逐层过程审核(LPA)

CHRYSLERGROUPCHRYSLERGROUP1Copyright@2005byDaimlerChrysler,Version1.1October2005LayeredProcessAudit(LPA)逐层过程审核(LPA)SQAP供应商质量保证程序CHRYSLERGROUPCHRYSLERGROUP2Copyright@2005byDaimlerChrysler,Version1.1October2005AGENDA安排IntrotoLPALPA介绍DevelopingaeffectiveLPA制订一套有效的LPALPAImplementationLPA实施TrackingIssuesandCompliance跟踪问题和符合性Questions&Answers提问和答案SQAPCHRYSLERGROUPCHRYSLERGROUP3Copyright@2005byDaimlerChrysler,Version1.1October2005LayeredProcessAudit逐层过程审核I.ANINTRODUCTION介绍SQAPCHRYSLERGROUPCHRYSLERGROUP4Copyright@2005byDaimlerChrysler,Version1.1October2005SupplierInterface–LPA’swillbeMandatory供应商接口-逐层过程审核是强制性的ISO/TS16949DaimlerChryslerCustomerSpecificRequirements戴姆勒-克莱斯勒用户特殊要求NewsectionunderInternalAudits正对新章节进行内部审核Effective7/01/04forPowertrain&ComponentPlantssuppliers;动力总成及其零部件的供应商于7/01/04日开始执行；1/1/05forallremainingsuppliers对所有其余的供应商于1/1/05年开始执行PostedonAIAG,IAOB,andQMSwebsites在AIAG，IAOB，和QMS网站上发布Lettermailedtoallsuppliers信函已经发给了所有的供应商SQAPCHRYSLERGROUPCHRYSLERGROUP5Copyright@2005byDaimlerChrysler,Version1.1October2005WhatAreLayeredProcessAudits?什麽是逐层过程审核LayeredProcessAudits(LPA)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.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。ThepurposeofLayeredProcessAuditsistoensurecontinuousconformance,therebyimprovingprocessstabilityandfirst-timethroughcapability.(AsrequiredbyChryslerGroupTSCustomerSpecifics(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)SQAPCHRYSLERGROUPCHRYSLERGROUP6Copyright@2005byDaimlerChrysler,Version1.1October2005WhatisaLayeredProcessAudit(LPA)?什么是逐层过程审核（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、防误装置和其他输入是否到位从而确保产品无缺陷产生。SQAPCHRYSLERGROUPCHRYSLERGROUP7Copyright@2005byDaimlerChrysler,Version1.1October2005ThereareTwoTypesofLayeredProcessAudits:有两类逐层过程审核:•ProcessControlAuditsshallbeperformedoncepershiftbysupervisors.Plantmanagementshallperformtheauditonceperweek.•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。Error&MistakeProofingVerificationauditsshallbeconductedoncepershiftatthestartofeachshift.OnlyqualifiedemployeesshallperformError&MistakeProofVerificationAudits.Set-up,maintenanceorqualityauditorsareusuallyqualified.防错防误验证审核应该在每班生产执行一次。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。SQAPCHRYSLERGROUPCHRYSLERGROUP8Copyright@2005byDaimlerChrysler,Version1.1October2005WhoPerformsLayeredProcessAudits?谁执行逐层过程审核？AnybodycanperformaLayeredProcessAudit.任何人都能够执行逐层过程审核。Manufacturingmanagementmustowntheprocessandperformaudits.生产管理部门是该程序的归口部门并执行审核。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。SQAPCHRYSLERGROUPCHRYSLERGROUP9Copyright@2005byDaimlerChrysler,Version1.1October2005LayeredProcessAuditBenefitsLPA的益处TheimplementationofLayeredProcessAudits:LPA的实施：•Reducesvariation(bothassignableandcommoncause)减少变差（普通原因和特定原因）•Preventsprocesserrorsandoperatormistakes预防过程错误和操作者错误•Improvesandmaintainsdiscipline改进和保持纪律•InitiatesContinuousImprovementactions引入持续改进行动•Reducesrework减少返工•Reducesscrapandeliminateswaste减少废品和消除浪费•Improvescommunication改善沟通•Instillsandimprovesstandardization灌输和改进标准化•ImprovesoverallQualityandreducescosts全面提高质量和降低成本SQAPCHRYSLERGROUPCHRYSLERGROUP10Copyright@2005byDaimlerChrysler,Version1.1October2005LPABenefits逐层过程审核的益处•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因工作标准化而使变差减少•End-of-lineinspection线尾检验•Partdefects零件缺陷Reduces减少SQAPCHRYSLERGROUPCHRYSLERGROUP11Copyright@2005byDaimlerChrysler,Version1.1October2005CostofNon-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/PreventionSQAPCHRYSLERGROUPCHRYSLERGROUP12Copyright@2005byDaimlerChrysler,Version1.1October2005在各阶段发生的不符造成的成本在以下阶段发现的缺陷:货源下个流程线末尾最终检验最终用户的手里*非常小*划伤*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*保修成本*增加检验次数*声誉*失去市场份额*失去业务Note:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLC早期探测/预防SQAPCHRYSLERGROUPCHRYSLERGROUP13Copyright@2005byDaimlerChrysler,Version1.1October2005LPASuccessStoryLPA成功案例TheDaimlerChryslerKokomoTransmissionPlant戴姆勒克莱斯勒的变速箱厂KokomohasachievedsignificantgainsinFTCusingLPA.运用LPA使FTC得到了显著的改进FTCinthehigh90%FTC达到90%Rework