LPA(逐层过程审查)

1、Copywrite 2005 by DaimlerChrysler,1,Layered Process Audit (LPA) 逐层工艺审查(LPA),SQAP 供应商质量保证程序,Copywrite 2005 by DaimlerChrysler,2,Supplier Interface LPAs will be Mandatory 供应商接口-逐层工艺审查是被强制性的,ISO/ TS 16949 DaimlerChrysler Customer Specific Requirements 戴姆勒-克莱斯勒用户特别要求 New section under Internal Audits 正对

2、新章节进行内部审查 Effective 7/01/04 for Powertrain 对传动系及其零部件的供应商于7/01/04日开始执行； 1/1/05 for all remaining suppliers 对所有其余的供应商于1/1/05年开始执行 Posted on AIAG, IAOB, and QMS web sites 在AIAG， IAOB， 和QMS网站上发布 Letter mailed to all suppliers 信函已经发给了所有的供应商,SQAP,Copywrite 2005 by DaimlerChrysler,3,What Are Layered Proces

3、s Audits? 什么是逐层过程审查?,There are two Types of Layered Process Audits: 有两种逐层过程审查: Process Control Audits 过程控制审核 Error & Mistake Proofing Verification Audits 防错防误验证审核,Layered Process Audits (LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited f

4、requently to verify process conformance. 逐层过程审查(LPA)是由多个管理层进行的系统审查。对关键程序特征进行经常性的审核来确认过程性能。,The purpose of Layered Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. 逐层过程审查的目的是确保连续性能，从而改善过程稳定和一次通过率。,SQAP,Copywrite 2005 by DaimlerC

5、hrysler,4,What is a Layered Process Audit (LPA)? 什么是逐层过程审查（LPA）？,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. 逐层过程审查确保被选择的方法和工作指令被运用， 确保问题解决方案在使用中， 所有工艺问题都被确定并被迅速更正。,LPA

6、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. 逐层过程审查是一项持续的工艺检验系统， 用来验证正确的方法、 设置、 操作员技能、防错措施和其他确保避免次品产生的办法。,SQAP,Copywrite 2005 by DaimlerChrysler,5,Who Perform

7、s Layered Process Audits? 谁执行逐层过程审查？,Anybody can perform a Layered Process Audit. 任何人都能够执行逐层过程审查。 Manufacturing management must own the process and perform audits. 制造管理部门必须拥有此程序并执行审查。 All managers, regardless of function, can be auditors. 所有经理，无论他的职责是什么， 都可以作为审查员。 Each management level should perfor

8、m audits. 每个管理层都应该执行审查。 Process Control Audits shall be performed once per shift by supervisors. Plant management shall perform the audit once per week. 过程控制审查应该在每班生产时由车间主管进行一次审查。工厂管理应该在每周执行一次审查。 Error & Mistake Proofing Verification audits shall be conducted once per shift. Only qualified employees

9、 shall perform Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usually qualified. 防错防误确认审查应该在每班生产执行一次。仅仅应该由具备资格的人员进行防错防误确认审查。 建立、维护或质量审查员通常是具备资格的人员。,SQAP,Copywrite 2005 by DaimlerChrysler,6,Cost of Non-Conformances at Various Points,Defect found at: The Next En

10、d of Final End Users Source Process Line Inspection Hand *Very minor *Scrap *Repair *Significant Rework *3rd Party Containment *Minor Delay *Containment *Additional Operations *Premium Freight *Rework *Overtime *Administrative costs *Reschedule *Delay in delivery *Warranty Costs of Work *Added inspe

11、ction *Reputation *Lost market share *Lost business Note: Taken from “Layered Process Audits”, The Luminous Group, LLC,Early Detection / Prevention,SQAP,Copywrite 2005 by DaimlerChrysler,7,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 线末尾 最终检验 最终用户的手里 *非常小 *划伤 *修理 *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

12、班 *管理成本 *重订工作计划 *延时发货 *质量保证成本 *增加检验次数 *声誉 *失去市场占有率 *失去业务 Note: Taken from “Layered Process Audits”, The Luminous Group, LLC,早期检测 / 预防,SQAP,Copywrite 2005 by DaimlerChrysler,8,LPA Benefits 逐层工艺审查的优点,Safety regulations 安全法规,Reinforces 加强,Facilitates 简化,Operator training 操作员培训 Management/operator inter

