LPA逐层工艺审查简述

SQAP供给商质量保证程序供给商质量保证程序ISO/TS 16949 DaimlerChrysler Customer Specific Requirements 戴姆勒戴姆勒-克莱斯勒用户特别要求克莱斯勒用户特别要求 New section under Internal Audits 正对新章节进行内部审查正对新章节进行内部审查 Effective 7/01/04 for Powertrain&Component Plants suppliers;对传动系及其零部件的供给商于对传动系及其零部件的供给商于7/01/04日开始执行；日开始执行；1/1/05 for all remaining suppliers 对所有其余的供给商于对所有其余的供给商于1/1/05年开始执行年开始执行Posted on AIAG,IAOB,and QMS web sites 在在AIAG，IAOB，和和QMS网站上发布网站上发布Letter mailed to all suppliers 信函已经发给了所有的供给商信函已经发给了所有的供给商SQAPThere are two Types of Layered Process Audits:有两种逐层过程审查有两种逐层过程审查:Process Control Audits 过程控制审核过程控制审核 Error&Mistake Proofing Verification Audits 防错防误验证审核防错防误验证审核Layered Process Audits(LPA)are a system of audits performed by multiple levels of management.Key process characteristics are audited frequently 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。SQAPLPAs 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 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防止次品产生的方法。SQAP 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 perform 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 shall perform Error&Mistake Proof Verification Audits.Set-up,maintenance or quality auditors are usually qualified.防错防误确认审查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*Lost market share*Lost businessNote:Taken from“Layered Process Audits,The Luminous Group,LLCSQAPSQAPSafety regulations 平安法规平安法规Reinforces加强加强Facilitates简化简化Operator training 操作员培训操作员培训Management/operator interface 管理管理/操作员界面操作员界面First time through capability 一次通过率一次通过率Morale 士气士气Improves提高提高Build variation based on work standardization 因为工作的标准化而产生的多样性因为工作的标准化而产生的多样性End-of-line inspection 线尾检验线尾检验Part defects 零件缺陷零件缺陷Reduces减少减少SQAPRepair Inventory vs First Time Capability vs LPA比照：比照：修理库存修理库存/一次通过率一次通过率/逐层工艺审查逐层工艺审查18-0221-0224-0227-0230-0233-0236-0239-0242-0245-0248-0251-021-034-037-0310-0313-0316-0319-0322-0325-0328-0331-0334-0337-0340-0343-0346-0349-0352-03Weekly 周周#of LPA Checks/Week每周每周LPA检查次数检查次数556065707580859095100First Time Through(%)一次通过率（一次通过率（%)KTP Now conducting 6700 Process Layered Audit ChecksKTP目前正执行6700 逐层工艺审查0 Process Layered Audits 0层工艺审查18001805400Repair Inventory修理库存FTC一次通过率SQAPSQAPPROCESS工艺工艺(过程过程/程序程序)ErrorProofing 防错防错 Process Audits 工艺审查工艺审查CorrectiveActions 纠正行动纠正行动PreventionActions 预防行动预防行动EmployeeWorkshops 车间职工车间职工ContinuousImprovementInputs 持续改进输入持续改进输入Audits are conducted regularly by all levels of supervision 各各监督级定期地进行审查监督级定期地进行审查Non-conformances are immediately addressed 立即发现不符合处立即发现不符合处LAYERED PROCESSAUDITS ARE PROCESSBASED,NOT PART BASED.逐层过程审查是基于逐层过程审查是基于程序程序的的,而不而不是基于零件的是基于零件的SQAPSQAP质量系统审查，货场审查，检验记录质量系统审查，货场审查，检验记录 Rework instructions 返工指导书返工指导书 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 Discretion when adding items to the checklist 在向检查表中添加工程的时候使用判断力。Audit items are issues that would cause Customer Dissatisfaction.审查工程是那些导致客户不满的问题。SQAP2 X Week 每周两次每周两次Area Management 区域主任区域主任1 X Shift 每班一次每班一次Production Supervisor 生产主管生产主管1 X Week 每周一次每周一次Plant Manager 车间主任车间主任 Encourages Management Involvement 鼓励参与管理鼓励参与管理 Encourages Operator Feedback 鼓励操作员反响鼓励操作员反响 Establishes Accountability 建立责任制建立责任制SQAPEXAMPLE:LPA FREQUENCY AND STRUCTURE举例：举例：逐层工艺审查频率与结构逐层工艺审查频率与结构SQAP123123123123123123123123123MONXXTUESXXWEDXXTHURXXFRIXXSATXXMONXXTUESXXWEDXXTHURXXFRIXXSATXXPLANNEDCOMPLETEDSHIFT 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 11 149 987 75Note:Example Illustrates that 3rd Shift Not Being Audited Per the Rotation Matrix Unacceptable Condition!注意注意:例子显示例子显示,在第三班生产中没有进行审查在第三班生产中没有进行审查 不可接受的条件不可接受的条件!XXXXXX生产生产 主管周主管周LPA检查方案安排表检查方案安排表每每9天对每条线轮流每班进行审查天对每条线轮流每班进行审查.在你工作的那班中在你工作的那班中,用差号标明已经完成了审查用差号标明已经完成了审查.SQAPSENIOR 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 24XWEEK 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 52XPLANNEDCOMPLETEDDAYSXEVERY LINE IS AUDITED EVERY 9 WEEKSPLACE A CHECK MARK IN THE ABOVE BOX FOR AUDITS COMPLETED PLANT MANAGER工厂经理周工厂经理周LPA检查方案安排表检查方案安排表每条线轮流在每每条线轮流在每9周进行一次审查周进行一次审查.在上面表格中在上面表格中,用差号标明已经完成了审查用差号标明已经完成了审查.SQAPSQAPSQAPSQAPSQAPSQAP带入到遏制行动中带入到遏制行动中).SQAPSQAPSQAP Auditors must understand 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响。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.一旦一旦LPA方案得到批准，供给商应该培训自己的逐层工艺审查员方案得到批准，供给商应该培训自己的逐层工艺审查员SQAPwork areas.当在工作地点执行审查时，将当在工作地点执行审查时，将LPA活动活动和对结果的期望和对结果的期望通知给操作工人。通知给操作工人。Encourage workforce feedback.鼓励操作工人进行反响。鼓励操作工人进行反响。Communicate LPA results frequently.经常对经常对LPA的结果进行交流。的结果进行交流。SQAP Begin Audits 开始审查开始审查 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。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.根据审查员的反响来改善审查检验表。根据审查员的反响来改善审查检验表。Management must instill discipline early in the process to complete 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并提供资 源给快速更正行动。源给快速更正行动。During early phase-Management audits will find problems,but later management audits will find improvements.在早期在早期-管理层的审查将发现问题，管理层的审查将发现问题，但是以后管理层的审查会但是以后管理层的审查会发现改发现改 进。进。-Develop and apply Lessons Learned to improve audit.-制定并运用吸取的教训来改进审查。制定并运用吸取的教训来改进审查。SQAP 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 process 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客户标准4.2.1.9.1的要求向管理层提供汇报。SQAPPlease note请注意:1.This shows three levels of management.Chrysler Group TS requirements state that the supplier must have“multiple levels of management.此图说明了三个管理级别.克莱斯勒TS要求阐述了供给商必须进行多层次的管理2.The number of LPA auditable items refers to the number of items on the LPA checklist multiplied by the number of times the items are checked in that month.LPA可审查项的数量指的是LPA检验表上工程数乘以当月这些工程被检查的次数.SQAPSQAP