伟世通分层审核培训课件

1、Layered ProcessAudits分层审核1LPA Training Revision 2 (February 2007)Driven by demands for zero defects and aggressive cost-reductions, the need for control of manufacturing processes has never been greater, especially in the automotive industry. In todays business environment suppliers cannot rely on i

2、nspection of parts and remain cost competitive. Instead, the focus is swinging to the basics of proactive process control, for both automatic and human-dependant tasks. Murray Sittsamer, The Luminous Group 受到零缺陷和大幅度成本降低要求的驱使，对于制造过程控制的需求变得空前强烈，尤其是在汽车工业。在当今的商业环境中，供应商不能依靠零部件的检查并保持价格的竞争力。相反，不论是自动化生产还是手工

3、制造，工作的核心内容正在朝前期过程控制的基础转移。 默里 斯特赛默，Luminous 公司2LPA Training Revision 2 (February 2007)What is a Layered Process Audit?什么是分层审核？3LPA Training Revision 2 (February 2007)The Layered Process Auditis a tool that:分层审核是一个工具：Reduces variation (both assignable and common cause) 减少变差（包含指定的和一般的原因）Prevents proces

4、s errors and operator mistakes 预防过程中的错误和操作失误Improves and maintains discipline 改进和维护工艺要求Initiates Continuous Improvement actions 启动持续改进措施Reduces rework 减少返工Reduces scrap and eliminates waste 减少废料和消除浪费Improves communication 加强交流Instills and improves standardization 逐渐加强和改进标准Improves overall Quality an

5、d reduces cost. 提高整体质量和降低成本Meets Customer Requirements 满足客户的需求4LPA Training Revision 2 (February 2007)Layered Process Audits (LPA):分层审核：A Layered Process Audit is a quality improvement process involving multiple layers of management. Key process & product characteristics are audited more frequently

6、to verify process conformance.分层审核是一项由多个层次管理人员参与的质量改进过程。关键过程特性和产品特性将会被经常审核，以验证过程的符合性。It consists of regularly scheduled reviews of all elements in a manufacturing/assembly process to ensure that: 分层审核对制造业/装配过程所有要素进行定期评估， 以确保：Equipment is being properly maintained.设备被适当的维护。Error proofing is working.

7、防错装置正常运行Proper craftsmanship and/or build techniques, from standardized work instructions, are being followed. 标准化工作指导书中规定的工艺或技术要求被正确执行。Ensure continuous conformance thereby improving process stability and first-time through capability. 确保连续的符合性，以提高过程的稳定性和首次通过合格率。5LPA Training Revision 2 (February 2

8、007)Why perform Layered Process Audits?为什么要实施分层审核？Reduce errors, reduce scrap, increase first time through and therefore reduce cost. 减少失误、降低报废，增加首次通过合格率，从而降低成本。Encourage work process standardization. 鼓励工作过程的标准化。Reinforce key process steps, including customer requirements. 增强关键过程工序控制，包括顾客的需求。Increas

9、e interaction between plant management and line operators. 加强工厂管理和流水线操作员间可交换性。Improve product quality + customer satisfaction. 提高产品质量和顾客满意度。To become or remain ISO/TS 16949:2002 certified, suppliers must meet all of the Customer Specific Requirements. 获得或保持ISO/TS 16949:2002的认证，供应商必须满足所有的顾客特殊需求。6LPA

10、Training Revision 2 (February 2007)Chrysler (DCX)Customer Specific Requirements克莱斯勒顾客特殊要求7LPA Training Revision 2 (February 2007)DaimlerChrysler (customer group) Customer-Specific Requirementsfor use with ISO/TS 16949 Second edition (July 2004)戴姆勒克莱斯勒（客户部）顾客特殊需求与ISO/TS 16949 第二版（2004.7）一起使用4.2.1.9.1

11、 Layered Process Audits4.2.1.9.1 分层审核Organizations supplying Components to DaimlerChrysler Powertrain and component Manufacturing Plants shall conduct Layered Process Control Audits on all manufacturing and assembly lines that produce components for DaimlerChrysler. These shall include all error-pro

12、ofing operations. 为DCX动力总成和零部件制造厂供应配件的组织应该启动分层审核，并且在为戴姆勒克莱斯勒制造产品的所有生产和装配线上实施。分层审核应覆盖所有的防错工序。Organizations shall provide evidence of compliance to the following requirements: 组织应提供以下要求的符合性证据：Audit process SHALL involve multiple levels of management, from line supervisor up to top management. 审核过程应包括多

