戴姆勒克莱斯勒LPA

LayeredProcessAudit(LPA)

逐层过程审核(LPA)SQAP供应商质量保证程序1Copywrite@2005byDaimlerChryslerSupplierInterface–LPA’swillbeMandatory

供应商接口-逐层过程审核是被强制性的ISO/TS16949

DaimlerChryslerCustomerSpecificRequirements戴姆勒-克莱斯勒用户特别要求NewsectionunderInternalAudits正对新章节进行内部审核Effective7/01/04forPowertrain&ComponentPlantssuppliers;对传动系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SQAP2Copywrite@2005byDaimlerChryslerWhatAreLayeredProcessAudits?什么是逐层过程审核?TherearetwoTypesofLayeredProcessAudits:有两种逐层过程审核:

ProcessControlAudits过程控制审核Error&MistakeProofingVerificationAudits防错防误验证审核

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。ThepurposeofLayeredProcessAuditsistoensurecontinuousconformancetherebyimprovingprocessstabilityandfirst-timethroughcapability.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。SQAP3Copywrite@2005byDaimlerChryslerWhatisaLayeredProcessAudit(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、防错装置和其他输入是否到位从而确保产品无缺陷产生。SQAP4Copywrite@2005byDaimlerChryslerWhoPerformsLayeredProcessAudits?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。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&MistakeProofingVerificationauditsshall

beconductedoncepershift.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。建立、维护或质量审核员通常是具备资格的人员。SQAP5Copywrite@2005byDaimlerChryslerCostofNon-ConformancesatVariousPointsDefectfoundat:The Next Endof Final EndUser’sSource Process LineInspection Hand*Veryminor*Scrap *Repair*SignificantRework*3rdPartyContainment *MinorDelay*Containment*AdditionalOperations*PremiumFreight *Rework*Overtime*Administrativecosts*Reschedule*Delayindelivery*WarrantyCostsofWork*Addedinspection*Reputation *Lostmarketshare *LostbusinessNote:Takenfrom“LayeredProcessAudits”,TheLuminousGroup,LLCEarlyDetection/PreventionSQAP6Copywrite@2005byDaimlerChrysler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SQAP7Copywrite@2005byDaimlerChryslerLPABenefits逐层过程审核的优点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SQAP8Copywrite@2005byDaimlerChryslerLPASuccessatKokomoTransmissionPlant

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逐层过程审核0ProcessLayeredAudits

0层过程审epairInventory修理库存FTC一次通过率SQAP9Copywrite@2005byDaimlerChryslerLayeredProcessAudit逐层过程审核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SQAP10Copywrite@2005byDaimlerChryslerHowdoesanLPAWork?逐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SQAP11Copywrite@2005byDaimlerChryslerDevelopingthePlan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。SQAP12Copywrite@2005byDaimlerChryslerIdentifyWheretobeginLPAImplementation

确定从哪里开始实施LPA

Review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&RPFMEA,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。Use

Discretion

whenaddingitemstothechecklist

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。SQAP13Copywrite@2005byDaimlerChrysler2XWeek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SQAP14Copywrite@2005byDaimlerChryslerEXAMPLE:LPAFREQUENCYANDSTRUCTURE举例：逐层过程审核频率与结构SQAP15Copywrite@2005byDaimlerChryslerExample:FrequencyChartComplianceMatrix

forSupervisors举例:主管执行频次矩阵图Note:ExampleIllustratesthat3rdShiftNotBeingAuditedPertheRotationMatrix–UnacceptableCondition!注意:例子显示,在每个循环矩阵中第三班生产中没有进行审核–不可接受的状况!XXXXXX生产主管周LPA检查计划安排表每9天对每条线轮流每班进行审核.在你工作的那班中,用差号标明已经完成了审核.SQAP16Copywrite@2005byDaimlerChryslerWeeklyAuditRotation9WeekstoRotateThroughall9ProductionLines周审核循环9周内循环审核所有9条生产线

PLANTMANAGERExample:FrequencyChartComplianceMatrix

forPlantManager举例:工厂经理执行频次矩阵图工厂经理周LPA检查计划安排表每条线轮流在每9周进行一次审核.在上面表格中,用差号标明已经完成了审核.SQAP17Copywrite@2005byDaimlerChryslerLPAChecklistDevelopmentSQAP18Copywrite@2005byDaimlerChryslerLPA检查表的制定SQAP19Copywrite@2005byDaimlerChryslerLPAChecklistDevelopment

OPERATION

orPROCESS

LPACHECKLISTQUESTION

CORRECTIVEACTIONRECEIVING

INSPECTION

IfpartsaretaggedwithredNon-ConformanceTag,isthetagcompletewith1)partnumber,2)dateand3)descriptionofthediscrepancy4)disposition?

NotifyReceivingInspectionSupervisor.MOLDING

Verifymachineprocesssettingsarecorrectaspertheset-upsheet.

NotifyMoldingManager.InformQualityInspectortobegincontainment.