13、face 管理/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,SQAP,Copywrite 2005 by DaimlerChrysler,9,LPA Success at Kokomo Transmission Plant 逐层过程审查在KoKoMo变速箱厂的成功运用,Repa

14、ir Inventory vs First Time Capability vs LPA 对比： 修理库存/一次通过率/逐层工艺审查,SQAP,Copywrite 2005 by DaimlerChrysler,10,Layered Process Audit 逐层过程审查,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） Lo

15、w investment significant quality return 低投资 获得显著的质量回报,SQAP,Copywrite 2005 by DaimlerChrysler,11,How does an LPA Work? 逐层过程审查是如何工作的？,PROCESS 工艺(过程/程序),Error Proofing 防错,Process Audits 工艺审查,Audits are conducted regularly by all levels of supervision 各监督级定期地进行审查 Non-conformances are immediately address

16、ed 立即发现不符合处,LAYERED PROCESS AUDITS ARE PROCESS BASED, NOT PART BASED.,逐层过程审查是基于程序的,而不是基于零件的,SQAP,Copywrite 2005 by DaimlerChrysler,12,Developing the Plan 制定计划,Form a LPA Team to implement the audit process 成立一个逐层审查团队 实施审查 Develop procedure for LPA Process and Documentation 为LPA程序和文件制定程序 Develop audi

17、t checklist. 制订审查清单 Based on Key process elements that affect part quality 根据影响零件质量的关键过程要素， Determine who will conduct audits. 确定谁来执行审查。 Determine audit frequency for each level (Process Control Audit and Error & Mistake Proofing Verification Audit). 为每个级别（过程控制审核与防错防误确认审查）确定审查频次 Develop a monitoring

18、 process and reports for management review. 制定一个监控程序并向管理部门汇报。,SQAP,Copywrite 2005 by DaimlerChrysler,13,Identify Where to begin LPA Implementation 确定从哪里开始实施LPA审查 Review 审查: Customer Complaints, Quality Alerts 客户抱怨，质量预警 First-Time Through data, Scrap Reports 一次通过数据，废品报告 Key Characteristics and Proces

19、s Capability: Cpk & Gage R&R 关键特征和过程能力：CPK与R&R PFMEA, Process Flow Diagram, Control Plan PFMEA，工艺流程图，控制计划 Set-up Sheets, Work Instructions, Inspection Instructions 制定表格、操作指导书、检验指导书 Error and Mistake Proofing 防错防误 Quality System Audits, Dock Audits, Inspection Reports 质量系统审查，货场审查，检验记录 Rework instruct

20、ions 返工指导书,The Area of Highest Risk should be the first area to implement the Layered Process 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 Layered Process Audit across the entire manufacturing facility. 此区域也可以被作为整个制造厂学习如何实施逐层审核的用途。 Use Discretio

21、n 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. 审查项目是那些导致客户不满的问题。,SQAP,Copywrite 2005 by DaimlerChrysler,14,LPA - Frequency Plan 逐层工艺审查-频率计划,Encourages Management Involvement 鼓励参与管理 Encourages Operator Feedback 鼓励操作员反馈 Establ

22、ishes Accountability 建立责任制,SQAP,Copywrite 2005 by DaimlerChrysler,15,EXAMPLE: LPA FREQUENCY AND STRUCTURE 举例： 逐层工艺审查频率与结构,SQAP,Copywrite 2005 by DaimlerChrysler,16,Example: Frequency Chart Compliance Matrix for Supervisors 举例: 主管频次图符合排列,Note: Example Illustrates that 3rd Shift Not Being Audited Per

23、the Rotation Matrix Unacceptable Condition! 注意: 例子显示, 在第三班生产中没有进行审查 不可接受的条件!,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查. 在你工作的那班中,用差号标明已经完成了审查.,SQAP,Copywrite 2005 by DaimlerChrysler,17,Weekly Audit Rotation 9 Weeks to Rotate Through all 9 Production Lines 周审查轮流进行 9周内轮流审查所有9条 生产线,PLANT MANAGER,Exa

