Layered Process Audit (LPA) 逐层过程审核(LPA)

Layered Process Audit (LPA) 逐层过程审核(LPA)
SQAP 供应商质量保证程序 by DaimlerChrysler, Version 1.1 October 2005

Copyright @ 2005 by DaimlerChrysler, Version 1.1 October 2005
AGENDA 安排 SQAP Intro to LPA LPA介绍 Developing a effective LPA 制订一套有效的LPA LPA Implementation LPA实施 Tracking Issues and Compliance 跟踪问题和符合性 Questions & Answers 提问和答案 by DaimlerChrysler, Version 1.1 October 2005

Layered Process Audit 逐层过程审核
SQAP AN INTRODUCTION 介绍 by DaimlerChrysler, Version 1.1 October 2005

Supplier Interface – LPA’s will be Mandatory 供应商接口-逐层过程审核是强制性的
SQAP Supplier Interface – LPA’s will be Mandatory 供应商接口-逐层过程审核是强制性的 ISO/ TS 16949 DaimlerChrysler Customer Specific Requirements 戴姆勒-克莱斯勒用户特殊要求 New section under Internal Audits 正对新章节进行内部审核 Effective 7/01/04 for Powertrain & Component Plants suppliers; 动力总成及其零部件的供应商于7/01/04日开始执行； 1/1/05 for all remaining suppliers 对所有其余的供应商于1/1/05年开始执行 Posted on AIAG, IAOB, and QMS web sites 在AIAG， IAOB，和QMS网站上发布 Letter mailed to all suppliers 信函已经发给了所有的供应商 by DaimlerChrysler, Version 1.1 October 2005

What Are Layered Process Audits?
SQAP What Are Layered Process Audits? 什麽是逐层过程审核 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。 The purpose of Layered Process Audits is to ensure continuous conformance, thereby improving process stability and first-time through capability. (As required by Chrysler Group TS Customer Specifics ( ) 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 ) by DaimlerChrysler, Version 1.1 October 2005

What is a Layered Process Audit (LPA)? 什么是逐层过程审核（LPA）？
SQAP What is a Layered Process Audit (LPA)? 什么是逐层过程审核（LPA）？ 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。 LPA’s 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。 by DaimlerChrysler, Version 1.1 October 2005

There are Two Types of Layered Process Audits: 有两类逐层过程审核:
SQAP There are Two Types of Layered Process Audits: 有两类逐层过程审核: 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 & Mistake Proofing Verification audits shall be conducted once per shift at the start of each shift. Only qualified employees shall perform Error & Mistake Proof Verification Audits. Set-up, maintenance or quality auditors are usually qualified. 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。 by DaimlerChrysler, Version 1.1 October 2005

Who Performs Layered Process Audits?
SQAP Who Performs Layered Process Audits? 谁执行逐层过程审核？ Anybody can perform a Layered Process Audit. 任何人都能够执行逐层过程审核。 Manufacturing management must own the process and perform audits.生产管理部门是该程序的归口部门并执行审核。 All managers, regardless of function, can be auditors. 所有经理，无论他的职责是什么，都可以作为审核员。 Each management level should perform audits. 每个管理层都应该执行审核。 by DaimlerChrysler, Version 1.1 October 2005

Layered Process Audit Benefits
LPA的益处 SQAP The implementation of Layered Process Audits: LPA的实施： Reduces variation (both assignable and common cause) 减少变差（普通原因和特定原因） Prevents process errors and operator mistakes 预防过程错误和操作者错误 Improves and maintains discipline 改进和保持纪律 Initiates Continuous Improvement actions 引入持续改进行动 Reduces rework 减少返工 Reduces scrap and eliminates waste 减少废品和消除浪费 Improves communication 改善沟通 Instills and improves standardization 灌输和改进标准化 Improves overall Quality and reduces costs 全面提高质量和降低成本 by DaimlerChrysler, Version 1.1 October 2005

