过数据，废品报告 Key Characteristics and Process Capability:Cp

10、k&Gage R&R 关键特性和过程能力：CPK与检具 R&R PFMEA,Process Flow Diagram,Control Plan PFMEA,过程流程图，控制计划 Set-up Sheets,Work Instructions,Inspection Instructions 工艺卡片、作业指导书、检验指导书 Error and Mistake Proofing 防错防误 Quality System Audits,Dock Audits,Inspection Reports 质量体系审核，货场审核，检验报告 Rework instructions 返工指导书 The Area o

11、f Highest Risk should be the first area to implement the Layered Process Audit 最高风险区域最高风险区域应该是实施逐层过程审核的第一个区域 This area will also be used as a Lessons Learned for implementing the Layered Process Audit across the entire manufacturing facility.此区域也被用于整个制造厂学习如何实施逐层审核。Use Discretion when adding items to

12、 the checklist 在向检查表中添加项目的时候使用判断力判断力。Audit items are issues that would cause Customer Dissatisfaction.审核项目是那些导致客户不满客户不满的问题。2 X Week 每周两次每周两次Area Management 区域管理者区域管理者1 X Shift 每班一次每班一次Production Supervisor 生产主管生产主管1 X Week 每周一次每周一次Plant Manager 工厂经理工厂经理 Encourages Management Involvement 鼓励管理层参与鼓励管理层

13、参与 Encourages Operator Feedback 鼓励操作员反馈鼓励操作员反馈 Establishes Accountability 建立责任制建立责任制EXAMPLE:LPA FREQUENCY AND STRUCTURE举例：举例：逐层过程审核频率与结构逐层过程审核频率与结构Example:Frequency Chart Compliance Matrixfor Supervisors 举例举例:主管执行频次矩阵图主管执行频次矩阵图123123123123123123123123123MONXXTUESXXWEDXXTHURXXFRIXXSATXXMONXXTUESXXWED

14、XXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 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 11 149 987 75Note:Example Illustrat

15、es that 3rd Shift Not Being Audited Per the Rotation Matrix Unacceptable Condition!注意注意:例子显示例子显示,在每个循环矩阵中第三班生产中没有进行审核在每个循环矩阵中第三班生产中没有进行审核 不可接受不可接受的状况的状况!XXXXXX生产生产 主管周主管周LPA检查计划安排表检查计划安排表每每9天对每条线轮流每班进行审核天对每条线轮流每班进行审核.在你工作的那班中在你工作的那班中,用差号标明已经完成了审核用差号标明已经完成了审核.SENIOR SUPERVISOR WEEKLY LAYERED AUDIT LI

16、NE 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 10XWEEK 23XWEEK 11XWEEK 24XWEEK 12XWEEK 25XWEEK 13XWEEK 26XQUARTER 3QUARTER 4987514 12 11410987514 12

17、 11410WEEK 27XWEEK 40XWEEK 28XWEEK 41XWEEK 29XWEEK 42XWEEK 30XWEEK 43XWEEK 31XWEEK 44XWEEK 32XWEEK 45XWEEK 33XWEEK 46XWEEK 34XWEEK 47XWEEK 35XWEEK 48XWEEK 36XWEEK 49XWEEK 37XWEEK 50XWEEK 38XWEEK 51XWEEK 39XWEEK 52XPLANNEDCOMPLETEDDAYSXEVERY LINE IS AUDITED EVERY 9 WEEKSPLACE A CHECK MARK IN THE ABOV

18、E BOX FOR AUDITS COMPLETED PLANT MANAGERExample:Frequency Chart Compliance Matrixfor Plant Manager 举例举例:工厂经理执行频次矩阵图工厂经理执行频次矩阵图工厂经理周工厂经理周LPA检查计划安排表检查计划安排表每条线轮流在每每条线轮流在每9周进行一次审核周进行一次审核.在上面表格中在上面表格中,用差号标明已经完成了审核用差号标明已经完成了审核.OPERATIONor PROCESS LPA CHECKLIST QUESTION CORRECTIVE ACTIONRECEIVING INSPECTIO

19、N If parts are 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.MOLDING Verify machine process settings are correct as per the set-up sheet.Notify Molding Manager.Inform Quality

20、 Inspector to begin containment.Verify that the operators are checking for and removing any flash from edges of the molded part Notify 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 for

21、m.Notify department supervisor.HEAT STAKE Is 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 gag

22、e reads between 140 and 150 degrees Fahrenheit Notify area supervisor and Engineering Manager.Inform Quality Inspector to begin containment.ASSEMBLY Verify the operator is applying grease on both the spring and pivot pin Notify Assembly Supervisor Inform Quality Inspector to begin containment and in

23、itiate 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 squeak Notify Assembly Supervisor Inform Quality Inspector to begin contai

24、nment.SHIPPING Using one part from the top of a packed tray,verify that the part number stamped on the part matches the pallet label Notify 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 initi

