LPA-分层审核PPT幻灯片

LayeredProcessAudit分层过程审核（LPA）,1,Copywrite2005byDaimlerChrysler,2020/5/18,WhatAreLayeredProcessAudit?什么是分层过程审核?,LayeredProcessAudit(LPA)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.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。,ThepurposeofLayeredProcessAuditsistoensurecontinuousconformancetherebyimprovingprocessstabilityandfirst-timethroughcapability.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。,2,Copywrite2005byDaimlerChrysler,2020/5/18,WhatisaLayeredProcessAudit(LPA)?什么是分层过程审核（LPA）？,LPAsassurethatdefinedmethodsandworkinstructionsareutilized,problemsolvingsolutionsareheldinplace,andallprocessissuesareidentifiedandquicklycorrected.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。,LPAisanongoingsystemofprocesschecksthatverifypropermethods,settings,operatorcraftsmanship,errorproofingdevicesandotherinputsareinplacetoensureadefectfreeproduct.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。,3,Copywrite2005byDaimlerChrysler,2020/5/18,WhoPerformsLayeredProcessAudit?谁执行分层过程审核？,AnybodycanperformaLayeredProcessAudit.任何人都能够执行逐层过程管理。Manufacturingmanagementmustowntheprocessandperformaudits.生产管理部门必须领导此程序并执行审核。Allmanagers,regardlessoffunction,canbeauditors.所有经理，无论他的职责是什么，都可以作为审核员。Eachmanagementlevelshouldperformaudits.每个管理层都应该执行审核。LayeredProcessAuditshallbeperformedoncepershiftbysupervisors.Plantmanagementshallperformtheauditonceperweek.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。,4,Copywrite2005byDaimlerChrysler,2020/5/18,CostofNon-ConformancesatVariousPoints,Defectfoundat:TheNextEndofFinalEndUsersSourceProcessLineInspectionHand*Veryminor*Scrap*Repair*SignificantRework*3rdPartyContainment*MinorDelay*Containment*AdditionalOperations*PremiumFreight*Rework*Overtime*Administrativecosts*Reschedule*Delayindelivery*WarrantyCostsofWork*Addedinspection*Reputation*Lostmarketshare*LostbusinessNote:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC,EarlyDetection/Prevention,5,Copywrite2005byDaimlerChrysler,2020/5/18,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*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:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC,早期探测/预防,6,Copywrite2005byDaimlerChrysler,2020/5/18,LPABenefits分层过程审核的优点,Safetyregulations安全法规,Reinforces加强,Facilitates简化,Operatortraining操作员培训Management/operatorinterface管理/操作员界面,Firsttimethroughcapability一次通过率Morale士气,Improves提高,Buildvariationbasedonworkstandardization因为工作的标准化而产生的多样性End-of-lineinspection线尾检验Partdefects零件缺陷,Reduces减少,7,Copywrite2005byDaimlerChrysler,2020/5/18,LPASuccessatKokomoTransmissionPlant逐层过程审核在KoKoMo变速箱厂的成功运用,RepairInventoryvsFirstTimeCapabilityvsLPA对比：修理库存/一次通过率/逐层过程审核,8,Copywrite2005byDaimlerChrysler,2020/5/18,LayeredProcessAudit分层过程审核,ProvenSuccessfulInternally内部经过成功验证ExpandingCollaborationtoourSupplybase加强与我们供应商网络的合作NotaskingSupplierstodosomethingwearenot不向供应商询问我们不要的（零件）Lowinvestmentsignificantqualityreturn低投资获得显著的质量回报,9,Copywrite2005byDaimlerChrysler,2020/5/18,HowdoesanLPAWork?分层过程审核是如何工作的？,PROCESS过程,ErrorProofing防错,ProcessAudits过程审核,Auditsareconductedregularlybyalllevelsofsupervision各监督级定期地进行审核Non-conformancesareimmediatelyaddressed立即发现不符合处,LAYEREDPROCESSAUDITSAREPROCESSBASED,NOTPARTBASED.,逐层过程审核是基于过程的,而不是基于零件的,10,Copywrite2005byDaimlerChrysler,2020/5/18,DevelopingthePlan制定计划,FormaLPATeamtoimplementtheauditprocess成立一个逐层审核团队实施审核DevelopprocedureforLPAProcessandDocumentation为LPA过程和文件制定程序Developauditchecklist.