LPA 培训资料.ppt

1、1,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Layered Process Audit (LPA) 逐层过程审核 (LPA) Element # 16 要素 #16,SQAP 供应商质量保证程序,2,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Layered Process Audit (LPA) 逐层过程审核 (LPA) Element # 16 要素 #16,Trainer: Charlie Che 培训人：车建福 Venue:

2、 Shanghai Real 地点：上海瑞尔 Time: Jan-9-2008 时间：2008.1.9,3,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Cost of Non-Conformances at Various Points,Defect found at: The Next End of Final End Users Source Process Line Inspection Hand *Very minor *Scrap *Repair *Significant Rework *3rd Part

3、y Containment *Minor Delay *Containment *Additional Operations *Premium Freight *Rework *Overtime *Administrative costs *Reschedule *Delay in delivery *Warranty Costs of Work *Added inspection *Reputation *Lost market share *Lost business Note: Taken from “Layered Process Audits”, The Luminous Group

4、, LLC,Early Detection / Prevention,SQAP,4,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,在各阶段发生的不符造成的成本,在以下阶段发现的缺陷: 源头 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 *加班 *管理成本 *重订计划 *延时发货 *保修成本 *增加检验次数 *声誉 *失去市场份额 *失去业务 Note: Taken from “Layered Process

5、 Audits”, The Luminous Group, LLC,早期探测 / 预防,SQAP,5,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Supplier Interface LPA is DC Mandatory Requirement供应商接口-逐层过程审核是戴克强制性要求,ISO/ TS 16949 DaimlerChrysler Customer Specific Requirements 戴姆勒-克莱斯勒用户特殊要求 New section under Internal Audits 正对新章节进

6、行内部审核 Effective 7/01/04 for Powertrain 动力总成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,LPA is a new Quality Tool.LPA是一项新的质量工具,6,Copyright 2007 by Daim

7、lerChrysler, Version 1.3 September 2007,Supplier Interface LPA is DC Mandatory Requirement供应商接口-逐层过程审核是戴克强制性要求,SQAP,Farmington Managers and Supervisors,Daimler Chrysler,7,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Objectives 目标,Knowledge 知识 Be able to explain the rationale behind

8、LPAs 能够描述LPA的基本原理 Be able to describe how to conduct LPAs 能够描述如何开展LPA Be able to describe the benefits of LPAs 能够描述LPA的益处 Skills 技能 Be able to to integrate LPAs into your plants quality system 能够将LPA纳入工厂的质量体系 Be able to develop LPA check sheet 能够制定LPA检查清单 Be able to conduct and LPA on the factory fl

9、oor 能够在工厂内开展LPA,SQAP,8,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,1. Layered Process Audit Plan 逐层过程审核计划,LPA Definitions and Requirements 逐层过程审核定义和要求 LPA Benefits 逐层过程审核的益处 LPA Plan LPA 计划,SQAP,9,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,What Are Layered Proces

10、s Audits? 什麽是逐层过程审核,Layered Process Audits (LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 逐层过程审核(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。,The purpose of Layered Process Audits is to ensure c

11、ontinuous conformance, thereby improving process stability and first-time through capability. (As required by Chrysler Group TS Customer Specifics (4.2.1.9.1) 逐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。( 见克莱斯勒TS用户特殊要求4.2.1.9.1),SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,10,Copyright 2007 by DaimlerCh

12、rysler, Version 1.3 September 2007,What is a Layered Process Audit? 什么是逐层过程审核,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

13、速纠正。,LPA 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、防误装置和其他输入是否到位从而确保产品无缺陷产生。,SQAP,LPA Definitions and Requirements

14、 逐层过程审核定义和要求,11,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,12,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,13,Copyright 2007 by DaimlerChrysler, Version 1.3 Septemb

15、er 2007,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,14,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,LPA Definitions and Requirements 逐层过程审核定义和要求,15,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,AGENDA 安排,1. Layered Process Audit Plan 逐层过程审核计划 Developing LPA Che

16、ck Sheet 制定LPA检查表 LPA Implementation 实施LPA 4. Monitor & Adjust Plan 监控与调整计划 Summary 总结,SQAP,16,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,There are three types of Layered Process Audits: 有三类逐层过程审核,Process Control Audits should be conduct on any process with customer complaint issu