13、个管理层次，从线上主管到高层管理者。Top management at the plant SHALL conduct process control audits at least once per week. Delegation of this activity will not be accepted with the exception of extenuating circumstances. 工厂的最高管理者应至少每周一次进行过程控制审核，除非情有可原，否则不允许授权给他人。Note: Effective January 2005, all production supplier

14、s will be required to comply with LPA which will become a prerequisite for obtaining PSO (process sign-off) approval. 提示：从2005.1开始，所有的产品供应商必须完成分层审核工作，这将成为获得PSO认可的必要条件。8LPA Training Revision 2 (February 2007)Chrysler (DCX)克莱斯勒（DCX）The organization SHALL have a documented audit structure with auditor

15、level and frequency of inspection (Ref. VF-213e). 组织应制定书面的审核程序，明确审核员标准及审核频次要求。（参考 VF-213e）Process control audits SHALL be conducted at least once per shift for build techniques and craftsmanship related processes. 对与工艺技术相关的过程控制审核应至少每班进行一次。Error Proofing Audits SHALL be conducted at least once per sh

16、ift, preferably at the start of each shift. 防错验证审核应每班至少进行一次，最好在每班开始时进行。Compliance charts SHALL be completed quarterly and maintained for the life of the program (Ref. VF-213d): 审核监控图应每季度总结一次，并在项目生命周期内进行维护(参考 VF-213d)：The following metrics should be included: 以下内容应被包含：Audit completion by all auditing

17、 layers 审核工作由所有层面审核完成By-Item percentage conformance by area 按区域的条款通过百分比9LPA Training Revision 2 (February 2007)Examples of Compliance Charts (VF-213d):监控图实例（VF-213d）：10LPA Training Revision 2 (February 2007)DCXReaction plans SHALL be in place to immediately resolve all nonconformities (Ref. VG-213b)

18、. 反应计划必须及时解决所有的不符合项目(参考 VG-213b)。The organization SHALL show evidence of immediate corrective action, containment (as required), and root cause analysis (as required)(Ref. VF-213b). 组织应迅速制定反应计划，必要时实施遏制措施并进行根本原因分析。（ 参考 VF-213b ）。A Communication Procedure is required to address reoccurring nonconformi

19、ties. Specific areas of focus shall include the following (local proforma): 应确定沟通过程以防止不符合项重复发生。以下内容应被重点关注（本地格式）：Resolution of nonconformities 不符合项的解决Escalation of issue for management review 扩大管理评审关注点Lessons learned 经验教训总结11LPA Training Revision 2 (February 2007)DCXSuppliers SHALL monitor/measure im

20、pact of LPA on business metrics. 供应商应监控/测量分层审核运行的商务效果。Suppliers SHALL upload in Powerway Quality Gate Z the deliverable “Layered Process Audit Results” and provide supplier opinion(s). (Red, Yellow, Green) Results shall be updated quarterly. 供应商应将可交付的分层审核结果上载到Powerway Quality Gate Z ，并提供供应商的意见。（红，黄，

21、绿）结果应每季度更新。Supplier Quality specialist SHALL review LPA as part of corrective action(s) for quality spills. 供应商质量专家应对分层审核进行评审，作为质量问题改进措施的组成部分之一。Removal of a checklist item SHALL be approved by a Supplier Quality Specialist. 检查清单条款的删减应获得供应商质量专家的认可。12LPA Training Revision 2 (February 2007)General Moto

22、rsCustomer Specific Requirements通用汽车顾客的特殊需求13LPA Training Revision 2 (February 2007)GMLayered Audits SHALL be conducted for manufacturing and assembly of high risk items at a minimum of once per shift. 对于制造和装配高风险零件的单位，分层审核应至少每班进行一次。Frequency of Layered Audits for other processes should be based on p

23、roduction volumes or level of risk associated with processes (Ref. VF-213e). 其它过程的分层审核频次应以产量或过程风险水平为基础(Ref. VF-213e).。Layered Audits will supplement ongoing control plan and job instruction checks. 分层审核作为对正在进行的控制计划和工作指导书检查的补充。A checklist of high risk items to be verified during Layered Audits shall

