LayeredProcessAudit(LPA)

逐層過程審核(LPA)SQAP供應商質(zhì)量保證程序1Copywrite@2005byDaimlerChryslerSupplierInterface–LPA’swillbeMandatory

供應商接口-逐層過程審核是被強制性的ISO/TS16949

DaimlerChryslerCustomerSpecificRequirements戴姆勒-克萊斯勒用戶特別要求NewsectionunderInternalAudits正對新章節(jié)進行內(nèi)部審核Effective7/01/04forPowertrain&ComponentPlantssuppliers;對傳動系及其零部件的供應商于7/01/04日開始執(zhí)行；1/1/05forallremainingsuppliers對所有其余的供應商于1/1/05年開始執(zhí)行PostedonAIAG,IAOB,andQMSwebsites

在AIAG，IAOB，和QMS網(wǎng)站上發(fā)布Lettermailedtoallsuppliers信函已經(jīng)發(fā)給了所有的供應商SQAP2Copywrite@2005byDaimlerChryslerWhatAreLayeredProcessAudits?什么是逐層過程審核?TherearetwoTypesofLayeredProcessAudits:有兩種逐層過程審核:

ProcessControlAudits過程控制審核Error&MistakeProofingVerificationAudits防錯防誤驗證審核

LayeredProcessAudits(LPA)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.逐層過程審核(LPA)是由多個管理層進行的系統(tǒng)審核。對關鍵過程特性進行頻繁的審核以驗證過程符合性。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。SQAP3Copywrite@2005byDaimlerChryslerWhatisaLayeredProcessAudit(LPA)?

什么是逐層過程審核（LPA）？LPA’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。LPAisanongoingsystemofprocesschecksthatverifypropermethods,settings,operatorcraftsmanship,errorproofingdevicesandotherinputsareinplacetoensureadefectfreeproduct.

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。SQAP4Copywrite@2005byDaimlerChryslerWhoPerformsLayeredProcessAudits?誰執(zhí)行逐層過程審核？

AnybodycanperformaLayeredProcessAudit.任何人都能夠執(zhí)行逐層過程審核。Manufacturingmanagementmustowntheprocessandperformaudits.生產(chǎn)管理部門必須領導此程序并執(zhí)行審核。Allmanagers,regardlessoffunction,canbeauditors.

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

每個管理層都應該執(zhí)行審核。ProcessControlAuditsshallbeperformedoncepershiftbysupervisors.Plantmanagementshallperformtheauditonceperweek.過程控制審核應該在每班生產(chǎn)時由車間主管進行一次審核。工廠管理應該在每周執(zhí)行一次審核。Error&MistakeProofingVerificationauditsshall

beconductedoncepershift.OnlyqualifiedemployeesshallperformError&MistakeProofVerificationAudits.Set-up,maintenanceorqualityauditorsareusuallyqualified.防錯防誤驗證審核應該在每班生產(chǎn)執(zhí)行一次。由具備資格的人員進行防錯防誤驗證審核。建立、維護或質(zhì)量審核員通常是具備資格的人員。SQAP5Copywrite@2005byDaimlerChryslerCostofNon-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/PreventionSQAP6Copywrite@2005byDaimlerChrysler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:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC早期探測/預防SQAP7Copywrite@2005byDaimlerChryslerLPABenefits逐層過程審核的優(yōu)點Safetyregulations

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

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

因為工作的標準化而產(chǎn)生的多樣性End-of-lineinspection線尾檢驗Partdefects零件缺陷Reduces減少SQAP8Copywrite@2005byDaimlerChryslerLPASuccessatKokomoTransmissionPlant

逐層過程審核在KoKoMo變速箱廠的成功運用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SQAP9Copywrite@2005byDaimlerChryslerLayeredProcessAudit逐層過程審核ProvenSuccessfulInternally內(nèi)部經(jīng)過成功驗證ExpandingCollaborationtoourSupplybase加強與我們供應商網(wǎng)絡的合作NotaskingSupplierstodosomethingwearenot

