GM-Layered-Audit-通用分层审核课件

LayeredAuditProcedure分层审核流程ProcessControlLayeredAudit1LayeredAuditProcedureProcessDefinition定义Astandardizedauditperformedonaregular,frequentbasisbyalllayersoftheorganizationtoensurewemaintainprocesscontroladherence&toreinforcetheGMSvisionfortheentireorganization.分层审核是一种标准化的审核，它以组织结构中所有层次的定期频繁参与为基础，确保过程控制的进行，加强整个组织的全球制造系统的理念。Purpose目的Ensuresconsistentapplicationandexecutionofstandards,improvedbuilt-in-qualityandincreasedTM/leadershipGMSawareness,bycoaching&interactionbetweenleadership&T/M’s&T/L’s.通过培训和领导层与班组成员的互动来确保标准的应用和执行，促进质量改进，增强班组成员和领导层的全球制造系统的意识Scope范围ApplicabletoallAreasofGM.适用于通用汽车所有部门ProcessControlLayeredAudit2Definition定义ProcessControlLKeyCheckContents关键检查内容WorkstationGMS工位GMS–Detailcheckofoneworkstationprocesscontrols工位过程控制的详细检查QualityControl质量控制–Team’simportantQualitysystemsarefunctioning,&previousimportantproblemundercontrol班组的重要质量系统运行正常，之前的质量问题得到有效控制.TeamGMSManagement

班组GMS管理–Aretheimportantteammanagementprocessesundercontrol,i.e.;BPD,TPM,Andon,5S,Scrap,Training,etc班组管理（业务计划部署,全员生产性维护,暗灯,工作场地布置,废料,培训等）流程可控.ProcessControlLayeredAudit3KeyCheckContents关键检查内容ProceProcessOverviewI

过程总揽IThisToolisbeingputinplaceto实施分层审核是为了:Ensureahighlevelofprocesscontrolbyidentifying&controllinghighrisk/significantprocesselements.通过识别和控制高风险或重要过程元素来确保对过程的高水平控制MaintainsproperapplicationofGMSstandards.保持对GMS标准的合理应用Identifyopportunitiesforimprovement&provideaprocessforeffectivefollowup.识别改进的机会，提供对流程的有效跟踪ConfirmtheeffectivenessoftheAuditatalllevels.加强审核制度在各个层次的有效性InvolvealllevelsofLeadershipinsupportingtheT/M&T/Lthroughcoaching/teachingontheshopfloor.使各级领导层都参与车间的培训/指导工作以支持班组成员和班组长ProcessControlLayeredAudit4ProcessOverviewI过程总揽IThisProcessOverviewII过程总揽IIMethodology/Process方法：Frequentassessmentsbyalllayersoftheorganization(T/L–P/M)areperformedusingthelayeredauditchecklist(班组长至工厂经理)使用分层评审检查单来对组织中的各个层次进行定期评估Evaluationagainstestablishedstandards使用已经确定的标准进行评估Introductionofcorrectiveactions(countermeasures)引入问题纠正方法及相关措施Regularreviewprocessbyseniormanagement高层管理人员进行定期复核Results&actionstracked/visualizedineachunit在每个单元跟踪和目视化评审结果及改进情况LinkedtoGM-GMS(e.g.CoreRequirements&OperatingGuidelines)与GM-GMS相关联（例如核心需求、操作指导等）ProcessControlLayeredAudit5ProcessOverviewII过程总揽IIProProcessOverviewIII过程总揽IIIAlllevelsoftheorganizationusethe“LayeredAuditCheckSheet”toconducttheiraudit.各级人员都应使用分层评审检查单来进行评审ThisCheckSheetisstructuredaroundthe5GM-GMSprinciples(PeopleInvolvement,Standardization,Built-in-Quality,ShortLeadTime,andContinuousImprovement).分层评审检查单由GMS的五大原则组成（人员参与、标准化、制造质量、缩短制造周期和不断改进）The“LayeredAuditCheckSheet”iscomprisedof3mainsections分层评审检查单由三部分组成:WorkstationGMS–baselistofchecks,applicabletoallworkstations工位GMS－应用于所有工位的基本检查单QualityFocused–checksarespecifictooperationsanddevelopedbyplant,basedonqualityfeedback,processknowledge,andproblemsolving针对质量：对操作的评审是详细且明确的.其由工厂基于质量反馈、过程知识和问题解决来加以开发ProductionSystemGMS–baselistofchecks,applicabletoallGMSmanagement.生产系统GMS－可应用于所有GMS管理的基本检查清单ProcessControlLayeredAudit6ProcessOverviewIII过程总揽IIIPProcessOverviewIV过程总揽IVWorkstationGMSsectionoftheLayeredAuditCheckSheetisCommonforallworkstations.审核表中的工位GMS部分对所有工适用Ensuringpropertools,gagesandmaterialsareavailable&used.确保所有的工具、量具以及材料的可用性Ensuringstandardizedwork&qualitystandardsareunderstood&followed.确保标准化工作和质量标准能够被理解和遵循EnsuringAndonsystemisfunctioningproperly&followsFPSstart.确保暗灯系统的正确应用，遵循FPSEnsuringWorkplaceOrganization&VisualManagementstandardsaremaintained(e.g.accordingtotheplantWPOstandardsandVisualManagementpolicy).确保工作场组织以及可视化管理标准的维护（遵循工厂的WPO标准和可视化管理政策）EnsuringcompliancetoMaterialProcesses–FIFO/Min.-Max.levels.确保遵循物料处理－先进现先出原则、最大最小量水平等Identifyingopenissuesthatrequirecountermeasures/followup.识别需要对策或跟踪的公开问题ProcessControlLayeredAudit7ProcessOverviewIV过程总揽IVWorProcessOverviewV过程总揽V

