分層審核 Modified Revision

1、There are two Types of Layered Process Audits: 有兩種分層過程審核有兩種分層過程審核: Process Control Audits 過程控制審核過程控制審核 Error & Mistake Proofing Verification Audits 防錯防誤驗證審核防錯防誤驗證審核Layered Process Audits (LPA) are a system of audits performed by multiple Layered Process Audits (LPA) are a system of audits perfor

2、med by multiple levels of management. Key process characteristics are audited frequently to levels of management. Key process characteristics are audited frequently to verify process conformance. verify process conformance. 分層過程審核分層過程審核(LPA)(LPA)是一種標(biāo)準(zhǔn)化的審核是一種標(biāo)準(zhǔn)化的審核, ,在組織的所有層面上定期在組織的所有層面上定期, ,經(jīng)常實施經(jīng)常實施

3、, ,由多個管理由多個管理層進(jìn)行的系統(tǒng)審核。對關(guān)鍵過程特性進(jìn)行頻繁的審核以驗證過程符合性。層進(jìn)行的系統(tǒng)審核。對關(guān)鍵過程特性進(jìn)行頻繁的審核以驗證過程符合性。The purpose of Layered Process Audits is to ensure continuous conformance The purpose of Layered Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. ther

4、eby improving process stability and first-time through capability. 分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。分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。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

5、 corrected.分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。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. 分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(shè)置、 操作員技能、防錯裝置和其

6、他輸入是否到位從而確保產(chǎn)品無缺陷產(chǎn)生。 Anybody can perform a Layered Process Audit. 任何人都能夠執(zhí)行分層過程審核。 Manufacturing management must own the process and perform audits. 生產(chǎn)管理部門必須領(lǐng)導(dǎo)此程序并執(zhí)行審核。 All managers, regardless of function, can be auditors. 所有經(jīng)理，無論他的職責(zé)是什么， 都可以作為審核員。 Each management level should perform audits. 每個管理層都應(yīng)

7、該執(zhí)行審核。Process Control Audits shall be performed once per shift by supervisors. Plant management shall perform the audit once per week.過程控制審核過程控制審核應(yīng)該在每班生產(chǎn)時由車間主管進(jìn)行一次審核。工廠管理應(yīng)該在每周執(zhí)行一次審核。Error & Mistake Proofing Verification audits shall be conducted once per shift. Only qualified employees shall per

8、form Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usually qualified.防錯防誤驗證審核防錯防誤驗證審核應(yīng)該在每班生產(chǎn)執(zhí)行一次。由具備資格的人員進(jìn)行防錯防誤驗證審核。 建立、維護(hù)或質(zhì)量審核員通常是具備資格的人員。SQAPSafety regulations 安全法規(guī)安全法規(guī)Reinforces加強(qiáng)加強(qiáng)Facilitates簡化簡化Operator training 操作員培訓(xùn)操作員培訓(xùn)Management/operator interfac

9、e 管理管理/操作員界面操作員界面First time through capability 一次通過率一次通過率Morale 士氣士氣Improves提高提高Build variation based on work standardization 因為工作的標(biāo)準(zhǔn)化而產(chǎn)生的多樣性因為工作的標(biāo)準(zhǔn)化而產(chǎn)生的多樣性End-of-line inspection 線尾檢驗線尾檢驗Part defects 零件缺陷零件缺陷Reduces減少減少18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0

10、316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 周周# of LPA Checks / Week每周每周LPA檢查次數(shù)檢查次數(shù)556065707580859095100First Time Through (%)一次通過率（一次通過率（%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正執(zhí)行6700 逐層過程審核0 Process Layered Audits 0層過程審epair Inventory修理

11、庫存FTC一次通過率Repair Inventory vs First Time Capability vs LPA對比：對比： 修理庫存修理庫存/一次通過率一次通過率/逐層過程審核逐層過程審核PROCESS過程過程ErrorProofing 防錯防錯 Process Audits 過程審核過程審核CorrectiveActions 糾正行動糾正行動PreventionActions 預(yù)防行動預(yù)防行動EmployeeWorkshops 車間職工車間職工ContinuousImprovementInputs 持續(xù)改進(jìn)輸入持續(xù)改進(jìn)輸入Audits are conducted regularly b

