1、Layered Process Audit 分层过程审核（LPA）,What Are Layered Process Audit? 什么是分层过程审核?,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
2、性。,The purpose of Layered Process Audits is to ensure continuous conformance thereby 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。,What is a Layered Process Audit (LPA)? 什么是分层过程审核（LPA）？,LPAs assure that defined methods and work instructions are ut
3、ilized, 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 ot
4、her 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。,Who Performs Layered Process Audit? 谁执行分层过程审核？,Anybody can perform a Layered Process Audit. 任何人都能够执行逐层过程管理。Manufacturing management must own the processand perform audits. 生产管理
5、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 shift 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
6、行一次审核。工厂管理层应该在每周执行一次审核。,Cost of Non-Conformances at Various Points,Defect found at:The Next End of Final End UsersSource Process Line Inspection Hand*Very minor *Scrap *Repair *Significant Rework *3rd Party Containment*Minor Delay *Containment *Additional Operations *Premium Freight*Rework *Overtime
7、 *Administrative costs*Reschedule *Delay in delivery *Warranty Costs of Work *Added inspection *Reputation*Lost market share*Lost businessNote: Taken from “Layered Process Audits”, The Luminous Group, LLC,Early Detection / Prevention,在各阶段发生的不符造成的成本,在下面阶段发现的缺陷:货源 下个流程 生产线末尾 最终检验 最终用户的手里*非常小 *废品 *返修 *
8、大的返工 *第三方的遏制*短时间延时 *遏制 *额外操作 *昂贵的运输成本*返工 *加班 *管理成本*重订工作计划 *延时发货 *索赔成本 *附加检验 *声誉*失去市场份额*失去业务Note: Taken from “Layered Process Audits”, The Luminous Group, LLC,早期探测 / 预防,LPA Benefits 分层过程审核的优点,Safety regulations安全法规,Reinforces 加强,Facilitates 简化,Operator training 操作员培训 Management/operator interface 管理/
9、操作员界面,First time through capability 一次通过率 Morale 士气,Improves 提高,Build variation based on work standardization因为工作的标准化而产生的多样性 End-of-line inspection 线尾检验 Part defects 零件缺陷,Reduces 减少,LPA Success at Kokomo Transmission Plant 逐层过程审核在KoKoMo变速箱厂的成功运用,Repair Inventory vs First Time Capability vs LPA 对比： 修
10、理库存/一次通过率/逐层过程审核,Layered Process Audit 分层过程审核,Proven Successful Internally 内部经过成功验证Expanding Collaboration to our Supply base加强与我们供应商网络的合作 Not asking Suppliers to do something we are not不向供应商询问我们不要的（零件） Low investment significant quality return低投资 获得显著的质量回报,How does an LPA Work? 分层过程审核是如何工作的？,PROCES
11、S 过程,Error Proofing 防错,Process Audits 过程审核,Audits are conducted regularly by all levels of supervision 各监督级定期地进行审核 Non-conformances are immediately addressed 立即发现不符合处,LAYERED PROCESS AUDITS ARE PROCESS BASED, NOT PART BASED.,逐层过程审核是基于过程的,而不是基于零件的,Developing the Plan 制定计划,Form a LPA Team to implement
12、 the audit process成立一个逐层审核团队 实施审核 Develop procedure for LPA Process and Documentation为LPA过程和文件制定程序 Develop audit checklist. 制订审核清单 Based on Key process elements that affect part quality基于影响零件质量的关键过程要素 Determine who will conduct audits.确定谁来执行审核。 Determine audit frequency for each level (Process Contr
13、ol Audit and Error & Mistake Proofing Verification Audit).为每个级别（过程控制审核与防错防误验证审核）确定审核频次 Develop a monitoring process and reports for management review.制定一个监控过程并向管理部门汇报。,Identify Where to begin LPA Implementation 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 da
14、ta, Scrap Reports 一次通过数据，废品报告Key Characteristics and Process Capability: Cpk & Gage R&R关键特性和过程能力：CPK与检具 R&RPFMEA, 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 A
15、udits, 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 of Highest Risk should be the first area to implement the LayeredProcess Audit 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 LayeredProcess Audit across the entire manufacturing
16、 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 the checklist在向检查表中添加项目的时候使用判断力。Audit items are issues that would cause Customer Dissatisfaction. 审核项目是那些导致客户不满的问题。,LPA - Frequency Plan 逐层过程审核-频率计划,Encourages Management Involvement 鼓励管理层参与Encourages Operator Feedback 鼓励操作员反馈Estab
17、lishes Accountability 建立责任制,EXAMPLE: LPA FREQUENCY AND STRUCTURE 举例： 逐层过程审核频率与结构,Example: Frequency Chart Compliance Matrix for Supervisors 举例: 主管执行频次矩阵图,Note: Example Illustrates that 3rd Shift Not Being Audited Per the Rotation Matrix Unacceptable Condition! 注意: 例子显示, 在每个循环矩阵中第三班生产中没有进行审核 不可接受的状况!