Verifythattheoperatorsarecheckingforandremovinganyflashfromedgesofthemoldedpart

NotifyMoldingManager.InformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifythattheoperatorsaredocumentingflashremovalonoperatorinspectionform.

Notifydepartmentsupervisor.HEATSTAKE

Istheoperatorusingthedigitaldial-indicatortocheckthestakeheightofassemblyasperinspectioninstructions?

Notifydepartmentsupervisor.(ErrorDetectiondeviceatnextstationissettorejectnonconformingparts.)

Verifythatthe#2temperaturegagereadsbetween140and150degreesFahrenheit

NotifyareasupervisorandEngineeringManager.InformQualityInspectortobegincontainment.ASSEMBLY

Verifytheoperatorisapplyinggreaseonboththespringandpivotpin

NotifyAssemblySupervisorInformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifyonthreeassembliesthatthepartsarefreeofexcessgreaseandflash.

NotifyAssemblySupervisorInformQualityInspectortobegincontainment.

Verifythatthehandleoperatessmoothlywithoutbindingorsqueak

NotifyAssemblySupervisorInformQualityInspectortobegincontainment.SHIPPING

Usingonepartfromthetopofapackedtray,verifythatthepartnumberstampedonthepartmatchesthepalletlabel

NotifyMaterialsManagerInformQualityInspectortobegincontainmentandinitiateaC.A.R..

Verifythatshippinglabeloneachwrappedpallethasabluedotwithinitialsanddate

NotifyMaterialsManagerInformQualityInspectortobegincontainmentandinitiateaC.A.R..SQAP20Copywrite@2005byDaimlerChryslerLPA逐层检验清单的制定

操作或流程

LPA逐层检验清单提问

纠正行动进货检验

零件是否被贴上了红色不符合标牌,标牌是否包括:1)零件号,2)日期,3)不符描述,4)位置?

通知进货检验主管.造型

确认机器的流程设置是按照流程过程卡进行设置的.

.通知造型经理;通知质检员开始实施遏制措施.

确认操作工人正在检查并清除成型零件边缘上的光泽.

通知造型经理;通知质检员开始实施遏制措施并采取一个C.A.R(纠正行动请求).

确认操作工人在工位零件检验表上记录了将光泽清除的行为.

通知部门主管热桩

操作员是否按照检验要求使用数字表来检验桩的高度?

通知部门主管,(下个工位设置了错误检测装置来拒绝不符合零件的通过);

确认2号温度表的读数在140到150华氏度之间.

通知区域主管和工程经理.通知质检员采取遏制措施.装配

确认操作工人正在对弹簧和转动梢上添加润滑油.

通知装配主管;通知质检员开始采取遏制措施并实施一个纠正行动请求.

确认在三个总成上,零件没有多余的润滑油和光泽.

通知装配主管;通知质检员开始采取遏制措施.

确认手柄的活动自如且无阻塞或吱吱响

通知装配主管;通知质检员开始采取遏制措施.运输

从装满零件的工位箱中拿出一个零件,确认贴在这个零件上的零件号与工位箱上的零件号标签一致.

通知材料经理;通知质检员采取遏制措施并实施一个纠正行动请求.

确认每个零件包裹托盘上贴着的发货标签上有一个大写字母和日期的蓝点

通知材料经理;通知质检员采取遏制措施并实施一个纠正行动请求.SQAP21Copywrite@2005byDaimlerChryslerDevelopAuditChecklist.

制定审核检查表-ProcessControlAuditChecklist.过程控制审核检查表-Error&MistakeProofingVerificationAuditChecklist.防错防误验证审核检查表

Consider:考虑到:Questionsmustbeconciseandspecific.提问必须简明具体Phrasequestionssoa“no”alwaysindicatesanonconformance.使用简单提问,使用“不”来表明一个不符合.Questionsshouldincludecompleteidentificationof operation,equipment,documentation,etc…

提问应该包含对操作、设备、文件等的完整说明。Reactiontonon-conformancesmustassureimmediateresponse.对不符的响应速度必须及时。SQAP22Copywrite@2005byDaimlerChryslerMakingQuestionsSpecific(Example#1)

使问题具体(举例#1)InitialQuestion最初提问:InspectionLogBook:Lookandseeifthelogisbeingfilledoutproperlyandchecksarebeingmade.检验记录书:检查记录是否填写正确,同时是否完成了检验.ImprovedQuestion改进提问:InspectionLogBook:VerifyQAFM250092isbeingfilledoutwithdate,shift,badge,andinitialsandchecksarebeingmade.(MissingorIncorrectdatacouldresultinincorrectunitsbeingheldintheeventofacontainment.)检验记录书:确认QAFM250092的记录填写了日期,班次,印章,和大写字母,同时检验是否已经完成.(缺少数据或错误数据可能会将不正确的零件带入到遏制行动中).What什么?How如何?Why为什么?SQAP23Copywrite@2005byDaimlerChryslerMakingQuestionsSpecific(Example#2)