12、y all levels of supervision 各監(jiān)督級定期地進(jìn)行審核各監(jiān)督級定期地進(jìn)行審核Non-conformances are immediately addressed 立即發(fā)現(xiàn)（記錄）不符合處立即發(fā)現(xiàn)（記錄）不符合處LAYERED PROCESSAUDITS ARE PROCESSBASED, NOT PART BASED.分層過程審核是基于過程的分層過程審核是基于過程的,而不而不是基于零件的是基于零件的確定從哪里開始實施確定從哪里開始實施LPA Review 回顧: Customer Complaints, Quality Alerts 客戶抱怨，質(zhì)量警告 First-Ti

13、me Through data, Scrap Reports 一次通過數(shù)據(jù)，廢品報告 Key Characteristics and Process Capability: Cpk & Gage R&R 關(guān)鍵特性和過程能力：CPK與檢具 R&R PFMEA, Process Flow Diagram, Control Plan PFMEA, 過程流程圖，控制計劃 Set-up Sheets, Work Instructions, Inspection Instructions 工藝卡片、作業(yè)指導(dǎo)書、檢驗指導(dǎo)書 Error and Mistake Proofing 防錯防

14、誤 Quality System Audits, Dock Audits, Inspection Reports 質(zhì)量體系審核，貨場審核，檢驗報告 Rework instructions 返工指導(dǎo)書 The Area of Highest Risk should be the first area to implement the Layered Process Audit 最高風(fēng)險區(qū)域最高風(fēng)險區(qū)域應(yīng)該是實施分層過程審核的第一個區(qū)域 This area will also be used as a Lessons Learned for implementing the Layered Pro

15、cess Audit across the entire manufacturing facility. 此區(qū)域也被用于整個制造廠學(xué)習(xí)如何實施分層審核。 Use Discretion when adding items to the checklist在向檢查表中添加項目的時候使用判斷力判斷力。 Audit items are issues that would cause Customer Dissatisfaction. 審核項目是那些導(dǎo)致客戶不滿客戶不滿的問題。2 X Week 每周兩次每周兩次Area Management 區(qū)域管理者區(qū)域管理者1 X Shift 每班一次每班一次Pro

16、duction Supervisor 生產(chǎn)主管生產(chǎn)主管1 X Week 每周一次每周一次Plant Manager 工廠經(jīng)理工廠經(jīng)理 Encourages Management Involvement 鼓勵管理層參與鼓勵管理層參與 Encourages Operator Feedback 鼓勵操作員反饋鼓勵操作員反饋 Establishes Accountability 建立責(zé)任制建立責(zé)任制EXAMPLE: LPA FREQUENCY AND STRUCTURE舉例：舉例： 分層過程審核頻率與結(jié)構(gòu)分層過程審核頻率與結(jié)構(gòu)123123123123123123123123123MONXXTUESXX

17、WEDXXTHURXXFRIXXSATXXMONXXTUESXXWEDXXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 1XEVERY LINE IS AUDITED ACROSS EACH SHIFT EVERY 9 DAYS IN ROTATIONSHIFT 2XPLACE A CHECK MARK IN THE ABOVE BOX FOR YOUR SHIFT FOR AUDITS COMPLETEDSHIFT 3X1 10 0PRODUCTION SUPERVISOR WEEKLY LAYERED AUDIT LINE SCHEDULE1 14 4121

18、11 149 987 75Note: Example Illustrates that 3rd Shift Not Being Audited Per the Rotation Matrix Unacceptable Condition!注意注意: 例子顯示例子顯示, 在每個循環(huán)矩陣中第三班生產(chǎn)中沒有進(jìn)行審核在每個循環(huán)矩陣中第三班生產(chǎn)中沒有進(jìn)行審核 不可接受不可接受的狀況的狀況!生產(chǎn)生產(chǎn) 主管周主管周LPA檢查計劃安排表檢查計劃安排表SENIO R SUPERVISO R W EEKLY LAYERED AUDIT LINE SCHEDULEQ U AR TER 1Q U AR TER 298