LPA Benefits 逐层过程审核的益处
SQAP Build variation based on work standardization 因工作标准化而使变差减少 End-of-line inspection 线尾检验 Part defects 零件缺陷 Reduces 减少 Improves 提高 First time through capability 一次通过率 Morale 士气 Facilitates 简化 Operator training 操作员培训 Management/operator interface 管理/操作员界面 Reinforces 加强 Safety regulations 安全法规 by DaimlerChrysler, Version 1.1 October 2005

Cost of Non-Conformances at Various Points
SQAP Defect found at: The Next End of Final End User’s Source Process Line Inspection Hand *Very minor *Scrap *Repair *Significant Rework *3rd Party Containment *Minor Delay *Containment *Additional Operations *Premium Freight *Rework *Overtime *Administrative costs *Reschedule *Delay in delivery *Warranty Costs of Work *Added inspection *Reputation *Lost market share *Lost business Note: Taken from “Layered Process Audits”, The Luminous Group, LLC Early Detection / Prevention by DaimlerChrysler, Version 1.1 October 2005

在各阶段发生的不符造成的成本 SQAP 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: Taken from “Layered Process Audits”, The Luminous Group, LLC 早期探测 / 预防 by DaimlerChrysler, Version 1.1 October 2005

SQAP LPA Success Story LPA 成功案例 The DaimlerChrysler Kokomo Transmission Plant 戴姆勒克莱斯勒的变速箱厂Kokomo has achieved significant gains in FTC using LPA. 运用LPA使FTC得到了显著的改进 FTC in the high 90% FTC达到90% Rework now minimal 返工最少 Improvements correlate with LPA deployment 　改进与LPA的开展相关联 It worked for us, it can work for you and your Suppliers! LPA为我们服务，它也可以为你们和你们的供应商服务 MINUTES: 2 Explain graph and ask, “Do you see a correlation in your LPA use?” Draw correlation to hypothesis chart. %FTC Number of LPA Checks Per Week 每周的LPA检查数量 by DaimlerChrysler, Version 1.1 October 2005

How does an LPA Work? 逐层过程审核是如何工作的？
SQAP LAYERED PROCESS AUDITS ARE PROCESS BASED, NOT PART BASED. Corrective Actions 纠正行动 Prevention Actions 预防行动 Employee Workshops 车间职工 Inputs 持续改进输入 Improvement Continuous 逐层过程审核是基于过程的,而不是基于零件的 Process Audits 过程审核 PROCESS 过程 Error Proofing 防误 Audits are conducted regularly by all levels of supervision 各监督级定期地进行审核 Non-conformances are immediately addressed 立即发现不符合处 by DaimlerChrysler, Version 1.1 October 2005

SQAP Proven Successful Internally 内部经过成功验证 Expanding Collaboration to our Supply base 加强与我们供应商网络的合作 Not asking Suppliers to do something we are not 不让供应商做我们不做的事情 Low investment – significant quality return 低投资 – 获得显著的质量回报 by DaimlerChrysler, Version 1.1 October 2005

SQAP II. DEVELOPING A EFFECTIVE LPA 开发出一套有效的LPA by DaimlerChrysler, Version 1.1 October 2005

Developing the Plan 制定计划
SQAP Form a LPA Team to implement the audit process 　成立一个逐层过程审核团队实施审核 * Empower team to make decisions * Upper management should be included on the team Develop procedure for LPA Process and Documentation 　为LPA过程和文件制定程序 Develop audit checklist. 制订审核清单 Based on Key process elements that affect part quality 　基于影响零件质量的关键过程要素。 Determine who will conduct audits. 确定谁来执行审查。 Determine audit frequency for each level (Process Control Audit and Error & Mistake Proofing Verification Audit). 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 Develop a monitoring process and reports for management review. 建立一个监控过程并形成报告供管理层评审。 by DaimlerChrysler, Version 1.1 October 2005

LPA Checklist: Items to include LPA检查表：应包括的项目
SQAP Safety items 安全事项 Craftsmanship items 技术要点 Machine settings & parameters 机器设置和参数 Secondary operations (machining, welding, sub-assy….) 第二道操作工序（机加工，焊接，次级装配） Tool change verification 工具更换验证 Mastering of gages 量检具控制 Set-up procedures 点检程序 Verify layout checks completed 验证布局检查完成 Verify PM checks completed 验证预防性维护保养检查完成 Touch point inspection 触点检查 Part cleanliness (free from burrs, scratches, etc…) 零件清洁度（无毛刺，擦伤等） Housekeeping items 整理事项 by DaimlerChrysler, Version 1.1 October 2005

