LPA-分層審核

1、Layered Process Audit(LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 分層過(guò)程審核(LPA)是由多個(gè)管理層進(jìn)行的系統(tǒng)審核。對(duì)關(guān)鍵過(guò)程特性進(jìn)行頻繁的審核以驗(yàn)證過(guò)程符合性。The purpose of Layered Process Audits is to ensure continuous conformance t

2、hereby improving process stability and first-time through capability. 分層過(guò)程審核的目的是確保持續(xù)的符合性，從而提高過(guò)程穩(wěn)定性和一次通過(guò)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 corrected.逐層過(guò)程審核確保使用固定的方法和操作說(shuō)明，

3、 確保使用問(wèn)題解決方案， 所有過(guò)程問(wèn)題都被識(shí)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. 逐層過(guò)程審核是一項(xiàng)持續(xù)的過(guò)程檢查系統(tǒng)， 用來(lái)驗(yàn)證正確的方法、 設(shè)置、 操作員技能、防錯(cuò)裝置和其他輸入是否到位從而確保產(chǎn)品無(wú)缺陷產(chǎn)生。 Anybody can

4、perform a Layered Process Audit. 任何人都能夠執(zhí)行逐層過(guò)程管理。 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(wú)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(gè)管理層都應(yīng)該執(zhí)行審核。 Layered Process Audit sha

5、ll be performed once per shift by supervisors. Plant management shall perform the audit once per week.分層過(guò)程審核應(yīng)該在每班生產(chǎn)時(shí)由車間主管進(jìn)行一次審核。工廠管理層應(yīng)該在每周執(zhí)行一次審核。Safety regulations 安全法規(guī)安全法規(guī)Reinforces加強(qiáng)加強(qiáng)Facilitates簡(jiǎn)化簡(jiǎn)化Operator training 操作員培訓(xùn)操作員培訓(xùn)Management/operator interface 管理管理/操作員界面操作員界面First time through capabil

6、ity 一次通過(guò)率一次通過(guò)率Morale 士氣士氣Improves提高提高Build variation based on work standardization 因?yàn)楣ぷ鞯臉?biāo)準(zhǔn)化而產(chǎn)生的多樣性因?yàn)楣ぷ鞯臉?biāo)準(zhǔn)化而產(chǎn)生的多樣性End-of-line inspection 線尾檢驗(yàn)線尾檢驗(yàn)Part defects 零件缺陷零件缺陷Reduces減少減少Repair Inventory vs First Time Capability vs LPA對(duì)比：對(duì)比： 修理庫(kù)存修理庫(kù)存/一次通過(guò)率一次通過(guò)率/逐層過(guò)程審核逐層過(guò)程審核18-0221-0224-0227-0230-0233-0236-0239

7、-0242-0245-0248-0251-021-034-037-0310-0313-0316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 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(guò)率（一次通過(guò)率（%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正執(zhí)行6700 分層過(guò)程審核0 Process Layere

8、d Audits 0層過(guò)程審epair Inventory修理庫(kù)存FTC一次通過(guò)率PROCESS過(guò)程過(guò)程ErrorProofing 防錯(cuò)防錯(cuò) Process Audits 過(guò)程審核過(guò)程審核CorrectiveActions 糾正行動(dòng)糾正行動(dòng)PreventionActions 預(yù)防行動(dòng)預(yù)防行動(dòng)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 by all levels of supervision 各各監(jiān)督級(jí)定期地進(jìn)行審核監(jiān)督級(jí)

9、定期地進(jìn)行審核Non-conformances are immediately addressed 立即發(fā)現(xiàn)不符合處立即發(fā)現(xiàn)不符合處LAYERED PROCESSAUDITS ARE PROCESSBASED, NOT PART BASED.逐層過(guò)程審核是基于過(guò)程的逐層過(guò)程審核是基于過(guò)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(shí)施確定從哪里開始實(shí)施LPA Review 回顧: Customer Complaints, Quality Alerts 客戶抱怨，質(zhì)量警告 First-Time Through data, Scrap Reports 一次通過(guò)數(shù)據(jù)，廢品報(bào)告 Key Char

