LPA-分层审核

LayeredProcessAudit分层过程审核（LPA）WhatAreLayeredProcessAudit?什么是分层过程审核?LayeredProcessAudit(LPA)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.分层过程审核(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。ThepurposeofLayeredProcessAuditsistoensurecontinuousconformancetherebyimprovingprocessstabilityandfirst-timethroughcapability.分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。WhatisaLayeredProcessAudit(LPA)?什么是分层过程审核（LPA）？LPA’sassurethatdefinedmethodsandworkinstructionsareutilized,problemsolvingsolutionsareheldinplace,andallprocessissuesareidentifiedandquicklycorrected.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速纠正。LPAisanongoingsystemofprocesschecksthatverifypropermethods,settings,operatorcraftsmanship,errorproofingdevicesandotherinputsareinplacetoensureadefectfreeproduct.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、防错装置和其他输入是否到位从而确保产品无缺陷产生。WhoPerformsLayeredProcessAudit?谁执行分层过程审核？AnybodycanperformaLayeredProcessAudit.任何人都能够执行逐层过程管理。Manufacturingmanagementmustowntheprocessandperformaudits.生产管理部门必须领导此程序并执行审核。Allmanagers,regardlessoffunction,canbeauditors.所有经理，无论他的职责是什么，都可以作为审核员。Eachmanagementlevelshouldperformaudits.每个管理层都应该执行审核。LayeredProcessAuditshallbeperformedoncepershiftbysupervisors.Plantmanagementshallperformtheauditonceperweek.分层过程审核应该在每班生产时由车间主管进行一次审核。工厂管理层应该在每周执行一次审核。CostofNon-ConformancesatVariousPointsDefectfoundat:TheNextEndofFinalEndUser’sSourceProcessLineInspectionHand*Veryminor*Scrap*Repair*SignificantRework*3rdPartyContainment*MinorDelay*Containment*AdditionalOperations*PremiumFreight*Rework*Overtime*Administrativecosts*Reschedule*Delayindelivery*WarrantyCostsofWork*Addedinspection*Reputation*Lostmarketshare*LostbusinessNote:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLCEarlyDetection/Prevention在各阶段发生的不符造成的成本在下面阶段发现的缺陷:货源下个流程生产线末尾最终检验最终用户的手里*非常小*废品*返修*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*重订工作计划*延时发货*索赔成本*附加检验*声誉*失去市场份额*失去业务Note:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC早期探测/预防LPABenefits分层过程审核的优点•Safetyregulations安全法规Reinforces加强Facilitates简化•Operatortraining操作员培训•Management/operatorinterface管理/操作员界面•Firsttimethroughcapability一次通过率•Morale士气Improves提高•Buildvariationbasedonworkstandardization因为工作的标准化而产生的多样性•End-of-lineinspection线尾检验•Partdefects零件缺陷Reduces减少LPASuccessatKokomoTransmissionPlant逐层过程审核在KoKoMo变速箱厂的成功运用RepairInventoryvsFirstTimeCapabilityvsLPA对比：修理库存/一次通过率/逐层过程审核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#ofLPAChecks/Week每周LPA检查次数556065707580859095100FirstTimeThrough(%)一次通过率（%)KTPNowconducting6700ProcessLayeredAuditChecksKTP目前正执行6700分层过程审核0ProcessLayeredAudits0层过程审核18001805400RepairInventory修理库存FTC一次通过率LayeredProcessAudit分层过程审核ProvenSuccessfulInternally内部经过成功验证ExpandingCollaborationtoourSupplybase加强与我们供应商网络的合作NotaskingSupplierstodosomethingwearenot不向供应商询问我们不要的（零件）Lowinvestment–significantqualityreturn低投资–获得显著的质量回报HowdoesanLPAWork?分层过程审核是如何工作的？PROCESS过程ErrorProofing防错ProcessAudits过程审核CorrectiveActions纠正行动PreventionActions预防行动EmployeeWorkshops车间职工ContinuousImprovementInputs持续改进输入•Auditsareconductedregularlybyalllevelsofsupervision各监督级定期地进行审核•Non-conformancesareimmediatelyaddressed立即发现不符合处LAYEREDPROCESSAUDITSAREPROCESSBASED,NOTPARTBASED.逐层过程审核是基于过程的,而不是基于零件的DevelopingthePlan制定计划FormaLPATeamtoimplementtheauditprocess成立一个逐层审核团队实施审核DevelopprocedureforLPAProcessandDocumentation为LPA过程和文件制定程序Developauditchecklist.制订审核清单•BasedonKeyprocesselementsthataffectpartquality基于影响零件质量的关键过程要素Determinewhowillconductaudits.确定谁来执行审核。Determineauditfrequencyforeachlevel(ProcessControlAuditandError&MistakeProofingVerificationAudit).为每个级别（过程控制审核与防错防误验证审核）确定审核频次Developamonitoringprocessandreportsformanagementreview.制定一个监控过程并向管理部门汇报。IdentifyWheretobeginLPAImplementation确定从哪里开始实施LPAReview回顾:CustomerComplaints,QualityAlerts客户抱怨，质量警告First-TimeThroughdata,ScrapReports一次通过数据，废品报告KeyCharacteristicsandProcessCapability:Cpk&GageR&R关键特性和过程能力：CPK与检具R&RPFMEA,ProcessFlowDiagram,ControlPlanPFMEA,过程流程图，控制计划Set-upSheets,WorkInstructions,InspectionInstructions工艺卡片、作业指导书、检验指导书ErrorandMistakeProofing防错防误QualitySystemAudits,DockAudits,InspectionReports质量体系审核，货场审核，检验报告Reworkinstructions返工指导书TheAreaofHighestRiskshouldbethefirstareatoimplementtheLayeredProcessAudit最高风险区域应该是实施逐层过程审核的第一个区域ThisareawillalsobeusedasaLessonsLearnedforimplementingtheLayeredProcessAuditacrosstheentiremanufacturingfacility.此区域也被用于整个制造厂学习如何实施逐层审核。UseDiscretionwhenaddingitemstothechecklist在向检查表中添加项目的时候使用判断力。AudititemsareissuesthatwouldcauseCustomerDissatisfaction.审核项目是那些导致客户不满的问题。2XWeek每周两次AreaManagement区域管理者1XShift每班一次ProductionSupervisor生产主管1XWeek每周一次PlantManager工厂经理LPA-FrequencyPlan逐层过程审核-频率计划•EncouragesManagementInvolvement鼓励管理层参与•EncouragesOperatorFeedback鼓励操作员反馈•EstablishesAccountability建立责任制AssignedManagementCategory(example)分配的管理范畴（举例）AssignedManagementPersonnel(example)分配的管理人员（举例）AuditAssignment审查任务DepartmentA部门ADepartmentB部门BDepartmentC部门CDepartmen