LPA Checklist Development SQAP by DaimlerChrysler, Version 1.1 October 2005

LPA 检验清单的制定 SQAP by DaimlerChrysler, Version 1.1 October 2005

LPA Checklist Development
SQAP OPERATION or PROCESS LPA CHECKLIST QUESTION CORRECTIVE ACTION RECEIVING INSPECTION If parts are tagged with red Non-Conformance Tag, is the tag complete with 1) part number, 2) date and 3) description of the discrepancy 4) disposition? Notify Receiving Inspection Supervisor. MOLDING Verify machine process settings are correct as per the set-up sheet. Notify Molding Manager. Inform Quality Inspector to begin containment. Verify that the operators are checking for and removing any flash from edges of the molded part Notify Molding Manager. Inform Quality Inspector to begin containment and initiate a C.A.R.. Verify that the operators are documenting flash removal on operator inspection form. Notify department supervisor. HEAT STAKE Is the operator using the digital dial-indicator to check the stake height of assembly as per inspection instructions? Notify department supervisor.(Error Detection device at next station is set to reject nonconforming parts.) Verify that the #2 temperature gage reads between 140 and 150 degrees Fahrenheit Notify area supervisor and Engineering Manager. Inform Quality Inspector to begin containment. ASSEMBLY Verify the operator is applying grease on both the spring and pivot pin Notify Assembly Supervisor Inform Quality Inspector to begin containment and initiate a C.A.R.. Verify on three assemblies that the parts are free of excess grease and flash. Notify Assembly Supervisor Inform Quality Inspector to begin containment. Verify that the handle operates smoothly without binding or squeak SHIPPING Using one part from the top of a packed tray, verify that the part number stamped on the part matches the pallet label Notify Materials Manager Inform Quality Inspector to begin containment and initiate a C.A.R.. Verify that shipping label on each wrapped pallet has a blue dot with initials and date by DaimlerChrysler, Version 1.1 October 2005

SQAP LPA 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工艺卡进行设置的. .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 by DaimlerChrysler, Version 1.1 October 2005

Develop Audit Question
SQAP Questions Objective : Audit questions may ask the auditor to record data, or questions may be phrased to be answered with a “yes” or “no”. When questions are phrased to be answered “yes” or “no”, a “no” should always indicate a nonconformance. Specific: Questions should avoid subjective, unclear and evasive terms, such as properly” or “correctly” Concise: Questions should zero-in on items critical to quality, and be worded so that the audit could be conducted by people unfamiliar with the specific area Explanation Questions should be followed with a brief statement stating the reason for a particular check, thereby reinforcing its importance (e.g., “This is important for unrestrictive movement of the gearshift lever.”) Reaction Plan If the audit situation is out of compliance, vs. established standards, what must be done right away to initiate correction? Countermeasure What measure must be taken to protect the customer, since it is now known that the situation is out of conformance with established standards? by DaimlerChrysler, Version 1.1 October 2005

Develop Audit Question 制订审核问题
SQAP I 问题客观的：审核问题可以要求审核员记录数据或问题，问题可以用“是” 或“不是”回答。当回答“是”或“不是”时，“不是”应表明一项不符合。具体的: 问题应避免主观性，不清楚及推委言辞，如“适当地”或“正确地” 简明的: 问题应关注于对改进质量至关重要的项目，并且问题应使不熟悉特定领域的人员可以开展审核 Ii 解释一项特别检查的提问之后应附带一个简短的陈述说明，进一步加强其重要性（如：“这对于变速档级别的不受限移动很重要。” Iii 反应计划如果审核结果相对制订的标准不符，应立即做什麽以启动纠正行动 Iv 对策既然现在已经知道事实与所建立的标准不符，那麽必须采取什麽措施来保护客户呢？ by DaimlerChrysler, Version 1.1 October 2005