24、be established (Ref. VF-213c). 建立分层审核时应对高风险的项目检查清单进行验证(Ref. VF-213c)。Layered Audit results SHALL be recorded. 分层审核的结果应记录。Non-conformities SHALL be addressed immediately. 不符合情况应立即汇报并：Immediate containment 立即的遏制行动24 hours for corrective action 24小时内实施纠正措施Corrective actions SHALL be documented (Ref. VF

25、-213c). 纠正措施应书面化并备案(Ref. VF-213c)。Results shall be summarized and reviewed by manufacturing site leadership. 审核结果应进行总结并提交生产部门管理层评审。Elements should be considered in developing the check list. 审核要素应在开发检查清单的过程中得到确认。14LPA Training Revision 2 (February 2007)Typical Audit Elements 典型的审核要素Machining/Robotic

26、s - Automation driven processes: 设备/机器人自动化控制过程：Preventive Maintenance tasks 预防性维修任务Calibration of gages 量具的校正Technical parameters 技术参数Set-up procedures being followed 建立需遵守的程序Machine settings 设备设定Process sheets 过程参数卡Tool change verification 工具变更确认Positioning of coolant lines 冷却线的设置Pattern of shot bl

27、ast or deburr 喷砂处理或清除毛刺的模式Die coloration 上色Gage plan being followed 量具计划Sample part retention 零件样本Documentation of gage checks 量具验证文件SPC data capture and charting 统计过程控制的数据获取和图表Mastering of gages 量具控制Error & mistake proofing nonconformance testing 防错装置的不符合性测试15LPA Training Revision 2 (February 2007)

28、Audit Elements, cont. 审核要素（续）Assembly/Fabrication - manually dependant processes 装配/工装手工操作过程Craftsmanship 工艺Operation movement 操作运行Proper product identification 正确的产品识别Presence and content of instructions 指导书内容Presence and content of visual aids 目视样本内容Sustainment of 5S workplace 5S车间维护Touchpoint ins

29、pections 触摸板检查Checking of customer used features 对顾客以往信息的确认Use of manual assists 手工辅具的使用Packing and stacking techniques 包装和堆放条件Placement of labels 标签的放置Calibration of gages 量具的校正Inspection plan being followed 相关的检查计划Torque monitoring 扭矩控制Completion of documentation 文件的制定Error & mistake proofing nonc

30、onformance testing 防错装置的不符合性实验16LPA Training Revision 2 (February 2007)GMLayered Audit documentation SHALL be compiled in the Lessons Learned (key strategy) database. 分层审核的文件应汇编在经验教训总结数据库中。Customer used features SHALL be identified, listed and checked in the manufacturing process with emphasis on: 在

31、制造过程中应对顾客以往信息进行鉴别、整理和检查，并强调： -Supplier pass through features 供应商认可信息-Mounting (holes, taps, etc.) 工装（打孔、攻丝等）-Electrical connections/connectors 电路系统/连接器 -Mounting surfaces 工装表面-Clearances 间隙 -Missing/wrong brackets 丢失/放错的支架-Incorrect parts 失效的零件 -Others as identified by customer 其他顾客确认的内容17LPA Traini

32、ng Revision 2 (February 2007)Requirements伟世通要求18LPA Training Revision 2 (February 2007)Effective25 January 2007all Visteon sitesmust conductLayered Process Audits.2007年1月25日伟世通所有工厂必须实施分层审核19LPA Training Revision 2 (February 2007)There are two types of Layered Process Audits:分层审核的两种形式：Process Control

33、 Audits过程控制审核 Error & Mistake Proof Verification Audits 防错验证审核20LPA Training Revision 2 (February 2007)Process Control Audits过程控制审核Process control audits must be performed at least once per shift by the supervisor 主管每班至少进行一次过程控制审核Plant management shall perform the audit once per week. 工厂管理层需每周进行一次21

34、LPA Training Revision 2 (February 2007)Process Control AuditsAuditors must know the process 审核员必需懂工艺Develop and use a process control audit checklist (Ref. VF-213c). 建立并使用审核检查表（参见VF-213C）Process control based upon top 5 RPNs 过程控制基于RPN值最高的5个项目Address high risk items 主要为高风险的项目Audit items are issues th

35、at would cause Customer dissatisfaction 审核项目为会引起顾客不满意的项目Process controls must link with PFEMA, Control Plan and Work Instructions 过程控制必需与PFMEA、控制计划和作业指导书链接Check that all logs, checklists & data reports are used when required and required when used必要时检查所有的日志、检查表和正在使用的数据报告Verify all set-up parameters