17、es, high risk elements PFMEA and key characteristics that affect part quality. Process Control Audits shall be performed once per shift by supervisors. Plant management shall perform the audit once per week. 过程控制审核应在出现顾客抱怨的任何过程，PFMEA高风险要素以及影响零件质量的关键特性上开展。过程控制审核应该在每班生产时由车间主管进行一次审核。工厂管理应该在每周执行一次审核。 Er

18、ror & Mistake Proofing Verification audits shall be conducted on all error/mistake proofing techniques. They shall be conducted once per shift at the start of each shift. Only qualified employees shall perform Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usu

19、ally qualified. 防错防误验证审核应在所有防错防误技术上开展。应该在每班生产开始时执行一次。由具备资格的人员进行防错防误验证审核。 设置、维护或质量审核员通常是具备资格的人员。 Start up/ Shut Down LPA are aimed at exposing the common types of risk that occur during normal shut down and startup periods. The intent is to ensure that the plant management is aware of the risks, and

20、can take the appropriate actions to minimize the risks. 启动/终止生产LPA致力于暴露在正常的生产启动和终止期间发生的风险类型。目的是确保工厂管理层了解风险并能够采取适当的行动将风险最小化。,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,17,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,How does an LPA Work? 逐层过程审核是如何工作的？,PROCESS 过程,Error Proofing

21、 防误,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,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,18,Copyright 2007 by D

22、aimlerChrysler, Version 1.3 September 2007,Who Performs Layered Process Audits? 谁执行逐层过程审核？,Anybody can perform a Layered Process Audit. 任何人都能够执行逐层过程审核。 Manufacturing management must own the process and perform audits. 生产管理部门是该程序的归口部门并执行审核。 All managers, regardless of function, can be auditors. 所有经理，

23、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。,SQAP,LPA Definitions and Requirements 逐层过程审核定义和要求,19,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Improved process stability & reduce variation 改进过程稳定性及减少变差 Prevents process errors and operator mistakes 预

24、防过程错误和操作者错误 Improves and maintains discipline 改进和保持纪律 Initiates Continuous Improvement actions 引入持续改进行动 Lower Rework & Repair 返工返修减少 Reduces scrap and eliminates waste 减少废品和消除浪费 Improves communication 改善沟通 Instills and improves standardization 灌输和改进标准化 Improves overall Quality and reduces costs 全面提高

25、质量和降低成本 FTC in high 90% FTC 达到90% Initiates continuous improvement actions 启动持续改进行动 Early detection & prevention 早期探测及预防,SQAP,LPA Benefits 逐层过程审核的益处,20,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,LPA Benefits 逐层过程审核的益处,Safety regulations 安全法规,Reinforces 加强,Facilitates 简化,Operator t

26、raining 操作员培训 Management/operator interface 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 因工作标准化而使变差减少 End-of-line inspection 线尾检验 Part defects 零件缺陷,Reduces 减少,SQAP,21,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,LPA

27、 Success Story LPA 成功案例,The DaimlerChrysler Kokomo Transmission Plant 戴姆勒克莱斯勒的变速箱厂Kokomo has achieved significant gains in FTC using LPA. 运用LPA使FTC得到了显著的改进 FTC in the high 90% FTC达到90% Rework now minimal 返工最少 Improvements correlate with LPA deployment 改进与LPA的开展相关联,Number of LPA Checks Per Week 每周的LP

28、A检查数量,%FTC,It worked for us, it can work for you and your Suppliers! LPA为我们服务， 它也可以为你们 和你们的供应商服务,SQAP,22,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,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 w

29、e are not 不让供应商做我们不做的事情 Low investment significant quality return 低投资 获得显著的质量回报,SQAP,LPA Benefits 逐层过程审核的益处,23,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,LPA Plan ElementsLPA 计划 要素,1. Form LPA Team 成立LPA团队 2. Design Audit Check Sheet 设计审核检查表 3. Develop LPA Impl

30、ementation Procedures 制定LPA实施程序 4. Develop Monitoring Process 制定监控过程 5. Reporting Results to DaimlerChrysler 将结果提交戴姆勒克莱斯勒 6. Execute Plan 执行计划,24,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,Form LPA Team Form a Team: Select team members that are multi-functional