TheQualityFocusedsectionisspecifictoeachteam:针对质量的部分对不同的班组有特定的内容Ensuringerrorproofingisfunctioningproperlyandidentifiedhighrisk/significantprocesselementsarecontrolledtopreventknownproblemsfromreoccurring.确保问题确定的正确运行并确定高风险和显著过程元素得到控制以防止已知问题的再次发生Ensuringrequiredqualityinspectionand/ordocumentationisbeingcompletedcorrectly.确保必须的质量检测或文件记录的正确性ProcessControlLayeredAudit8ProcessOverviewV过程总揽V

TheTheProductionSystemGMSsectioniscommonforallteams.生产系统GMS部分对所有的班组是通用的TPMchecksarecompleted&updated.TPM审核是全面的并且是已更新的Compliancetorequiredqualitychecks.遵循必须的质量审核ConformancetoWorkplaceOrganization5Sstandards.遵循工作场地组织的5S原则ProperuseofAndonSystem.暗灯系统的正确使用Effectiveproblemsolving&countermeasureimplementation.有效的问题解决和对策实施Effectiveuseoflayeredauditprocessforcontrolandfollowup.分层审核在控制和跟踪中的有效应用AppropriatefollowupofcountermeasuresforBPD,SPQRCmetrics.对BPD/SPQRC的对策进行适当的跟踪Compliancetomaterialprocesses-FIFO,Min/Max.遵循物料处理中的先进先出、最大最小量原则ProcessOverviewVI过程总揽VIProcessControlLayeredAudit9TheProductionSystemGMSsectFrequency频次PlantDirector工厂总监1Time/Month每月一次ShiftLeader/AreaManager值班长/区域经理1Group/week每周一工段工段Supervisor(groupleader)主管/工段长1Team/week每周一班组Teamleader班组长2workstation/week每周两工位ProcessControlLayeredAudit10Frequency频次PlantDirector工厂总Auditworkstation/Teamareaperschedule.按计划审核工位/班组Followstandardizedchecklist,alwaysstudythestandardandcomparethestandardtotheworkarea.遵循标准审核单，研究标准并且比较标准与实际工作区域的差异Immediatelyinformallimpactedteammembersoftheauditresults.及时将评审结果通知有关的班组成员RecordalldeviationsonlayeredauditCheckSheetandpostinthegrouparea(e.g.BPD)在分层评审检查单中记录所有差异,并且张贴在工作场所（如:BPD墙）Identify,document&implementsuggestedcountermeasuresassoonaspossible.尽快的确认、记录、实施建议措施Follow-uponopenitems,targettocloseinoneweek.Elevateproblemtohigherlevelaftertargetdate.跟踪问题并于一周内解决，一周内不能解决的将问题向上一级汇报Chooseworkstation/team