使问题具体(举例#2)InitialQuestion最初提问:PistonRetainerInstall:Istheoperatorapplyinggreasetothegasket?(Absenceofgreasecouldresultinagasketfailure.)活塞卡环安装:操作员是否正在向垫圈上加润滑油?(缺少润滑油可能导致垫圈失效.)ImprovedQuestion改进提问:InspectionLogBook:IstheoperatorusingthegreasedispensertoapplygreasetotheL/Rgasket?(Absenceofgreasecouldresultinamiss-locatedgasketandleaktesterrejectorawarrantyfailure.)检验记录书:操作员是否正在使用油嘴向左后垫圈上加润滑油?(缺少润滑油可能导致垫圈错位且在泄漏检验仪上被拒绝通过,或带来售后故障.)SQAP24Copywrite@2005byDaimlerChryslerCustomerReview&Approval客户审核与批准YourCustomershallreview&approveLPAPlanwithsupplier(RequiredonlyforHigh&MediumRiskParts)priortothePSOvisit.Forlowriskparts,suppliersshallapprovetheirownLPAplan.

在PSO访问前，你们的客户应该与供应商一起评审并批准LPA计划。(仅对高风险和中风险零件有此要求)。对于低风险零件，供应商应该批准其自己的LPA计划。TheLPAPlanshallinclude(ataminimum)LPA计划应至少包括：LPARoll-OuttimingplanLPA滚动计划Frequency/Schedule&StructureChart

频次/计划与结构图AuditorTrainingPlan

审核员培训计划Checkliststhatincludeanarea/sectionforenteringimmediatereactionplan(s)

包括实施迅速反应计划的区域/部分的检查清单Non-conformancecorrectiveactionprocedure

对不符合的更正行动程序ScheduleofmanagementreviewsforLPAresultsLPA结果的管理检查进度ProvisionsforeventualLPAcoverageofallpartsproducedatsupplier’slocation

在供应商地点生产的所有零件的最终LPA范围的规定SQAP25Copywrite@2005byDaimlerChrysler

AuditorsmustunderstandLPAstrategyandpurpose.

审核员必须理解LPA策略和目的。Reviewchecklistandreactionswithauditors.

和审核员共同分析检查清单和反应计划。Auditorsmustknowtorespondimmediatelyafterfindinganonconformance.

审核员必须在发现一个不符合时快速作出响应。EMPVAuditorsshallbequalifiedtoperformerror andmistakeproofingverification.EMPV审核员具备执行防错防误验证的资格。Performapracticeauditwhereappropriate.

在适用的时候执行一次审核实践。OncetheLPAplanisapproved,theSuppliershalltraintheirLayeredProcessAuditors.一旦LPA计划得到批准，供应商应该培训自己的逐层过程审核员TrainAuditors培训审核员SQAP26Copywrite@2005byDaimlerChrysler

NotifyWorkforce通知操作工人Explainwhy

theLPAisbeingimplemented.

解释为什么LPA在被执行。ExplainthepurposeandbenefitsoftheLPAprocess.

解释LPA程序的目的和益处。

InformworkforceofLPAactivityandwhattoexpectwhenauditsareperformedintheirworkareas.

当在工作地点执行审核时，将LPA活动和对结果的期望

通知给操作工人。

Encourage

workforcefeedback.

鼓励操作工人进行反馈。

CommunicateLPAresultsfrequently.

经常对LPA的结果进行交流。SQAP27Copywrite@2005byDaimlerChrysler

BeginAudits开始审核

Reviewauditresultsfrequentlywhenstartingprocess.

在启动程序的时候经常对审核结果进行回顾。

Improveauditchecklistbasedonauditorfeedback.根据审核员的反馈来改进审核检验表。Managementmustinstilldisciplineearlyintheprocesstocompleteauditsontimeandprovideresourcesforimmediatecorrectiveaction.

管理层必须在程序的早期时候逐渐进行灌输，来按时完成审核并提供资源给快速更正行动。

Duringearlyphase-Managementauditswillfindproblems,butlatermanagementauditswillfindimprovements.

在早期-管理层的审核将发现问题，但是以后管理层的审核会发现改进。 -DevelopandapplyLessonsLearnedtoimproveaudit.-制定并运用吸取的教训来改进审核。SQAP28Copywrite@2005byDaimlerChrysler

CorrectiveactionsshallbedocumentedasrequiredbyISO/TS

更正行动应该按照ISO/TS的标准进行文件记录.Theremustbeasystemtomaintaintheauditscheduleandtrackcompletion.

必须有一套系统来保证审核进度和跟踪它的完成.ImprovementsdrivenbytheLPAprocessshallbemeasured,monitored,andreportedtomanagementasperChryslerGroupTSCustomerSpecifics(.1).

通过采用LPA程序而得到的改进应该是可以被测量、监测的，并能够按照克莱斯勒TS客户规范（.1）的要求向管理层提供汇报。DevelopaMonitoringProcessandReportsfor