31、 and multi-level: Managers, Supervisors, Inspectors, and Operators from all areas such as Manufacturing, Quality Engineering, and Maintenance. Upper Management: Need to be included as team members. Process Owner: Should be someone within plant management. Team Leader: Should be the person responsibl

32、e for overseeing implementation. Empower the Team: The team must be able to make necessary decisions related to LPA. Support: All management must be notified to provide immediate support when requested. Schedule frequent meetings: Meetings should be scheduled to review LPA results, track corrective

33、actions and make adjustments. Action Plan: Develop an action plan to identify all implementation steps. Periodic Reviews of Action Plan: Management team should schedule time to review status of action items.,25,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,成立 LPA

34、团队 成立团队: 团队成员应是跨功能的和多级别的：如生产，质量工程，和维护保养等部门的经理，主管，检验员以及操作者。 最高管理者: 需要被纳入团队. 团队领导: 将负责监督审核的执行情况 授权予团队: 团队须能够做出与LPA相关的决定 支持: 当团队有要求时，通知管理层以得到支持 安排定期会议: 安排会议评审LPA结果, 跟踪纠正措施并作调整 改进计划: 制定改进计划识别所有实施步骤 定期评审改进计划：管理团队应安排时间评审改进计划状态。,26,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,LPA Leadershi

35、p Role LPA 领导角色,LPA calls for substantial commitment of managements time and effort. LPA 要求管理层做出时间和努力的实质性承诺。 Leaderships role is to: 领导角色是 Fix system problems 解决体系问题 Instill discipline 灌输纪律 Show appreciation to operators for doing work correctly 对操作者的正确操作予以感谢 Encourage improvement ideas from the wor

36、kforce 鼓励操作者提出改进建议 All plant staff should conduct Layered Process Audits throughout the plant 逐层过程审核应贯彻到工厂所有员工 During early phase - Management audits will find problems, but later the management audits will find improvements. 早期阶段- 管理层的审核将发现问题， 但是后来的管理层审核将会发现改进。,SQAP,LPA Plan LPA计划,27,Copyright 2007

37、 by DaimlerChrysler, Version 1.3 September 2007,LPA Leadership Role LPA 领导角色,SQAP,LPA Plan LPA计划,28,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,LPA Plan LPA计划,LPA Leadership Role LPA 领导角色,2.5审核的权限 逐层过程审核不是由质量部门实施的额外审核，此外，逐层过程审核并不控制包含在控制计划中的内容。逐层过程审核用于检查在组织中由于各种功能而引进的带有潜在危险的程序和过程。审核

38、确认被定义的方法和被使用的工作说明，并且持续执行改善行动。 由于逐层过程审核的范围和上目的，引进审核的区域的运行管理必须有自己的步骤。执行审核的管理者必须确保以下内容： 逐层过程审核应被按时执行 逐层过程审核的实施由指定的团队成员 结果应按规定记录和回顾 可用的办法焦点在对确认的不符项的纠正行动,29,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Suppliers review & Approval供应商的评审和批准,Supplier shall conduct internal review of LPA Pla

39、n 供应商应开展LPA计划的内部评审 LPA plan to include LPA implementation timing LPA计划要包括LPA实施的时间表 Supplier shall finalize LPA plan 供应商应完成LPA计划 Shall be signed off by LPA team & Plant Manager prior to approval from your customer 在提交客户批准前LPA团队和工厂经理应先签字 For Medium and High risk parts, both the LPA plan and demonstrat

40、ion 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员来批准LPA计划和演示,SQAP,LPA Plan LPA计划,30,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,Example:,31,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,Example:,3

41、2,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,LPA Plan LPA计划,Example:,33,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Customer Complaints, Quality Alerts 客户抱怨，质量警告 First-Time Through data, Scrap Reports 首次交验合格率，废品报告 Key Characteristics and Process Capability:

42、Cpk & Gage R&R 关键特性和过程能力：Cpk与量检具重复性再现性 PFMEA, Process Flow Diagram, Control Plan PFMEA，过程流程图，控制计划 Set-up Sheets, Work Instructions, Inspection Instructions 点检表格、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 质量系统审核，货场审核，检验报告 Rework instructions 返工指

43、导书,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,LPA Check Sheet Input LPA检查表输入,34,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,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 Lea

44、rned for implementing the Layered Process Audit across the entire manufacturing facility. 此区域也可以被作为整个工厂学习如何实施逐层过程审核的经验教训来源。 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。,SQAP,2. Developing LPA

45、 Check Sheet 制定LPA检查表,35,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,Typical Audit Elements For,36,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,典型的审核要素,37,Copyright 2007 by Daim

46、lerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,Typical Audit Elements For,38,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,典型的审核要素,39,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2.