选择工位/班组Conductaudit进行审核Givefeedback/Documentresults反馈/纪录结果Follow-up跟踪Auditprocess评审过程ProcessControlLayeredAudit11Auditworkstation/TeamareapeChooseWorkstation/Team选择工位/班组Dir,S/MgrandShiftLeadersshouldprioritizetheirselectionofaworkstation/groupareatoauditbasedonplantspecificissues.值班长及以上领导应根据工厂的特点优先选择进行审核的工位和工作区域SIP/TQChighfrequencyproblems.SIP/QC高频率问题GCAprioritydefectsGCA优先缺陷SPA(ShippingPriorityAudit)Shifttoshiftcontrast不同班次间对比Otherareastofocusare(External-VoiceoftheCustomer):其他需重视的领域(客户的声音)WarrantyJ.D.PowerLeadershipshouldavoidauditingthesameworkstations/Teamareasrepeatedly.领导层应该避免对同一工位/班组进行反复的审核Allowdatatodrivethelayeredauditprocessdeepandwide!使用能够促进分层审核进行的更深入更广泛的数据ProcessControlLayeredAudit12ChooseWorkstation/Team选择工位/班WorkstationGMSAudit

PerformedbyTeamLeader&above班组长及以上人员执行:ProcessControlLayeredAudit13WorkstationGMSAudit

PerforQualityFocusedAudit

Performedbyalllayers,plantmustdefinespecificchecks:由所有层次实施，工厂必须进行明确且详细的审核Determinetheprocesseswithintheteamtobemonitoredbasedonqualitydata,processcapabilities(includingoperatorsensitiveoperations),safety,orhighimpactprocesses(processthatifnotfollowedproperlycouldleadtoamajorproductdeficiency).根据质量数据、处理能力（包括操作员敏感性操作）、安全、高危害处理（不正确的操作导致产品的主要缺陷）等来确定班组内的程序被监控Verifyrelatedprocesses/standardsaredocumentedinthestandardizedwork,updateasrequired核实相关过程和标准在标准化作业中被记录，根据需要进行更新Determineappropriatemethodandfrequencytoconduct,checkandupdatelayeredauditchecklist决定合适的方法和频率来进行审核和更新分层评审检查单ProcessControlLayeredAudit14QualityFocusedAudit

PerfoIdentifyqualityfocusedCheckitemsattheplant确定工厂内质检项目Developmethodandfrequency开发方法和频次Create/updatelayeredauditcheck-sheet建立/更新分层评审检查单单Communicatetoallthelayersoftheleadership与各级领导人员交流Conducttheaudits进行审核ACriticaloperationKPC’sprocess&FMEA关键操作流程Qualityfeedback质量反馈UpdateStdwork更新标准化作业GroupleaderEachlevel各层Add/removeReviseItems增删/修订BQualityFocusCheckFlowChartProcessControlLayeredAudit15IdentifyqualityDevelopmethoNon-conformancefound?发现不合标准处？Correctiveaction纠正措施Recordtheauditresults记录审核结果Evaluatelayeredauditprocess评估分层审核流程End结束BANoyesEachlevel各层Eachlevel各层Shiftleader值班长ProcessControlLayeredAudit16Non-conformancefound?Correcti

PerformedbyShiftLeader&above值班长及其以上管理人员执行:ProductionSystemGMSAuditProcessControlLayeredAudit17

PerformedbyShiftLeader&CommentsSectionLayeredAuditChecklist分层评审检查单单CommentsSectionisusedtodocumentissuespecificsandanyimmediatecorrectiveactionstaken注释部分用于记录问题细节和所有立即采取的正确措施ProcessControlLayeredAudit18CommentsSectionLayeredAuditTherearethreeresultsthatcancomeoutofthecheck