制订审核清单BasedonKeyprocesselementsthataffectpartquality基于影响零件质量的关键过程要素Determinewhowillconductaudits.确定谁来执行审核。Determineauditfrequencyforeachlevel(ProcessControlAuditandError&MistakeProofingVerificationAudit).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Developamonitoringprocessandreportsformanagementreview.制定一个监控过程并向管理部门汇报。,11,Copywrite2005byDaimlerChrysler,2020/5/18,IdentifyWheretobeginLPAImplementation确定从哪里开始实施LPAReview回顾:CustomerComplaints,QualityAlerts客户抱怨，质量警告First-TimeThroughdata,ScrapReports一次通过数据，废品报告KeyCharacteristicsandProcessCapability:Cpk&GageR&R关键特性和过程能力：CPK与检具R&RPFMEA,ProcessFlowDiagram,ControlPlanPFMEA,过程流程图，控制计划Set-upSheets,WorkInstructions,InspectionInstructions工艺卡片、作业指导书、检验指导书ErrorandMistakeProofing防错防误QualitySystemAudits,DockAudits,InspectionReports质量体系审核，货场审核，检验报告Reworkinstructions返工指导书,TheAreaofHighestRiskshouldbethefirstareatoimplementtheLayeredProcessAudit最高风险区域应该是实施逐层过程审核的第一个区域ThisareawillalsobeusedasaLessonsLearnedforimplementingtheLayeredProcessAuditacrosstheentiremanufacturingfacility.此区域也被用于整个制造厂学习如何实施逐层审核。UseDiscretionwhenaddingitemstothechecklist在向检查表中添加项目的时候使用判断力。AudititemsareissuesthatwouldcauseCustomerDissatisfaction.审核项目是那些导致客户不满的问题。,12,Copywrite2005byDaimlerChrysler,2020/5/18,LPA-FrequencyPlan逐层过程审核-频率计划,EncouragesManagementInvolvement鼓励管理层参与EncouragesOperatorFeedback鼓励操作员反馈EstablishesAccountability建立责任制,13,Copywrite2005byDaimlerChrysler,2020/5/18,EXAMPLE:LPAFREQUENCYANDSTRUCTURE举例：逐层过程审核频率与结构,14,Copywrite2005byDaimlerChrysler,2020/5/18,Example:FrequencyChartComplianceMatrixforSupervisors举例:主管执行频次矩阵图,Note:ExampleIllustratesthat3rdShiftNotBeingAuditedPertheRotationMatrixUnacceptableCondition!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!,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.,15,Copywrite2005byDaimlerChrysler,2020/5/18,WeeklyAuditRotation9WeekstoRotateThroughall9ProductionLines周审核循环9周内循环审核所有9条生产线,PLANTMANAGER,Example:FrequencyChartComplianceMatrixforPlantManager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,用差号标明已经完成了审核.,16,Copywrite2005byDaimlerChrysler,2020/5/18,LPAChecklistDevelopment,17,Copywrite2005byDaimlerChrysler,2020/5/18,LPA检查表的制定,18,Copywrite2005byDaimlerChrysler,2020/5/18,LPAChecklistDevelopment,19,Copywrite2005byDaimlerChrysler,2020/5/18,LPA逐层检验清单的制定,20,Copywrite2005byDaimlerChrysler,2020/5/18,DevelopAuditChecklist.制定审核检查表,-ProcessControlAuditChecklist.过程控制审核检查表-Error&MistakeProofingVerificationAuditChecklist.防错防误验证审核检查表Consider:考虑到:Questionsmustbeconciseandspecific.提问必须简明具体Phrasequestionssoa“no”alwaysindicatesanonconformance.使用简单提问,使用“不”来表明一个不符合.Questionsshouldincludecompleteidentificationofoperation,equipment,documentation,etc提问应该包含对操作、设备、文件等的完整说明。Reactiontonon-conformancesmustassureimmediateresponse.对不符的响应速度必须及时。,21,Copywrite2005byDaimlerChrysler,2020/5/18,MakingQuestionsSpecific(Example#1)使问题具体(举例#1),InitialQuestion最初提问:InspectionLogBook:Lookandseeifthelogisbeingfilledoutproperlyandchecksarebeingmade.检验记录书:检查记录是否填写正确,同时是否完成了检验.ImprovedQuestion改进提问:InspectionLogBook:VerifyQAFM250092isbeingfilledoutwithdate,shift,badge,andinitialsandchecksarebeingmade.(MissingorIncorrectdatacouldresultinincorrectunitsbeingheldintheeventofacontainment.)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?,22,Copywrite2005byDaimlerChrysler,2020/5/18,MakingQuestionsSpecific(Example#2)使问题具体(举例#2),InitialQuestion最初提问:PistonRetainerInstall:Istheoperatorapplyinggreasetothegasket?