47、 Developing LPA Check Sheet 制定LPA检查表,典型的审核要素- 例子,40,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,典型的审核要素- 例子,41,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,典型的非审核要素,42,Copyright

48、 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,Audit Question Criteria 审核问题准则,Questions: Objective, Specific & Concise 问题：客观，明确及简明 Explanation: Reason for Check 解释：检查的原因 Reaction Plan: What to do if non-conformance 反应计划：如出现不符合如何处理 Countermeasure: Mea

49、surement to protect customer 对策：保护顾客的措施,Each audit question should ask HOW? WHAT? And WHY?每个审核问题都应问：什麽/怎样/为什麽？,43,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,How to Develop Questions如何制定问题,Objective: 客观的 After looking at evidence vs state

50、d criteria, can be easily answered with a “Yes” or a “No”. 与审核准则相对照，可以很容易地用“是”或“否”表示 Specific: 明确的 Avoid unclear terms like properly or correctly 避免使用含糊的词如适当地或正确地 Concise: 简明的 Critical to quality 影响质量的关键点 Conducted by people unfamiliar with area 可以由不熟悉该领域的人员开展,44,Copyright 2007 by DaimlerChrysler, V

51、ersion 1.3 September 2007,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: Verify QAFM250092 is bei

52、ng filled out with date, shift, badge 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，同时检验是否已经完成.(缺少数据或错误数据可能会使非对应的零件批次被遏制）,What 什么 ?,How 如何 ?,Why 为什么?,SQAP,45,Copyright 2007 by Daimle

53、rChrysler, Version 1.3 September 2007,Making Questions Specific (Example #1) 使问题具体(举例#2),Initial Question 最初提问: Pressure Dial Settings: Look and see if the pressure dial is being properly set. 压力表设置: 检查压力表是否正确设置。 Improved Question 改进提问: Hydraulics Pressure Dial Settings (Right): Verify Pressure dial

54、 is set to 450 psi prior to start-up. If not set to 450 psi contact maintenance prior to operation. (Verification of Hydraulics pressure dial settings ensures machine operates within the correct press force range.) 右侧水压表设定: 确认压力表是否设置在450psi。如果不是，操作前与设备部门联系。（水压验证确保机器在正确压力范围内操作）,What 什么 ?,How 如何 ?,Why

55、 为什么?,SQAP,46,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,2. Developing LPA Check Sheet,SQAP,47,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. 制定LPA检查表,48,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. 制定LPA检查表,Example:,49,Copyright 200

56、7 by DaimlerChrysler, Version 1.3 September 2007,SQAP,2. 制定LPA检查表,Example:,50,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Make sure EACH process has its own specific LPA 确保每道工序均有自己对应的特定LPA Complete LPAs at the beginning of shift(s) 在开班生产时完成LPA Critical plant processes are addressed

57、 着重关键过程 All “Nos” or non-conformances should be addressed immediately 所有回答“No”的问题或不符合应立即着手解决 Do not ever consider an LPA as final. It is a living document that should be updated regularly with corrective actions, error-mistake proofing, etc. 不要认为LPA是一成不变的。它是动态文件，应随纠正措施的实施， 防误防错的开展定期进行更新。 Do not crea

58、te one LPA for a whole facility. Do not make an LPA generic. 不要整个工厂只有一种LPA。不要使LPA流于俗套。,SQAP,2. Developing LPA Check Sheet 制定LPA检查表,51,Copyright 2007 by DaimlerChrysler, Version 1.3 September 2007,Items are NEVER removed unless there is a product/process change or improvement. 除非有产品/过程变更或改进发生否则检查表中的项目不能删除。 Audits should include visual checks 审核应包括目视检查。 “Verify somebody doing something right.” “验证他人做正确的事”。 All quality issues should be addressed with corrective action updated in the LPAs. 所有质量问题应使用LPA中的纠正措施解决。 If separate part numbers, or di