18、,X,X,X,X,X,X,生产 主管周LPA检查计划安排表,每9天对每条线轮流每班进行审核. 在你工作的那班中,用差号标明已经完成了审核.,Weekly Audit Rotation 9 Weeks to Rotate Through all 9 Production Lines周审核循环 9周内循环审核所有9条 生产线,PLANT MANAGER,Example: Frequency Chart Compliance Matrix for Plant Manager 举例: 工厂经理执行频次矩阵图,工厂经理周LPA检查计划安排表,每条线轮流在每9周进行一次审核. 在上面表格中, 用差号标明已
19、经完成了审核.,LPA Checklist Development,LPA 检查表的制定,LPA Checklist Development,LPA 逐层检验清单的制定,Develop Audit Checklist. 制定审核检查表,- Process Control Audit Checklist. 过程控制审核检查表 - Error & Mistake Proofing Verification AuditChecklist. 防错防误验证审核检查表Consider: 考虑到:Questions must be concise and specific.提问必须简明具体Phrase qu
20、estions so a “no” always indicates anonconformance. 使用简单提问, 使用“不”来表明一个不符合.Questions should include complete identification of operation, equipment, documentation, etc提问应该包含对操作、设备、文件等的完整说明。Reaction to non-conformances must assure immediateresponse. 对不符的响应速度必须及时。,Making Questions Specific (Example #1)
21、 使问题具体(举例#1),Initial Question 最初提问: Inspection Log Book: Look and see if the log is being filled out properly and checks are being made. 检验记录书: 检查记录是否填写正确, 同时是否完成了检验.Improved Question 改进提问: Inspection Log Book: Verify QAFM250092 is being filled out with date, shift, badge, and initials and checks ar
22、e being made. (Missing or Incorrect data could result in incorrect units being held in the event of a containment.) 检验记录书: 确认QAFM250092的记录填写了日期,班次, 印章, 和大写字 母, 同时检验是否已经完成.(缺少数据或错误数据可能会将不正确的零件 带入到遏制行动中).,What什么 ?,How如何 ?,Why 为什么?,Making Questions Specific (Example #2) 使问题具体(举例#2),Initial Question 最初提
23、问: Piston Retainer Install: Is the operator applying grease to the gasket? (Absence of grease could result in a gasket failure.) 活塞卡环安装: 操作员是否正在向垫圈上加润滑油? (缺少润滑油 可能导致垫圈失效.)Improved Question 改进提问: Inspection Log Book: Is the operator using the grease dispenser to apply grease to the L/R gasket? (Absen
24、ce of grease could result in a miss-located gasket and leak tester reject or a warranty failure.) 检验记录书: 操作员是否正在使用油嘴向左后垫圈上加润滑油? (缺少润滑油可能导致垫圈错位且在泄漏检验仪上被拒绝通过, 或 带来售后故障.),Customer Review & Approval 客户审核与批准,Your Customer shall review & approve LPA Plan with supplier (Required only for High & Medium Risk
25、 Parts) prior to the PSO visit. For low risk parts, suppliers shall approve their own LPA plan.在PSO访问前， 你们的客户应该与供应商一起评审并批准LPA计划。(仅对高风险和中风险零件有此要求)。 对于低风险零件， 供应商应该批准其自己的LPA计划。The LPA Plan shall include (at a minimum) LPA计划应至少包括： LPA Roll-Out timing planLPA滚动计划 Frequency/Schedule & Structure Chart频次/计划
26、与结构图 Auditor Training Plan审核员培训计划 Checklists that include an area/section for entering immediate reaction plan(s)包括实施迅速反应计划的区域/部分的检查清单 Non-conformance corrective action procedure对不符合的更正行动程序 Schedule of management reviews for LPA resultsLPA结果的管理检查进度 Provisions for eventual LPA coverage of all parts p
27、roduced at suppliers location在供应商地点生产的所有零件的最终LPA范围的规定,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 to 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
28、qualified to perform error andmistake 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 Layered Process Auditors. 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,Train Auditors 培训审核员,Notify Workforce 通知操作
29、工人Explain why the LPA is being implemented.解释为什么LPA在被执行。Explain the purpose and benefits of the LPAprocess.解释LPA程序的目的和益处。Inform workforce of LPA activity and what to expectwhen audits are performed in their work areas.当在工作地点执行审核时，将LPA活动和对结果的期望通知给操作工人。Encourage workforce feedback.鼓励操作工人进行反馈。Communica
30、te LPA results frequently.经常对LPA的结果进行交流。,Begin Audits 开始审核Review audit results frequently when starting process.在启动程序的时候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 discipline early in the process to completeaudits on time and provide resourc
31、es 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。- Develop and apply Lessons Learned to improve audit. - 制定并运用吸取的教训来改进审核。,Correctiv
32、e 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 measured, monitored, and reported to management as per Chrysler Group TS Custome
33、r 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 a Monitoring Process and Reports for Management Review. 制定一个监控流程并为管理层评审提供报告Develop 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 nonconfor
34、mances审核结果总结: 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.,Manufacturing Location Summary Indicators 制造地点总结指示器 Supplier Name 供应商名称: Supplier Location 供应商地点:,Please note
35、请注意: 1. This shows three levels of management. Chrysler Group TS requirements state that the supplier must have “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
36、 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 Supplier Name 供应商名称: Supplier Location 供应商地点:,Layered Process Audit 逐层过程审核,Summary 总结The LPA is an audit of the process. LPA是一个对过程进行的审核 For Medium and High risk part
37、s, both the LPA plan and demonstration shall be approved by the Supplier Quality Specialist. 对于中高等风险的零件，应该由供应商质量专家来批准LPA的计划和演示。 The LPA checklist is a living document. 检验清单是个动态文件 Plant Management must remain involved and committed to the LPA process. 车间管理层必须参与并保证LPA程序的实施。 The Customer shall review LPA as part of corrective action(s) for quality issues. 客户将检查LPA, 这也是解决质量问题所采取纠正行动的一部分。,