10、acteristics and Process Capability: Cpk & Gage R&R 關(guān)鍵特性和過(guò)程能力：CPK與檢具 R&R PFMEA, Process Flow Diagram, Control Plan PFMEA, 過(guò)程流程圖，控制計(jì)劃 Set-up Sheets, Work Instructions, Inspection Instructions 工藝卡片、作業(yè)指導(dǎo)書、檢驗(yàn)指導(dǎo)書 Error and Mistake Proofing 防錯(cuò)防誤 Quality System Audits, Dock Audits, Inspection Re

11、ports 質(zhì)量體系審核，貨場(chǎng)審核，檢驗(yàn)報(bào)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(xiǎn)區(qū)域最高風(fēng)險(xiǎn)區(qū)域應(yīng)該是實(shí)施逐層過(guò)程審核的第一個(gè)區(qū)域 This area will also be used as a Lessons Learned for implementing the Layered Process Audit across the entire manufacturing facility

12、. 此區(qū)域也被用于整個(gè)制造廠學(xué)習(xí)如何實(shí)施逐層審核。 Use Discretion when adding items to the checklist 在向檢查表中添加項(xiàng)目的時(shí)候使用判斷力判斷力。 Audit items are issues that would cause Customer Dissatisfaction. 審核項(xiàng)目是那些導(dǎo)致客戶不滿客戶不滿的問(wèn)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Production Supervisor 生產(chǎn)主管生產(chǎn)主管1 X Week 每周一次每周一次Plant

13、Manager 工廠經(jīng)理工廠經(jīng)理 Encourages Management Involvement 鼓勵(lì)管理層參與鼓勵(lì)管理層參與 Encourages Operator Feedback 鼓勵(lì)操作員反饋鼓勵(lì)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： 逐層過(guò)程審核頻率與結(jié)構(gòu)逐層過(guò)程審核頻率與結(jié)構(gòu)Example: Frequency Chart Compliance Matrixfor Supervisors 舉例舉例: 主管執(zhí)行頻次矩陣圖主管執(zhí)行頻次矩陣圖123123

14、123123123123123123123MONXXTUESXXWEDXXTHURXXFRIXXSATXXMONXXTUESXXWEDXXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 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 LAYER

15、ED AUDIT LINE SCHEDULE1 14 4121 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(gè)循環(huán)矩陣中第三班生產(chǎn)中沒(méi)有進(jìn)行審核在每個(gè)循環(huán)矩陣中第三班生產(chǎn)中沒(méi)有進(jìn)行審核 不可接受不可接受的狀況的狀況!XXXXXX生產(chǎn)生產(chǎn) 主管周主管周LPA檢查計(jì)劃安排表檢查計(jì)劃安排表每每9天對(duì)每條線輪流每班進(jìn)行審核天對(duì)每條線輪流每班進(jìn)行審核. 在你工作的那班中在你工作

16、的那班中,用差號(hào)標(biāo)明已經(jīng)完成了審核用差號(hào)標(biāo)明已經(jīng)完成了審核.SENIOR SUPERVISOR WEEKLY LAYERED AUDIT LINE SCHEDULEQUARTER 1QUARTER 2987514 12 11410987514 12 11410WEEK 1XWEEK 14XWEEK 2XWEEK 15XWEEK 3XWEEK 16XWEEK 4XWEEK 17XWEEK 5XWEEK 18XWEEK 6XWEEK 19XWEEK 7XWEEK 20XWEEK 8XWEEK 21XWEEK 9XWEEK 22XWEEK 10XWEEK 23XWEEK 11XWEEK 24XWEE