Making Questions Specific (Example #1) 使问题具体(举例#1)
SQAP Initial Question 最初提问: Inspection Log Book: Look and see if the log is being filled out properly and checks are being made. 检验记录书: 检查记录是否填写正确, 同时是否完成了检验. Improved Question 改进提问: Inspection Log Book: Verify QAFM is being filled out with date, shift, badge, and initials and checks are being made. (Missing or Incorrect data could result in incorrect units being held in the event of a containment.) 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使出现的不符合零件被遏制） What什么 ? How如何 ? Why 为什么? by DaimlerChrysler, Version 1.1 October 2005

Making Questions Specific (Example #2) 使问题具体(举例#2)
SQAP Making Questions Specific (Example #2) 使问题具体(举例#2) Initial Question 最初提问: Piston Retainer Install: Is the operator applying grease to the gasket? (Absence of grease could result in a gasket failure.) 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.) Improved Question 改进提问: Inspection Log Book: Is the operator using the grease dispenser to apply grease to the L/R gasket? (Absence of grease could result in a miss-located gasket and leak tester reject or a warranty failure.) 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.) by DaimlerChrysler, Version 1.1 October 2005

Successful LPA Tips SQAP Each audit question should ask HOW? WHAT? And WHY? LPAs should include countermeasures procedures when non-functional. Length of LPAs should never be a concern; Quality knows no length. Items are NEVER removed unless there is a product/process change or improvement. (If error mistake proofing is added for an issue, change audit to check error and mistake proofing). Audits should include visual checks “Catch somebody doing something right.” All quality issues should be addressed with corrective action updated in the LPAs. If separate part numbers, or different customer’s parts share a common line, it should be audited at different times to include all parts. by DaimlerChrysler, Version 1.1 October 2005

成功的LPA技巧 SQAP 每个审核问题都应问：什麽/怎样/为什麽？ LPA应包括对所发现的不具备功能的过程/设备等采取对策程序。 LPA应永无止境；因为质量无止境。除非有产品/过程变更或改进发生否则检查表中的项目不能删除。（如果某一问题增加防误防错，则检查内容作相应更改检查该防误防错）审核应包括目视检查。 “验证他人做正确的事”。所有质量问题应使用LPA中的纠正措施解决。如果不同零件号或不同客户的零件共享一个平台，则应按不同的时间间隔执行审核以覆盖全部零件。 by DaimlerChrysler, Version 1.1 October 2005

LPA Do’s SQAP Make sure EACH process has its own specific LPA 确保每道工序均有自己对应的特定LPA Complete LPAs at the beginning of shift(s) 在开班生产时完成LPA Each operation in the process is on the LPA LPA涵盖过程中的每道工序 Critical plant processes are addressed 着重关键过程 Make sure LPA schedule overlaps with production 确保LPA审核时间表涵盖所有生产区域及班次 schedules, if not continuous 如果不是连续的，按时间表执行 All “No’s” or non-conformances should be addressed immediately 所有回答“No”的问题或不符合应立即着手解决 by DaimlerChrysler, Version 1.1 October 2005

LPA Don’ts SQAP Make sure audit is completed properly. 确保审核适当地完成。 Do not ever consider an LPA as final. It is a living document that should be updated regularly with corrective actions, error-mistake proofing, etc. 不要认为LPA是一成不变的。它是动态文件，应随纠正措施的实施，防误防错的开展定期进行更新。 Do not create one LPA for a whole facility. 不要整个工厂只有一种LPA。 Do not make an LPA generic. 不要使LPA流于俗套 by DaimlerChrysler, Version 1.1 October 2005

Determine Audit Frequency for
Each Level Process Control Audit - Once per shift done by group leaders, supervisors - Management performs audits weekly - Divide manufacturing areas and rotate so all areas are audited Error & Mistake Proofing Verification Audit -Once per shift, at the start of each shift, done by Maintenance, Set-up or Quality Auditor SQAP Minimum frequency requirements shall be met. Any scheduled audit must be performed to maintain discipline and improve quality. by DaimlerChrysler, Version 1.1 October 2005