不向供應商詢問我們不要的（零件）Lowinvestment–significantqualityreturn低投資–獲得顯著的質(zhì)量回報SQAP10Copywrite@2005byDaimlerChryslerHowdoesanLPAWork?逐層過程審核是如何工作的？PROCESS過程ErrorProofing防錯ProcessAudits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Auditsareconductedregularlybyalllevelsofsupervision各監(jiān)督級定期地進行審核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SQAP11Copywrite@2005byDaimlerChryslerDevelopingthePlan制定計劃FormaLPATeamtoimplementtheauditprocess

成立一個逐層審核團隊實施審核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)量的關鍵過程要素Determinewhowillconductaudits.確定誰來執(zhí)行審核。Determineauditfrequencyforeachlevel(ProcessControlAuditandError&MistakeProofingVerificationAudit).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Developamonitoringprocessandreportsformanagementreview.制定一個監(jiān)控過程并向管理部門匯報。SQAP12Copywrite@2005byDaimlerChryslerIdentifyWheretobeginLPAImplementation

確定從哪里開始實施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)，廢品報告KeyCharacteristicsandProcessCapability:Cpk&GageR&R關鍵特性和過程能力：CPK與檢具R&RPFMEA,ProcessFlowDiagram,ControlPlanPFMEA,過程流程圖，控制計劃Set-upSheets,WorkInstructions,InspectionInstructions

工藝卡片、作業(yè)指導書、檢驗指導書ErrorandMistakeProofing防錯防誤QualitySystemAudits,DockAudits,InspectionReports

質(zhì)量體系審核，貨場審核，檢驗報告Reworkinstructions返工指導書

TheAreaofHighestRiskshouldbethefirstareatoimplementtheLayeredProcessAudit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ThisareawillalsobeusedasaLessonsLearnedforimplementingtheLayeredProcessAuditacrosstheentiremanufacturingfacility.

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

whenaddingitemstothechecklist

在向檢查表中添加項目的時候使用判斷力。AudititemsareissuesthatwouldcauseCustomerDissatisfaction.審核項目是那些導致客戶不滿的問題。SQAP13Copywrite@2005byDaimlerChrysler2XWeek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-頻率計劃

EncouragesManagementInvolvement鼓勵管理層參與EncouragesOperatorFeedback鼓勵操作員反饋EstablishesAccountability

建立責任制SQAP14Copywrite@2005byDaimlerChryslerEXAMPLE:LPAFREQUENCYANDSTRUCTURE舉例：逐層過程審核頻率與結構SQAP15Copywrite@2005byDaimlerChryslerExample: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.SQAP16Copywrite@2005byDaimlerChryslerWeeklyAuditRotation9WeekstoRotateThroughall9ProductionLines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.SQAP17Copywrite@2005byDaimlerChryslerLPAChecklistDevelopmentSQAP18Copywrite@2005byDaimlerChryslerLPA檢查表的制定SQAP19Copywrite@2005byDaimlerChryslerLPAChecklistDevelopment

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..SQAP20Copywrite@2005byDaimlerChryslerLPA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

確認機器的流程設置是按照流程過程卡進行設置的.

.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.

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.SQAP21Copywrite@2005byDaimlerChryslerDevelopAuditChecklist.

制定審核檢查表-ProcessControlAuditChecklist.過程控制審核檢查表-Error&MistakeProofingVerificationAuditChecklist.防錯防誤驗證審核檢查表

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”來表明一個不符合.Questionsshouldincludecompleteidentificationof operation,equipment,documentation,etc…

提問應該包含對操作、設備、文件等的完整說明。Reactiontonon-conformancesmustassureimmediateresponse.對不符的響應速度必須及時。SQAP22Copywrite@2005byDaimlerChryslerMakingQuestionsSpecific(Example#1)