(Absenceofgreasecouldresultinagasketfailure.)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.)ImprovedQuestion改进提问:InspectionLogBook:IstheoperatorusingthegreasedispensertoapplygreasetotheL/Rgasket?(Absenceofgreasecouldresultinamiss-locatedgasketandleaktesterrejectorawarrantyfailure.)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.),23,Copywrite2005byDaimlerChrysler,2020/5/18,CustomerReview&Approval客户审核与批准,YourCustomershallreview&approveLPAPlanwithsupplier(RequiredonlyforHigh&MediumRiskParts)priortothePSOvisit.Forlowriskparts,suppliersshallapprovetheirownLPAplan.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。TheLPAPlanshallinclude(ataminimum)LPA计划应至少包括：LPARoll-OuttimingplanLPA滚动计划Frequency/Schedule&StructureChart频次/计划与结构图AuditorTrainingPlan审核员培训计划Checkliststhatincludeanarea/sectionforenteringimmediatereactionplan(s)包括实施迅速反应计划的区域/部分的检查清单Non-conformancecorrectiveactionprocedure对不符合的更正行动程序ScheduleofmanagementreviewsforLPAresultsLPA结果的管理检查进度ProvisionsforeventualLPAcoverageofallpartsproducedatsupplierslocation在供应商地点生产的所有零件的最终LPA范围的规定,24,Copywrite2005byDaimlerChrysler,2020/5/18,AuditorsmustunderstandLPAstrategyandpurpose.审核员必须理解LPA策略和目的。Reviewchecklistandreactionswithauditors.和审核员共同分析检查清单和反应计划。Auditorsmustknowtorespondimmediatelyafterfindinganonconformance.审核员必须在发现一个不符合时快速作出响应。EMPVAuditorsshallbequalifiedtoperformerrorandmistakeproofingverification.EMPV审核员具备执行防错防误验证的资格。Performapracticeauditwhereappropriate.在适用的时候执行一次审核实践。,OncetheLPAplanisapproved,theSuppliershalltraintheirLayeredProcessAuditors.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,TrainAuditors培训审核员,25,Copywrite2005byDaimlerChrysler,2020/5/18,NotifyWorkforce通知操作工人ExplainwhytheLPAisbeingimplemented.解释为什么LPA在被执行。ExplainthepurposeandbenefitsoftheLPAprocess.解释LPA程序的目的和益处。InformworkforceofLPAactivityandwhattoexpectwhenauditsareperformedintheirworkareas.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。Encourageworkforcefeedback.鼓励操作工人进行反馈。CommunicateLPAresultsfrequently.经常对LPA的结果进行交流。,26,Copywrite2005byDaimlerChrysler,2020/5/18,BeginAudits开始审核Reviewauditresultsfrequentlywhenstartingprocess.在启动程序的时候经常对审核结果进行回顾。Improveauditchecklistbasedonauditorfeedback.根据审核员的反馈来改进审核检验表。Managementmustinstilldisciplineearlyintheprocesstocompleteauditsontimeandprovideresourcesforimmediatecorrectiveaction.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。Duringearlyphase-Managementauditswillfindproblems,butlatermanagementauditswillfindimprovements.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。-DevelopandapplyLessonsLearnedtoimproveaudit.-制定并运用吸取的教训来改进审核。,27,Copywrite2005byDaimlerChrysler,2020/5/18,CorrectiveactionsshallbedocumentedasrequiredbyISO/TS更正行动应该按照ISO/TS的标准进行文件记录.Theremustbeasystemtomaintaintheauditscheduleandtrackcompletion.必须有一套系统来保证审核进度和跟踪它的完成.ImprovementsdrivenbytheLPAprocessshallbemeasured,monitored,andreportedtomanagementasperChryslerGroupTSCustomerSpecifics(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。,DevelopaMonitoringProcessandReportsforManagementReview.制定一个监控流程并为管理层评审提供报告Develop制定:-CorrectiveActionRequestformsfornonconformnces为不符合制定更正行动要求表格.-Summaryofauditresults:Paretoofnonconformances审核结果总结:不符合的Pareto图.-Summaryofon-time/missed/lateauditcompletion按时/忘记/延迟审核完成后的总结-Frequencyformanagementreview管理层检查的频率-ManagementreactionplanforLPAprocess管理层对LPA过程的反应计划.,2