为每一级别确定审核频率过程控制审核 -由组长，班长每班审核一次 - 管理层每周一次 - 按生产区域划分并且循环以审核所有区域防误防错验证审核 - 在每班生产开始前由点检、维护或质量审核员执行一次审核 SQAP 应满足最低的频率要求. 任何安排好的审核必须执行以维持纪律及改进质量 by DaimlerChrysler, Version 1.1 October 2005

LPA - Frequency Plan 逐层过程审核-频率计划
SQAP LPA - Frequency Plan 逐层过程审核-频率计划 1 X Week 每周一次 Plant Manager 工厂总经理 2 X Week 每周两次 Area Management 区域主任 1 X Shift 每班一次 Production Supervisor 生产主管 Encourages Management Involvement 鼓励管理层参与 Encourages Operator Feedback 鼓励操作员反馈 Establishes Accountability 建立责任制 by DaimlerChrysler, Version 1.1 October 2005

SQAP EXAMPLE: LPA FREQUENCY AND STRUCTURE 举例： LPA审核频率与结构 by DaimlerChrysler, Version 1.1 October 2005

每9天对每条线，每班进行了审核. 在你工作的那班中,用差号标明已经完成了审核.
SQAP Example: Frequency Chart Compliance Matrix for Supervisors 举例: 主管频率图执行矩阵生产主管周LPA检查计划安排表 X X X X X X Note: Example Illustrates that 3rd Shift Not Being Audited Per the Rotation Matrix – Unacceptable Condition! 注意: 例子显示, 在第三班生产中没有进行审核 – 不可接受的情况！每9天对每条线，每班进行了审核. 在你工作的那班中,用差号标明已经完成了审核. by DaimlerChrysler, Version 1.1 October 2005

9 Weeks to Rotate Through 每条线每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.
SQAP Example: Frequency Chart Compliance Matrix for Plant Manager 举例: 工厂经理频率图执行矩阵工厂经理周LPA检查计划安排表 PLANT MANAGER Weekly Audit Rotation 9 Weeks to Rotate Through all 9 Production Lines 周审核滚动执行 9周内滚动审核了所有9条生产线每条线每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. by DaimlerChrysler, Version 1.1 October 2005

Customer Review & Approval 客户评审与批准
SQAP Customer Review & Approval 客户评审与批准 Customer shall review & approve LPA Plan with supplier (Required only for High & Medium Risk Parts) prior to the SQAP visit. For low risk parts, suppliers shall approve their own LPA plan. 在SQAP访问前，客户应该与供应商一起评审并批准LPA计划。(仅对高风险和低风险零件有此要求)。对于低风险零件，供应商应该批准其自己的LPA计划。 The LPA Plan shall include (at a minimum) LPA计划应至少包括： LPA Roll-Out timing plan LPA滚动时间计划 Frequency/Schedule & Structure Chart 频率/计划与结构图 Auditor Training Plan 审核员培训计划 Checklists that include an area/section for entering immediate reaction plan(s) 检查表：包含一栏能够填写即时反应计划 Non-conformance corrective action procedure 对不符合的纠正措施程序 Schedule of management reviews for LPA results 管理层评审LPA审核结果的时间表 Provisions for eventual LPA coverage of all parts produced at supplier’s location 在供应商地点生产的所有零件中最终LPA覆盖哪些零件的规定 by DaimlerChrysler, Version 1.1 October 2005

Supplier’s review & Approval 供应商的评审和批准
SQAP Supplier’s review & Approval 供应商的评审和批准 Supplier shall conduct internal review of LPA Plan 供应商应开展LPA计划的内部评审 * LPA plan to include LPA implementation timing LPA计划要包括LPA实施的时间表 Supplier shall finalize LPA plan 供应商应完成LPA计划 Shall be signed – off by LPA team & Plant Manager prior to approval from your customer 在提交客户批准前LPA团队和工厂总经理应先签字 by DaimlerChrysler, Version 1.1 October 2005