17、K 12XWEEK 25XWEEK 13XWEEK 26XQUARTER 3QUARTER 4987514 12 11410987514 12 11410WEEK 27XWEEK 40XWEEK 28XWEEK 41XWEEK 29XWEEK 42XWEEK 30XWEEK 43XWEEK 31XWEEK 44XWEEK 32XWEEK 45XWEEK 33XWEEK 46XWEEK 34XWEEK 47XWEEK 35XWEEK 48XWEEK 36XWEEK 49XWEEK 37XWEEK 50XWEEK 38XWEEK 51XWEEK 39XWEEK 52XPLANNEDCOMPLETE

18、DDAYSXEVERY LINE IS AUDITED EVERY 9 WEEKSPLACE A CHECK MARK IN THE ABOVE BOX FOR AUDITS COMPLETED PLANT MANAGERExample: Frequency Chart Compliance Matrixfor Plant Manager 舉例舉例: 工廠經(jīng)理執(zhí)行頻次矩陣圖工廠經(jīng)理執(zhí)行頻次矩陣圖工廠經(jīng)理周工廠經(jīng)理周LPA檢查計(jì)劃安排表檢查計(jì)劃安排表每條線輪流在每每條線輪流在每9周進(jìn)行一次審核周進(jìn)行一次審核. 在上面表格中在上面表格中, 用差號(hào)標(biāo)明已經(jīng)完成了審核用差號(hào)標(biāo)明已經(jīng)完成了審核.OPER

19、ATIONor PROCESS LPA CHECKLIST QUESTION CORRECTIVE ACTIONRECEIVING INSPECTION If parts are tagged with red Non-Conformance Tag, is the tag complete with 1) part number, 2) date and 3) description of the discrepancy 4) disposition? Notify Receiving Inspection Supervisor.MOLDING Verify machine process

20、settings are correct as per the set-up sheet. Notify Molding Manager. Inform Quality Inspector to begin containment. Verify that the operators are checking for and removing any flash from edges of the molded part Notify Molding Manager. Inform Quality Inspector to begin containment and initiate a C.

21、A.R. Verify that the operators are documenting flash removal on operator inspection form. Notify department supervisor.HEAT STAKE Is the operator using the digital dial-indicator to check the stake height of assembly as per inspection instructions? Notify department supervisor.(Error Detection devic

22、e at next station is set to reject nonconforming parts.) Verify that the #2 temperature gage reads between 140 and 150 degrees Fahrenheit Notify area supervisor and Engineering Manager. Inform Quality Inspector to begin containment.ASSEMBLY Verify the operator is applying grease on both the spring a

23、nd pivot pin Notify Assembly Supervisor Inform Quality Inspector to begin containment and initiate a C.A.R. Verify on three assemblies that the parts are free of excess grease and flash. Notify Assembly Supervisor Inform Quality Inspector to begin containment. Verify that the handle operates smoothl

24、y without binding or squeak Notify Assembly Supervisor Inform Quality Inspector to begin containment.SHIPPING Using one part from the top of a packed tray, verify that the part number stamped on the part matches the pallet label Notify Materials Manager Inform Quality Inspector to begin containment

25、and initiate a C.A.R. Verify that shipping label on each wrapped pallet has a blue dot with initials and date Notify Materials Manager Inform Quality Inspector to begin containment and initiate a C.A.R.操作或流程操作或流程 LPA 逐層檢驗(yàn)清單提問(wèn)逐層檢驗(yàn)清單提問(wèn) 糾正行動(dòng)糾正行動(dòng)進(jìn)貨檢驗(yàn)進(jìn)貨檢驗(yàn) 零件是否被貼上了紅色不符合標(biāo)牌, 標(biāo)牌是否包括:1) 零件號(hào), 2) 日期, 3) 不符描述, 4