使問題具體(舉例#1)InitialQuestion最初提問:InspectionLogBook:Lookandseeifthelogisbeingfilledoutproperlyandchecksarebeingmade.檢驗記錄書:檢查記錄是否填寫正確,同時是否完成了檢驗.ImprovedQuestion改進提問:InspectionLogBook:VerifyQAFM250092isbeingfilledoutwithdate,shift,badge,andinitialsandchecksarebeingmade.(MissingorIncorrectdatacouldresultinincorrectunitsbeingheldintheeventofacontainment.)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?SQAP23Copywrite@2005byDaimlerChryslerMakingQuestionsSpecific(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?(缺少潤滑油可能導致墊圈失效.)ImprovedQuestion改進提問:InspectionLogBook:IstheoperatorusingthegreasedispensertoapplygreasetotheL/Rgasket?(Absenceofgreasecouldresultinamiss-locatedgasketandleaktesterrejectorawarrantyfailure.)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被拒絕通過,或帶來售后故障.)SQAP24Copywrite@2005byDaimlerChryslerCustomerReview&Approval客戶審核與批準YourCustomershallreview&approveLPAPlanwithsupplier(RequiredonlyforHigh&MediumRiskParts)priortothePSOvisit.Forlowriskparts,suppliersshallapprovetheirownLPAplan.

在PSO訪問前，你們的客戶應該與供應商一起評審并批準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。TheLPAPlanshallinclude(ataminimum)LPA計劃應至少包括：LPARoll-OuttimingplanLPA滾動計劃Frequency/Schedule&StructureChart

頻次/計劃與結構圖AuditorTrainingPlan

審核員培訓計劃Checkliststhatincludeanarea/sectionforenteringimmediatereactionplan(s)

包括實施迅速反應計劃的區(qū)域/部分的檢查清單Non-conformancecorrectiveactionprocedure

對不符合的更正行動程序ScheduleofmanagementreviewsforLPAresultsLPA結果的管理檢查進度ProvisionsforeventualLPAcoverageofallpartsproducedatsupplier’slocation

在供應商地點生產(chǎn)的所有零件的最終LPA范圍的規(guī)定SQAP25Copywrite@2005byDaimlerChrysler

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計劃。Auditorsmustknowtorespondimmediatelyafterfindinganonconformance.

審核員必須在發(fā)現(xiàn)一個不符合時快速作出響應。EMPVAuditorsshallbequalifiedtoperformerror andmistakeproofingverification.EMPV審核員具備執(zhí)行防錯防誤驗證的資格。Performapracticeauditwhereappropriate.

在適用的時候執(zhí)行一次審核實踐。OncetheLPAplanisapproved,theSuppliershalltraintheirLayeredProcessAuditors.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TrainAuditors培訓審核員SQAP26Copywrite@2005byDaimlerChrysler

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.

當在工作地點執(zhí)行審核時，將LPA活動和對結果的期望

通知給操作工人。

Encourage

workforcefeedback.

鼓勵操作工人進行反饋。

CommunicateLPAresultsfrequently.

經(jīng)常對LPA的結果進行交流。SQAP27Copywrite@2005byDaimlerChrysler

BeginAudits開始審核

Reviewauditresultsfrequentlywhenstartingprocess.

在啟動程序的時候經(jīng)常對審核結果進行回顧。

Improveauditchecklistbasedonauditorfeedback.根據(jù)審核員的反饋來改進審核檢驗表。Managementmustinstilldisciplineearlyintheprocesstocompleteauditsontimeandprovideresourcesforimmediatecorrectiveaction.

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。

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。 -DevelopandapplyLessonsLearnedtoimproveaudit.-制定并運用吸取的教訓來改進審核。SQAP28Copywrite@2005byDaimlerChrysler

CorrectiveactionsshallbedocumentedasrequiredbyISO/TS

更正行動應該按照ISO/TS的標準進行文件記錄.Theremustbeasystemtomaintaintheauditscheduleandtrackcompletion.

必須有一套系統(tǒng)來保證審核進度和跟蹤它的完成.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（.1）的要求向管理層提供匯報。DevelopaMonitoringProcessandReportsfor