36、验证所有参数Know the process operations, materials, equipment and testing required, confirm use 了解操作过程、材料、设备和所需要的试验，确认使用Know all inspection checkpoints 了解所有检验站Verify barcode tags or tickets made at operation 验证条形码标签或操作中使用的标识22LPA Training Revision 2 (February 2007)Error & Mistake Proofing Verification Aud

37、its防错验证审核Verify effectiveness of error & mistake proofing 防错的有效验证Assure capability to stop defects 确保有能力消除缺陷Define countermeasures to assure quality 定义确保质量的措施Performed only by qualified individuals 有资质的人员实施Must be performed at least once per day 至少每天实施一次23LPA Training Revision 2 (February 2007)Error

38、 & Mistake Proofing Verification Audit guidelines防错验证审核概要Check all mistake proofing devices at least once per day 每天至少一次检查所有防错装置Check all critical mistake proofing devices at least once per shift 每班至少一次检查所有主要防错装置Send a known nonconforming part through the system or device发送一个已知不合格的零件通过该系统或装置Send a k

39、nown conforming part through the system or device发送一个已知合格的零件通过该系统或装置Document checks on a checklist or log 在检查清单或日志上将检查内容书面化Check all error proofing检查所有防错设施Check all mistake proofing检查所有防错系统Check all proofing devices that may fail or wear检查所有可能失效或磨损的防错装置Check all devices for misalignment or misalloca

40、tion检查所有未校准或未调整的设施Check that all devices have not been switched off or disabled检查所有未切断或未失效的设施Check that devices cant be by-passed or removed检查所有使用的设备24LPA Training Revision 2 (February 2007)Who performs Layered Process Audits?谁来实施分层审核Anyone can be a Layered Process Auditor. 任何人都可以是分层审核员All managers,

41、 regardless of function, can be auditors. 所有经理（无论是什么部门）都可以是审核员Manufacturing Management must own the LPA process and perform audits. 制造经理必须是分层审核的过程所有者，并实施审核Each management level should perform audits (Ref. VF-213e). 各管理层都需要实施审核（参见VF-213e）The manufacturing supervisor SHALL verify (daily) all quality d

42、ocumentation is completed by operators. 制造主管必须每天验证所有的质量文件都被实施The manufacturing area manager SHALL verify (weekly) that supervisor verification is being completed. 制造区域经理必须每周验证主管的验证是否已完成Site leadership SHALL conduct layered audits at a frequency defined locally. 工厂领导必须以一定的频次在本厂内指导分层审核25LPA Training R

43、evision 2 (February 2007)Visteon requirements: 伟世通要求Each Plant SHALL每个工厂必须：Have a documented audit structure (Ref. VF-213e)有一个文件化的审核机构（参见VF-213e）Conduct daily process audits of all areas 指导所有区域的日常过程审核Conduct daily error & mistake proofing audits指导防错审核Document all audits 审核文件化Have compliance charts (

44、Ref. VF-213d)有图表（参见VF-213d）Have reaction plans to resolve all nonconformities (Ref. VG-213b)有反应计划解决所有不符合项（参见VF-213b）Be able to show evidence of immediate corrective action, assignable root cause analysis (containment immediately) and corrective action plan within 24 hours.能出示快速纠正、根本原因分析和在24小时内制定纠正措施

45、计划的证据Have a communication procedure and documentation for resolution of nonconformities, escalation of issues for management review, and local lessons learned database建立沟通的程序文件，解决不符合项，扩大管理评审关注焦点，并完善本地的经验教训总结数据库。Have a checklist of high risk items to be verified during audits (Ref. VF-213c)有一张高风险项目的检

46、查表，并在审核中得到验证（参见VF-213c）Have documentation of results reviewed by leadership 领导评审结果文件化Identify customer used features listed and checked in the manufacturing process识别顾客使用的特性清单，并在制造过程中检查26LPA Training Revision 2 (February 2007)How to begin如何开始Plan 策划Do 实施 检查Adjust调整27LPA Training Revision 2 (February

47、 2007)PLAN策划Form a team to develop the checklist组成工作小组制定计划The team shall be Cross Functional :工作小组成员来自以下职能部门:Manufacturing, Quality, Engineering, Maintenance, etc 生产、质量、工程、维护.等The team shall be multi-level:工作小组成员应来自各个层面：Managers, Supervisors, Inspectors, Operators 经理、主管、审核员、操作工28LPA Training Revisio