19、751412114109875141211410W EEK 1XW EEK 14XW EEK 2XW EEK 15XW EEK 3XW EEK 16XW EEK 4XW EEK 17XW EEK 5XW EEK 18XW EEK 6XW EEK 19XW EEK 7XW EEK 20XW EEK 8XW EEK 21XW EEK 9XW EEK 22XW EEK 10XW EEK 23XW EEK 11XW EEK 24XW EEK 12XW EEK 25XW EEK 13XW EEK 26XQ U AR TER 3Q U AR TER 498751412114109875141211410W

20、 EEK 27XW EEK 40XW EEK 28XW EEK 41XW EEK 29XW EEK 42XW EEK 30XW EEK 43XW EEK 31XW EEK 44XW EEK 32XW EEK 45XW EEK 33XW EEK 46XW EEK 34XW EEK 47XW EEK 35XW EEK 48XW EEK 36XW EEK 49XW EEK 37XW EEK 50XW EEK 38XW EEK 51XW EEK 39XW EEK 52XPLANNEDCOMPLETEDD AYSXEVER Y LIN E IS AU D ITED EVER Y 9 W EEKSPLAC

21、 E A C H EC K M AR K IN TH E AB O VE B O X FO R AU D ITS C O M PLETED每條線輪流在每9周進(jìn)行一次審核. 在上面表格中, 用差號標(biāo)明已經(jīng)完成了審核工廠經(jīng)理周工廠經(jīng)理周LPA檢查計劃安排表檢查計劃安排表和日期的藍(lán)點(diǎn)措施并實施一個糾正行動請求.提問應(yīng)該包含對操作、設(shè)備、文件等的完整說明。 Reaction to non-conformances must assure immediate response. 對不符的響應(yīng)速度必須及時。). Auditors must understand LPA strategy and purpo

22、se. 審核員必須理解LPA策略和目的。 Review checklist and reactions with auditors. 和審核員共同分析檢查清單和反應(yīng)計劃。 Auditors must know to respond immediately after finding a nonconformance. 審核員必須在發(fā)現(xiàn)一個不符合時快速作出響應(yīng)。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV審核員具備執(zhí)行防錯防誤驗證的資格。 Perform a p

23、ractice audit where appropriate. 在適用的時候執(zhí)行一次審核實踐。Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 一旦一旦LPA計劃得到批準(zhǔn)，供應(yīng)商應(yīng)該培訓(xùn)自己的分層過程審核員計劃得到批準(zhǔn)，供應(yīng)商應(yīng)該培訓(xùn)自己的分層過程審核員 Explain why the LPA is being implemented. 解釋為什么為什么LPA在被執(zhí)行。 Explain the purpose and benefits of the LPA proce

24、ss. 解釋LPA程序的目的和益處益處。 Inform workforce of LPA activity and what to expect when audits are performed in their work areas. 當(dāng)在工作地點(diǎn)執(zhí)行審核時，將LPA活動和對結(jié)果的期望 通知通知給操作工人。 Encourage workforce feedback. 鼓勵鼓勵操作工人進(jìn)行反饋。 Communicate LPA results frequently. 經(jīng)常對LPA的結(jié)果進(jìn)行交流進(jìn)行交流。 Review audit results frequently when startin

25、g process. 在啟動程序的時候經(jīng)常經(jīng)常對審核結(jié)果進(jìn)行回顧。 Improve audit checklist based on auditor feedback. 根據(jù)審核員的反饋來改進(jìn)審核檢驗表。 Management must instill discipline early in the process to complete audits on time and provide resources for immediate corrective action. 管理層必須在程序的早期時候逐漸進(jìn)行灌輸，來按時完成審核并提供資 源給快速更正行動。 During early phas

26、e - Management audits will find problems, but later management audits will find improvements. 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)（這些問題的）改進(jìn)。 - Develop and apply Lessons Learned to improve audit. - 制定并運(yùn)用吸取的教訓(xùn)吸取的教訓(xùn)來改進(jìn)審核。 Corrective actions shall be documented as required by ISO/TS 更正行動應(yīng)該按照ISO/TS的標(biāo)準(zhǔn)進(jìn)行文件記錄. There must be a system to maintain the audit schedule and track completion. 必須有