审核会出现三种结果O–NoDeviationsareFound没有发现偏差X–DeviationFound发现偏差N/A–NotApplicable不适用AllDeviationsshouldberecordedontheLayeredAuditChecklistanddescribedinthecommentssection.在分层审核单上记录所有问题并且在注释部分进行描述AnyDeviationsthatcannotbeimmediatelycorrectedmusthavecountermeasuresidentified.所有不能立即修正的问题必须确定对策Reasonsfornon-complianceshouldbeunderstood.不遵循的原因应是可理解的Completedauditispostedpreviousauditsareretainedfor6months.目视化保存检查单6个月CompletionandCompliancetrackingchartsareupdated.完成和遵循图表的跟踪应保持更新ChecklistEvaluation检查单记录方法ProcessControlLayeredAudit19TherearethreeresultsthatcLayeredAuditTracking–Completion完成情况跟踪

Anauditscheduleisdevelopedateachlevelandtrackedtoassureauditsarecompletedasplanned(%completed).Samplecompletionchartbelow:各层应制定审核计划并进行跟踪以确保按照计划完成审核ProcessControlLayeredAudit20LayeredAuditTracking–CompleLayeredAuditTracking–OpenIssue关闭情况跟踪ProcessControlLayeredAudit21LayeredAuditTracking–OpenProcedureSchedule实施日程表

ProcessControlLayeredAudit22ProcedureSchedule实施日程表ProcesRevisionlogProcessControlLayeredAudit23RevisionlogProcessControlLaLayeredAuditProcedure分层审核流程ProcessControlLayeredAudit24LayeredAuditProcedureProcessDefinition定义Astandardizedauditperformedonaregular,frequentbasisbyalllayersoftheorganizationtoensurewemaintainprocesscontroladherence&toreinforcetheGMSvisionfortheentireorganization.分层审核是一种标准化的审核，它以组织结构中所有层次的定期频繁参与为基础，确保过程控制的进行，加强整个组织的全球制造系统的理念。Purpose目的Ensuresconsistentapplicationandexecutionofstandards,improvedbuilt-in-qualityandincreasedTM/leadershipGMSawareness,bycoaching&interactionbetweenleadership&T/M’s&T/L’s.通过培训和领导层与班组成员的互动来确保标准的应用和执行，促进质量改进，增强班组成员和领导层的全球制造系统的意识Scope范围ApplicabletoallAreasofGM.适用于通用汽车所有部门ProcessControlLayeredAudit25Definition定义ProcessControlLKeyCheckContents关键检查内容WorkstationGMS工位GMS–Detailcheckofoneworkstationprocesscontrols工位过程控制的详细检查QualityControl质量控制–Team’simportantQualitysystemsarefunctioning,&previousimportantproblemundercontrol班组的重要质量系统运行正常，之前的质量问题得到有效控制.TeamGMSManagement

班组GMS管理–Aretheimportantteammanagementprocessesundercontrol,i.e.;BPD,TPM,Andon,5S,Scrap,Training,etc班组管理（业务计划部署,全员生产性维护,暗灯,工作场地布置,废料,培训等）流程可控.ProcessControlLayeredAudit26KeyCheckContents关键检查内容ProceProcessOverviewI