24、mple: Frequency Chart Compliance Matrix for Plant Manager 举例: 工厂经理频率图符合组合,工厂经理周LPA检查计划安排表,每条线轮流在每9周进行一次审查. 在上面表格中, 用差号标明已经完成了审查.,SQAP,Copywrite 2005 by DaimlerChrysler,18,LPA Checklist Development,SQAP,Copywrite 2005 by DaimlerChrysler,19,LPA 逐层检验清单的制定,SQAP,Copywrite 2005 by DaimlerChrysler,20,LPA C

25、hecklist Development,SQAP,Copywrite 2005 by DaimlerChrysler,21,LPA 逐层检验清单的制定,SQAP,Copywrite 2005 by DaimlerChrysler,22,Develop Audit Checklist. 制定审查检验清单,- Process Control Audit Checklist. 过程控制审查检查清单 - Error & Mistake Proofing Verification Audit Checklist. 防错防误验证审查检验清单 Consider: 考虑到: Questions must b

26、e concise and specific.提问必须简明具体 Phrase questions so a “no” always indicates a nonconformance. 使用简单提问, 使用“不”来表明一个不符. 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 immediate response. 对不符的响应速

27、度必须及时。,SQAP,Copywrite 2005 by DaimlerChrysler,23,Making Questions Specific (Example #1) 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: V

28、erify QAFM250092 is being filled out with date, shift, badge, and initials and checks are 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 ?,

29、How如何 ?,Why 为什么?,SQAP,Copywrite 2005 by DaimlerChrysler,24,Making Questions Specific (Example #2) 使问题具体(举例#2),Initial Question 最初提问: 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.

30、) Improved Question 改进提问: Inspection Log Book: Is the operator using the grease dispenser to apply grease to the L/R gasket? (Absence 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.),S

31、QAP,Copywrite 2005 by DaimlerChrysler,25,Customer Review & Approval 客户审查与批准,Your Customer shall review & approve LPA Plan with supplier (Required only for High & Medium Risk 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检查并批准LPA计

32、划。(仅对高风险和低风险零件有此要求)。 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 plan LPA滚动计划 Frequency/Schedule & Structure Chart 频次/计划与结构图 Auditor Training Plan 审查员培训计划 Checklists that include an area/section for entering immediate reaction plan(s) 包括实施迅速反应

33、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 results LPA结果的管理检查进度 Provisions for eventual LPA coverage of all parts produced 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,SQAP,Copywrite 2005 by DaimlerChrysler,26,Auditors must understa

34、nd LPA strategy and purpose. 审查员必须理解LPA策略和目的。 Review checklist and reactions with auditors. 和审查员共同分析检查清单和反应。 Auditors must know to respond immediately after finding a nonconformance. 审查员必须在发现一个不符时快速作出响应。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV审查员应该为具

35、有资格的人士来执行防错防误确认。 Perform a practice audit where appropriate. 在适用的时候执行一次审查实践。,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工艺审查员,Train Auditors 培训审查员,SQAP,Copywrite 2005 by DaimlerChrysler,27,Notify Workforce 通知操作工人 Explain why the LP

36、A is being implemented. 解释为什么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。 Inform workforce of LPA activity and what to expect when audits are performed in their work areas. 当在工作地点执行审查时，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。 Communicate LPA re

37、sults frequently. 经常对LPA的结果进行交流。,SQAP,Copywrite 2005 by DaimlerChrysler,28,Begin Audits 开始审查 Review audit results frequently when starting process. 在启动程序的时候经常对审查结果进行检查。 Improve audit checklist based on auditor feedback. 根据审查员的反馈来改善审查检验表。 Management must instill discipline early in the process to com

38、plete 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，来按时完成审查并提供资 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- 管理层的审查将发现问题， 但是以后管理层的审查会发现改 进。 - Develop and apply Lessons Learned

39、 to improve audit. - 制定并运用吸取的教训来改进审查。,SQAP,Copywrite 2005 by DaimlerChrysler,29,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查进度和跟踪它的完成. Improvements driven by the LPA proc

40、ess shall be measured, 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，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. 制定一个检测流程并为管理层检查提供报告 Develop 制定: - Corrective Action Request forms for nonconformnces 为不符制定更正行动要求表格. - Summary of audit results: Pareto of nonconformances 审查结果总结: 不符合的Pareto图. - Summary of on-time/missed/late audit complet