SQAP III. LPA IMPLEMENTATION 实施 by DaimlerChrysler, Version 1.1 October 2005

SQAP Identify Where to begin LPA Implementation 确定从哪里开始实施LPA Review 审查: Customer Complaints, Quality Alerts 客户抱怨，质量警告 First-Time Through data, Scrap Reports 首次交验合格率，废品报告 Key Characteristics and Process Capability: Cpk & Gage R&R 关键特性和过程能力：CPK与量检具重复性再现性 PFMEA, Process Flow Diagram, Control Plan PFMEA，过程流程图，控制计划 Set-up Sheets, Work Instructions, Inspection Instructions 点检表格、操作指导书、检验指导书 Error and Mistake Proofing 防错防误 Quality System Audits, Dock Audits, Inspection Reports 质量系统审核，货场审核，检验报告 Rework instructions 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工厂学习如何实施逐层过程审核的经验教训来源。 Use Discretion when adding items to the checklist 在向检查表中添加项目的时候使用判断力。 Audit items are issues that would cause Customer Dissatisfaction. 审核项目是那些导致客户不满的问题。 by DaimlerChrysler, Version 1.1 October 2005

Notify Workforce 通知操作工人 Explain why the LPA is being implemented. 解释为什么执行LPA。 Explain the purpose and benefits of the LPA process. 解释LPA程序的目的和益处。 Inform workforce of LPA activity and what to expect when audits are performed in their work areas. 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 workforce feedback. 鼓励操作工人进行反馈。 Communicate LPA results frequently. 经常对LPA的结果进行交流。 SQAP by DaimlerChrysler, Version 1.1 October 2005

Train Auditors 培训审核员 SQAP Once the LPA plan is approved, the Supplier shall train their Layered Process Auditors. 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 Auditors must understand LPA strategy and purpose. 审查员必须理解LPA战略和目的。 Review checklist and reactions with auditors. 审核员共同评审检查清单和反应计划。 Auditors must know to respond immediately after finding a nonconformance. 审核员必须在发现一个不符合时立即作出响应。 EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV审核员应该为具备资格的人员来执行防错防误验证。 Perform a practice audit where appropriate. 在适用的时候实践一次审核。 by DaimlerChrysler, Version 1.1 October 2005

Begin Audits 开始审核 Review audit results frequently when starting process. 在刚开始执行审核程序的阶段要经常对审核结果进行回顾。 Improve audit checklist based on auditor feedback. 根据审核员的反馈来改进审核检验清单。 Management must instill discipline early in the process to complete audits on time and provide resources for immediate corrective action. 管理层必须在执行程序的早期阶段灌输纪律，确保审核按时完成并为须采取的即时纠正措施提供资源。 Develop and apply Lessons Learned to improve audit. 建立并应用得到的经验教训来改进审核。 SQAP by DaimlerChrysler, Version 1.1 October 2005

LPA Leadership Role SQAP LPA calls for substantial commitment of management’s time and effort. Leadership’s role is to: Fix system problems Instill discipline Show appreciation to operators for doing work correctly Encourage improvement ideas from the workforce All plant staff should conduct Layered Process Audits throughout the plant During early phase - Management audits will find problems, but later the management audits will find improvements. MINUTES: 3 Fix system problems – leardership’s responsibility to take a big picture view of non-conformances and identify systemic issues. You want to catch somebody doing something RIGHT! Instill discipline – discipline is important to achieve quality. Showing appreciation is a simple way to provide positive consequences and reinforce desired behaviors. Encourage improvement ideas from the workforce – all of plant staff (operations, finance, HR, engineering, etc.) have a role in finding opportunities to improve. by DaimlerChrysler, Version 1.1 October 2005