过程总揽IThisToolisbeingputinplaceto实施分层审核是为了:Ensureahighlevelofprocesscontrolbyidentifying&controllinghighrisk/significantprocesselements.通过识别和控制高风险或重要过程元素来确保对过程的高水平控制MaintainsproperapplicationofGMSstandards.保持对GMS标准的合理应用Identifyopportunitiesforimprovement&provideaprocessforeffectivefollowup.识别改进的机会，提供对流程的有效跟踪ConfirmtheeffectivenessoftheAuditatalllevels.加强审核制度在各个层次的有效性InvolvealllevelsofLeadershipinsupportingtheT/M&T/Lthroughcoaching/teachingontheshopfloor.使各级领导层都参与车间的培训/指导工作以支持班组成员和班组长ProcessControlLayeredAudit27ProcessOverviewI过程总揽IThisProcessOverviewII过程总揽IIMethodology/Process方法：Frequentassessmentsbyalllayersoftheorganization(T/L–P/M)areperformedusingthelayeredauditchecklist(班组长至工厂经理)使用分层评审检查单来对组织中的各个层次进行定期评估Evaluationagainstestablishedstandards使用已经确定的标准进行评估Introductionofcorrectiveactions(countermeasures)引入问题纠正方法及相关措施Regularreviewprocessbyseniormanagement高层管理人员进行定期复核Results&actionstracked/visualizedineachunit在每个单元跟踪和目视化评审结果及改进情况LinkedtoGM-GMS(e.g.CoreRequirements&OperatingGuidelines)与GM-GMS相关联（例如核心需求、操作指导等）ProcessControlLayeredAudit28ProcessOverviewII过程总揽IIProProcessOverviewIII过程总揽IIIAlllevelsoftheorganizationusethe“LayeredAuditCheckSheet”toconducttheiraudit.各级人员都应使用分层评审检查单来进行评审ThisCheckSheetisstructuredaroundthe5GM-GMSprinciples(PeopleInvolvement,Standardization,Built-in-Quality,ShortLeadTime,andContinuousImprovement).分层评审检查单由GMS的五大原则组成（人员参与、标准化、制造质量、缩短制造周期和不断改进）The“LayeredAuditCheckSheet”iscomprisedof3mainsections分层评审检查单由三部分组成:WorkstationGMS–baselistofchecks,applicabletoallworkstations工位GMS－应用于所有工位的基本检查单QualityFocused–checksarespecifictooperationsanddevelopedbyplant,basedonqualityfeedback,processknowledge,andproblemsolving针对质量：对操作的评审是详细且明确的.其由工厂基于质量反馈、过程知识和问题解决来加以开发ProductionSystemGMS–baselistofchecks,applicabletoallGMSmanagement.生产系统GMS－可应用于所有GMS管理的基本检查清单ProcessControlLayeredAudit29ProcessOverviewIII过程总揽IIIPProcessOverviewIV过程总揽IVWorkstationGMSsectionoftheLayeredAuditCheckSheetisCommonforallworkstations.审核表中的工位GMS部分对所有工适用Ensuringpropertools,gagesandmaterialsareavailable&used.确保所有的工具、量具以及材料的可用性Ensuringstandardizedwork&qualitystandardsareunderstood&followed.确保标准化工作和质量标准能够被理解和遵循EnsuringAndonsystemisfunctioningproperly&followsFPSstart.确保暗灯系统的正确应用，遵循FPSEnsuringWorkplaceOrganization&VisualManagementstandardsaremaintained(e.g.accordingtotheplantWPOstandardsandVisualManagementpolicy).确保工作场组织以及可视化管理标准的维护（遵循工厂的WPO标准和可视化管理政策）EnsuringcompliancetoMaterialProcesses–FIFO/Min.-Max.levels.确保遵循物料处理－先进现先出原则、最大最小量水平等Identifyingopenissuesthatrequirecountermeasures/followup.识别需要对策或跟踪的公开问题ProcessControlLayeredAudit30ProcessOverviewIV过程总揽IVWorProcessOverviewV过程总揽V

TheQualityFocusedsectionisspecifictoeachteam:针对质量的部分对不同的班组有特定的内容Ensuringerrorproofingisfunctioningproperlyandidentifiedhighrisk/significantprocesselementsarecontrolledtopreventknownproblemsfromreoccurring.确保问题确定的正确运行并确定高风险和显著过程元素得到控制以防止已知问题的再次发生Ensuringrequiredqualityinspectionand/ordocumentationisbeingcompletedcorrectly.确保必须的质量检测或文件记录的正确性ProcessControlLayeredAudit31ProcessOverviewV过程总揽V