48、n 2 (February 2007)1st Layer of Management LPA Checklist LPA检查清单管理第一层次Yes是No非N/AImmediate Reaction迅速的反应计划Date Closed关闭日期Plant Specific Issues:工厂重点关注：Is Assembly Operator at Station 30 crimping part properly? (example)装配操作工在第30工序的卷边操作是正确的吗？（举例）Process/Operator Checks:过程操作工检查：Are Operators following p

49、osted work Instructions at all stations? Are all operators following the process flow? Is the process following the Control plan?Are control plan checks being followed?Is the control plan linked to the PFMEA and Flow Chart and vice versa?Are the operators aware of Quality Alerts? Are Quality Alerts

50、easily identified?Is the Quality Alert current? (Expiration date -30 days)Is Versatility/Training Matrix current? (Check All)Are all operators trained to perform the job they are doing per vers matrix?HOUSEKEEPING:事务Are parts in their proper location? (In process or work in progress)Are operators wo

51、rking at the proper line speed (not ahead)?Are purchase parts at the area appropriately labeled and in their own containers so as not to cause mixed/wrong stock?Are there “spare fasteners” lying on the floor? (Possibly indicating a process/engineering problem and which may also lead to “bonus parts”

52、)Are nonconforming parts tagged? Is the repair area clean and organized with minimal repairs and scrap?Are end items in their proper storage locations?TEAM BOARDS:Is the team board up to date? Is there evidence of operator input, suggestions, ideas?Are team boards easy to read/understand and relevan

53、t to operator/associate?Are the quality objectives posted? Are they at the team level?Is performance vs. objective visible?Do metrics include external customer and internal performance?Are Trend Paynter Pareto (TPP) utilized?Are Trend Paynter Pareto (TPP) posted?POKA-YOKES:Are all poka-yokes working

54、?所有的防错装置都在工作？If poka-yokes are by-passed, are there actions to contain potential quality escapes?Has the root cause for bypassing been determined?Are operators aware of the poka-yoke and the risk of bypassing? Is there evidence that the poka-yokes are being verified each shift?Are rabbits available

55、and causing all expected errors/faults?Does the operator know what to do when the poka-yoke doesnt work?当防错装置失效时，操作工是否知道如何处理？Is the poka-yoke reaction plan in the control plan?防错的反应计划是否体现在控制计划中？Is the poka-yoke reaction plan available to the operator?防错的反应计划对操作工是否有效？Audited By:审核：Shift:班次123DATE:日期A

56、uditor Title:审核员签字Corrective Action/Root Cause Analysis:纠正措施/根本原因分析29LPA Training Revision 2 (February 2007)PLAN策划Develop a LPA plan to include (at a minimum):建立LPA计划，其中至少包括：LPA roll-out timing plan分层审核滚动计划Frequency/Schedule & Structure Chart (Ref. VF-213a)审核频次/日程及机构图（参考VF-213a）Auditor Training Plan

57、审核人员培训计划Checklists检查表Nonconformance Reaction Plan (Ref. VG-213b)不符合项反应计划Schedule of management reviews for LPA results分层审核结果的管理评审计划30LPA Training Revision 2 (February 2007)Reference VF-213b参考VF-213b31LPA Training Revision 2 (February 2007)Reference VF-213e参考VF-213e32LPA Training Revision 2 (February

58、 2007)PLAN策划Develop an Action Plan to identify all implementation steps制定行动计划确定实施步骤Identify where to begin implementation - which processes or manufacturing areas? (Ref. VG-213a)确定从哪个过程或生产区域开始实施？（参考VG-213a）The area of highest risk should be the first area audited风险最高的区域应首先被审核Consider customer compla

59、int history考虑以往的客户抱怨Process stability过程稳定性First-time through capability首次通过合格率High RPN values高RPN值Operator influences操作工影响Error Proofing/detection防错/检测This area will also be used as a Lessons Learned for implementing the Layered Process Audit across the entire manufacturing facility.该区域也将为在整个工厂内实施分层

60、审核提供经验教训33LPA Training Revision 2 (February 2007)PLAN (ref. VG-213a)策划（参考VG-213a）Review Process Steps评审过程工步Review Quality Metrics评审质量矩阵Review Customer complaints: Quality alerts, Written concerns, First-time through data, scrap reports评审顾客抱怨：质量预警，书面投诉、首次通过合格率、废品损失报告Review Work Instructions评审作业指导书Rev