LPA Leadership Role LPA 领导角色 SQAP LPA calls for substantial commitment of management’s time and effort. LPA 要求管理层做出时间和努力的实质性沉诺。 Leadership’s role is to: 领导角色是 Fix system problems 解决体系问题 Instill discipline 灌输纪律 Show appreciation to operators for doing work correctly 对操作者的正确操作予以感谢 Encourage improvement ideas from the workforce 鼓励操作者提出改进建议 All plant staff should conduct Layered Process Audits throughout the plant 逐层过程审核应贯彻到工厂所有员工 During early phase - Management audits will find problems, but later the management audits will find improvements. 早期阶段- 管理层的审核将发现问题，但是后来的管理层审核将会发现改进。 MINUTES: 3 Fix system problems – leardership’s responsibility to take a big picture view of non-conformances and identify systemic issues. You want to catch somebody doing something RIGHT! Instill discipline – discipline is important to achieve quality. Showing appreciation is a simple way to provide positive consequences and reinforce desired behaviors. Encourage improvement ideas from the workforce – all of plant staff (operations, finance, HR, engineering, etc.) have a role in finding opportunities to improve. by DaimlerChrysler, Version 1.1 October 2005

LPA Successful Implementation Tips LPA 成功实施的技巧
SQAP LPA Successful Implementation Tips LPA 成功实施的技巧 LPAs used as a training tool – new supervisors, new shift of associates. LPA 可作为培训工具- 培训新的主管/班长。 Clipboard required! 需要有纸夹的笔记板！ Do NOT push 100% compliance! Make problems visible. 不要力推100%的符合！让问题曝光。 Have a “system” to deal with audit item non-compliance. 使用“系统”方法解决审核出的不符合。 Track non-compliances and report out at plant manager level. 工厂经理层跟踪不符合及相关报告。 LPA should be completed by plant management- No delegating allowed! LPA应由工厂管理层亲自完成-不允许指派代表！ Wrong mindset if LPA audit is completed on Friday afternoon! 想安排周五下午完成LPA是错误是想法！ If audit issue is found, work for corrective action that is within TAKT time. 如果审核中发现问题，在零件生产时间内即时制订纠正措施予以解决。 by DaimlerChrysler, Version 1.1 October 2005

SQAP IV. TRACKING ISSUES AND COMPLIANCE 跟踪问题以及执行 by DaimlerChrysler, Version 1.1 October 2005

Develop a Monitoring Process and Reports for Management Review.
制定一个监控过程并为管理层评审提供报告 Develop 制定： - Corrective Action Request forms for nonconformnces 为不符合制定更正行动要求表格. - Summary of audit results: Pareto of nonconformances 审核结果总结: 不符合的Pareto图. - Summary of on-time/missed/late audit completion 按时/忘记/延迟审核完成后的总结 - Frequency for management review 管理层检查的频率 - Management reaction plan for LPA process 管理层对LPA过程的反应计划. 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 ( ). 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客户规范（）的要求向管理层提供汇报。 by DaimlerChrysler, Version 1.1 October 2005

DAP LPA Procedure 制订LPA的程序
SQAP DAP LPA Procedure 制订LPA的程序 THE LPA DAILY REVIEW LPA 日常评审 Each morning at the production/ quality meeting there is an LPA Daily Review 生产车间晨会/ 在质量例会上开展LPA 日常评审 LPA Example: DAP ( Detroit Axle Plant) by DaimlerChrysler, Version 1.1 October 2005

Open Issue Tracking Chart 当前问题跟踪单 SQAP Each Department has it’s own issue tracking chart. Open Issue Tracking charts are maintained on the “share” drive so everyone has access to the issues. 每个部门都有自己的问题跟踪表。将未解决的问题跟踪表放作为共享文件使每个人都能够看到。 3. Total # of issues found in department and Total # of Issues Closed are tracked to measure effectiveness of the LPA. 3. 跟踪发现的问题数和关闭的问题数以测量LPA的有效性。 2. Issues are tracked in binary color code. Open issues are in red. Closed issues are in green. 2. 问题跟踪采用两种颜色代码。未解决的问题用红色表示。关闭的问题用绿色表示。 by DaimlerChrysler, Version 1.1 October 2005

Open Issue Tracking Chart 当前问题跟踪单 SQAP 4. Issues are tracked by: 4. Issues are tracked by: 跟踪项包括： Open Date, 当前状态的日期 Item number, 项目编号 Issues Found, 发现的问题问题 Task 任务 Responsibility (Individuals may belong to support departments such as Maintenance, ME, Quality, etc.) 职责（支持部门的人员如：维护保养，ME, 质量等） Target date 目标日期 and Close Date. 关闭日期 by DaimlerChrysler, Version 1.1 October 2005