TheTheProductionSystemGMSsectioniscommonforallteams.生产系统GMS部分对所有的班组是通用的TPMchecksarecompleted&updated.TPM审核是全面的并且是已更新的Compliancetorequiredqualitychecks.遵循必须的质量审核ConformancetoWorkplaceOrganization5Sstandards.遵循工作场地组织的5S原则ProperuseofAndonSystem.暗灯系统的正确使用Effectiveproblemsolving&countermeasureimplementation.有效的问题解决和对策实施Effectiveuseoflayeredauditprocessforcontrolandfollowup.分层审核在控制和跟踪中的有效应用AppropriatefollowupofcountermeasuresforBPD,SPQRCmetrics.对BPD/SPQRC的对策进行适当的跟踪Compliancetomaterialprocesses-FIFO,Min/Max.遵循物料处理中的先进先出、最大最小量原则ProcessOverviewVI过程总揽VIProcessControlLayeredAudit32TheProductionSystemGMSsectFrequency频次PlantDirector工厂总监1Time/Month每月一次ShiftLeader/AreaManager值班长/区域经理1Group/week每周一工段工段Supervisor(groupleader)主管/工段长1Team/week每周一班组Teamleader班组长2workstation/week每周两工位ProcessControlLayeredAudit33Frequency频次PlantDirector工厂总Auditworkstation/Teamareaperschedule.按计划审核工位/班组Followstandardizedchecklist,alwaysstudythestandardandcomparethestandardtotheworkarea.遵循标准审核单，研究标准并且比较标准与实际工作区域的差异Immediatelyinformallimpactedteammembersoftheauditresults.及时将评审结果通知有关的班组成员RecordalldeviationsonlayeredauditCheckSheetandpostinthegrouparea(e.g.BPD)在分层评审检查单中记录所有差异,并且张贴在工作场所（如:BPD墙）Identify,document&implementsuggestedcountermeasuresassoonaspossible.尽快的确认、记录、实施建议措施Follow-uponopenitems,targettocloseinoneweek.Elevateproblemtohigherlevelaftertargetdate.跟踪问题并于一周内解决，一周内不能解决的将问题向上一级汇报Chooseworkstation/team

选择工位/班组Conductaudit进行审核Givefeedback/Documentresults反馈/纪录结果Follow-up跟踪Auditprocess评审过程ProcessControlLayeredAudit34Auditworkstation/TeamareapeChooseWorkstation/Team选择工位/班组Dir,S/MgrandShiftLeadersshouldprioritizetheirselectionofaworkstation/groupareatoauditbasedonplantspecificissues.值班长及以上领导应根据工厂的特点优先选择进行审核的工位和工作区域SIP/TQChighfrequencyproblems.SIP/QC高频率问题GCAprioritydefectsGCA优先缺陷SPA(ShippingPriorityAudit)Shifttoshiftcontrast不同班次间对比Otherareastofocusare(External-VoiceoftheCustomer):其他需重视的领域(客户的声音)WarrantyJ.D.PowerLeadershipshouldavoidauditingthesameworkstations/Teamareasrepeatedly.领导层应该避免对同一工位/班组进行反复的审核Allowdatatodrivethelayeredauditprocessdeepandwide!使用能够促进分层审核进行的更深入更广泛的数据ProcessControlLayeredAudit35ChooseWorkstation/Team选择工位/班WorkstationGMSAudit

PerformedbyTeamLeader&above班组长及以上人员执行:ProcessControlLayeredAudit36WorkstationGMSAudit

PerforQualityFocusedAudit

Performedbyalllayers,plantmustdefinespecificchecks:由所有层次实施，工厂必须进行明确且详细的审核Determinetheprocesseswithintheteamtobemonitoredbasedonqualitydata,processcapabilities(includingoperatorsensitiveoperations),safety,orhighimpactprocesses(processthatifnotfollowedproperlycouldleadtoamajorproductdeficiency).根据质量数据、处理能力（包括操作员敏感性操作）、安全、高危害处理（不正确的操作导致产品的主要缺陷）等来确定班组内的程序被监控Verifyrelatedprocesses/standardsaredocumentedinthestandardizedwork,updateasrequired核实相关过程和标准在标准化作业中被记录，根据需要进行更新Determineappropriatemethodandfrequencytoconduct,checkandupdatelayeredauditchecklist决定合适的方法和频率来进行审核和更新分层评审检查单ProcessControlLayeredAudit37QualityFocusedAudit

PerfoIdentifyqualityfocusedCheckitemsattheplant确定工厂内质检项目Developmethodandfrequency开发方法和频次Create/updatelayeredauditcheck-sheet建立/更新分层评审检查单单Communicatetoallthelayersoftheleadership与各级领导人员交流Conducttheaudits进行审核ACriticaloperationKPC’s