25、als and date Notify Materials Manager Inform Quality Inspector to begin containment and initiate a C.A.R.操作或流程操作或流程 LPA 逐层检验清单提问逐层检验清单提问 纠正行动纠正行动进货检验进货检验 零件是否被贴上了红色不符合标牌,标牌是否包括:1)零件号,2)日期,3)不符描述,4)位置?通知进货检验主管.造造 型型 确认机器的流程设置是按照流程过程卡进行设置的.通知造型经理;通知质检员开始实施遏制措 施.确认操作工人正在检查并清除成型零件边缘上的光泽.通知造型经理;通知质检员开始实施

26、遏制措施并采取一个C.A.R(纠正行动请求).确认操作工人在工位零件检验表上记录了将光泽清除的行为.通知部门主管热桩热桩 操作员是否按照检验要求使用数字表来检验桩的高度?通知部门主管,(下个工位设置了错误检测装置来拒绝不符合零件的通过);确认2号温度表的读数在140到150华氏度之间.通知区域主管和工程经理.通知质检员采取遏制措施.装配装配 确认操作工人正在对弹簧和转动梢上添加润滑油.通知装配主管;通知质检员开始采取遏制措施并实施一个纠正行动请求.确认在三个总成上,零件没有多余的润滑油和光泽.通知装配主管;通知质检员开始采取遏制措施.确认手柄的活动自如且无阻塞或吱吱响 通知装配主管;通知质检员

27、开始采取遏制措施.运输运输 从装满零件的工位箱中拿出一个零件,确认贴在这个零件上的零件号与工位箱上的零件号标签一致.通知材料经理;通知质检员采取遏制措施并实施一个纠正行动请求.确认每个零件包裹托盘上贴着的发货标签上有一个大写字母和日期的蓝点 通知材料经理;通知质检员采取遏制措施并实施一个纠正行动请求.Auditors must understand LPA strategy and purpose.审核员必须理解LPA策略和目的。Review checklist and reactions with auditors.和审核员共同分析检查清单和反应计划。Auditors must know t

28、o respond immediately after finding a nonconformance.审核员必须在发现一个不符合时快速作出响应。EMPV Auditors shall be qualified to perform error and mistake proofing verification.EMPV审核员具备执行防错防误验证的资格。Perform a practice audit where appropriate.在适用的时候执行一次审核实践。Once the LPA plan is approved,the Supplier shall train their La

29、yered Process Auditors.一旦一旦LPA计划得到批准，供应商应该培训自己的逐层过程审核员计划得到批准，供应商应该培训自己的逐层过程审核员 Explain why the LPA is being implemented.解释为什么为什么LPA在被执行。Explain the purpose and benefits of the LPA process.解释LPA程序的目的和益处益处。Inform workforce of LPA activity and what to expect when audits are performed in their work area

30、s.当在工作地点执行审核时，将LPA活动和对结果的期望 通知通知给操作工人。Encourage workforce feedback.鼓励鼓励操作工人进行反馈。Communicate LPA results frequently.经常对LPA的结果进行交流进行交流。Review audit results frequently when starting process.在启动程序的时候经常经常对审核结果进行回顾。Improve audit checklist based on auditor feedback.根据审核员的反馈来改进审核检验表。Management must instill

31、discipline early in the process to complete audits on time and provide resources for immediate corrective action.管理层必须在程序的早期时候逐渐进行灌输，来按时完成审核并提供资 源给快速更正行动。During early phase-Management audits will find problems,but later management audits will find improvements.在早期-管理层的审核将发现问题，但是以后管理层的审核会发现改 进。-Devel

32、op and apply Lessons Learned to improve audit.-制定并运用吸取的教训吸取的教训来改进审核。Corrective actions shall be documented as required by ISO/TS 更正行动应该按照ISO/TS的标准进行文件记录.There must be a system to maintain the audit schedule and track completion.必须有一套系统来保证审核进度和跟踪它的完成.Improvements driven by the LPA process shall be me

33、asured,monitored,and reported to management as per Chrysler Group TS Customer Specifics(4.2.1.9.1).通过采用LPA程序而得到的改进应该是可以被测量、监测的，并能够按照克莱斯勒TS客户规范（4.2.1.9.1）的要求向管理层提供汇报。Develop 制定制定:-Corrective Action Request forms for nonconformnces 为不符合制定更正行动要求表格.-Summary of audit results:Pareto of nonconformances 审核结

34、果总结:不符合的Pareto图.-Summary of on-time/missed/late audit completion 按时/忘记/延迟审核完成后的总结 -Frequency for management review 管理层检查的频率 -Management reaction plan for LPA process 管理层对LPA过程的反应计划.Please note请注意:1.This shows three levels of management.Chrysler Group TS requirements state that the supplier must have

35、“multiple levels”of management.此图表明了三个管理级别.克莱斯勒TS要求阐述了供应商必须进行”多层次”的管理2.The number of LPA auditable items refers to the number of items on the LPA checklist multiplied by the number of times the items are checked in that month.LPA可审核项的数量指的是LPA检验表上项目数乘以当月这些项目被检查的次数.Manufacturing Location Summary Indicators 制造地点总结指示器制造地点总结指示器Supplier Name 供应商名称供应商名称:Supplier Location 供应商地点供应商地点