26、) 位置? 通知進(jìn)貨檢驗(yàn)主管.造造 型型 確認(rèn)機(jī)器的流程設(shè)置是按照流程過(guò)程卡進(jìn)行設(shè)置的. .通知造型經(jīng)理; 通知質(zhì)檢員開始實(shí)施遏制措 施. 確認(rèn)操作工人正在檢查并清除成型零件邊緣上的光澤. 通知造型經(jīng)理; 通知質(zhì)檢員開始實(shí)施遏制措施并采取一個(gè)C.A.R (糾正行動(dòng)請(qǐng)求). 確認(rèn)操作工人在工位零件檢驗(yàn)表上記錄了將光澤清除的行為. 通知部門主管熱樁熱樁 操作員是否按照檢驗(yàn)要求使用數(shù)字表來(lái)檢驗(yàn)樁的高度? 通知部門主管,(下個(gè)工位設(shè)置了錯(cuò)誤檢測(cè)裝置來(lái)拒絕不符合零件的通過(guò)); 確認(rèn)2號(hào)溫度表的讀數(shù)在140到150華氏度之間. 通知區(qū)域主管和工程經(jīng)理. 通知質(zhì)檢員采取遏制措施.裝配裝配 確認(rèn)操作工人正在對(duì)

27、彈簧和轉(zhuǎn)動(dòng)梢上添加潤(rùn)滑油. 通知裝配主管;通知質(zhì)檢員開始采取遏制措施并實(shí)施一個(gè)糾正行動(dòng)請(qǐng)求. 確認(rèn)在三個(gè)總成上, 零件沒(méi)有多余的潤(rùn)滑油和光澤. 通知裝配主管; 通知質(zhì)檢員開始采取遏制措施. 確認(rèn)手柄的活動(dòng)自如且無(wú)阻塞或吱吱響 通知裝配主管; 通知質(zhì)檢員開始采取遏制措施.運(yùn)輸運(yùn)輸 從裝滿零件的工位箱中拿出一個(gè)零件, 確認(rèn)貼在這個(gè)零件上的零件號(hào)與工位箱上的零件號(hào)標(biāo)簽一致. 通知材料經(jīng)理; 通知質(zhì)檢員采取遏制措施并實(shí)施一個(gè)糾正行動(dòng)請(qǐng)求. 確認(rèn)每個(gè)零件包裹托盤上貼著的發(fā)貨標(biāo)簽上有一個(gè)大寫字母和日期的藍(lán)點(diǎn) 通知材料經(jīng)理; 通知質(zhì)檢員采取遏制措施并實(shí)施一個(gè)糾正行動(dòng)請(qǐng)求. Auditors must und

28、erstand LPA strategy and purpose. 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(jì)劃。 Auditors must know to respond immediately after finding a nonconformance. 審核員必須在發(fā)現(xiàn)一個(gè)不符合時(shí)快速作出響應(yīng)。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMP

29、V審核員具備執(zhí)行防錯(cuò)防誤驗(yàn)證的資格。 Perform a practice audit where appropriate. 在適用的時(shí)候執(zhí)行一次審核實(shí)踐。Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 一旦一旦LPA計(jì)劃得到批準(zhǔn)，供應(yīng)商應(yīng)該培訓(xùn)自己的逐層過(guò)程審核員計(jì)劃得到批準(zhǔn)，供應(yīng)商應(yīng)該培訓(xùn)自己的逐層過(guò)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

30、 and benefits of the LPA process. 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(shí)，將LPA活動(dòng)和對(duì)結(jié)果的期望 通知通知給操作工人。 Encourage workforce feedback. 鼓勵(lì)鼓勵(lì)操作工人進(jìn)行反饋。 Communicate LPA results frequently. 經(jīng)常對(duì)LPA的結(jié)果進(jìn)行交流進(jìn)行交流。 Review audit r

31、esults frequently when starting process. 在啟動(dòng)程序的時(shí)候經(jīng)常經(jīng)常對(duì)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(lái)改進(jìn)審核檢驗(yàn)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(shí)候逐漸進(jìn)行灌輸，來(lái)按時(shí)完成審核并提

32、供資 源給快速更正行動(dòng)。 During early phase - 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(wèn)題， 但是以后管理層的審核會(huì)發(fā)現(xiàn)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(lái)改進(jìn)審核。 Corrective actions shall be documented as required by ISO/TS 更正行動(dòng)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 completio