Open Issue Tracking Chart 当前问题跟踪单 SQAP
As tasks occur or obstacles are encountered on an open item, progression is documented on the open issue tracking chart, along with all target dates from the time the issue was opened. 将新任务以及出现的困难的进展记录在当前问题跟踪单上，问题解决期限也一同注明 by DaimlerChrysler, Version 1.1 October 2005

DAP LPA Procedure SQAP by DaimlerChrysler, Version 1.1 October 2005

DAP LPA Procedure 程序 SQAP 是任务是今明两天到期？之前就已到期？缺少信息？需要10天或更多的时间解决？需要两倍的时间？更新日常晨会总结（保存在 P: 盘）否在网站上公布最新的晨会报告在当前问题跟踪单上维持纠正措施的最新进展 by DaimlerChrysler, Version 1.1 October 2005

DAP LPA Procedure 程序 SQAP by DaimlerChrysler, Version 1.1 October 2005

DAP LPA Procedure 程序 SQAP 采取了纠正措施需要更新LPA吗？是否更新LPA表格（在 P: 盘上）当有需要时，在网站上公布更新的LPA 在当前问题跟踪单上维持纠正措施的最新进展 by DaimlerChrysler, Version 1.1 October 2005

SQAP Manufacturing Location Summary Indicators 制造地点总结结果 Supplier Name 供应商名称: Supplier Location 供应商地点: Please 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. 此图表明了三个管理级别. 克莱斯勒TS要求阐述了供应商必须进行”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检验表上项目数乘以当月这些项目被检查的次数. by DaimlerChrysler, Version 1.1 October 2005

SQAP Manufacturing Location Summary Indicators 制造地点总结结果 Supplier Name 供应商名称: Supplier Location 供应商地点: by DaimlerChrysler, Version 1.1 October 2005

SQAP A successful LPA System should: Have participation from every level Management level support may be necessary to resolve issues Continuously monitor the process Have scheduled reviews of LPA non-conformances Evolve for continuous improvement When issues within the system are found, resolve them. NOTE: The LPA team at DAP has been empowered by their leadership to develop this system as the need presents itself. Report out Make results of audits known as quickly as possible Be accessible to everyone Down to the operator level Be utilized to improve the process Find areas of weakness and make them strengths by DaimlerChrysler, Version 1.1 October 2005

SQAP 成功的LPA体系应：各级别都参与其中管理层的支持解决问题持续监控过程对审核中发现的不符合开展定期回顾开展持续改进当发现体系中有问题，则着手解决注：当有改进需求时，领导层授权的LPA 团队开展体系制定行动尽快将审核结果通知相关人员贯彻到每个人直到操作者级别应用于改进过程找出薄弱环节并予以加强 by DaimlerChrysler, Version 1.1 October 2005

Begin Audits 开始审核 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。 Improve audit checklist based on auditor feedback. 根据审查员的反馈来改善审查检验表。 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，来按时完成审查并提供资源给快速更正行动。 During early phase - Management audits will find problems, but later management audits will find improvements. 在早期- 管理层的审查将发现问题，但是以后管理层的审查会发现改进。 - Develop and apply Lessons Learned to improve audit. - 制定并运用吸取的教训来改进审查。 SQAP by DaimlerChrysler, Version 1.1 October 2005

SQAP Summary 总结 The LPA is an audit of the process. LPA是一个对过程进行的审核 For Medium and High risk parts, both the LPA plan and demonstration shall be approved by the Supplier Quality Specialist. 对于中高等风险的零件，应该由供应商质量专员来批准LPA计划和演示。 The LPA checklist is a living document. LPA检验清单是个动态文件. Plant Management must remain involved and committed to the LPA process. 车间管理层必须参与并保证LPA程序的执行。 The Customer shall review LPA as part of corrective action(s) for quality issues. 客户将评审LPA, 这也是解决质量问题所采取纠正措施的一部分。 by DaimlerChrysler, Version 1.1 October 2005

SQAP Layered Process Audit 逐层过程审核 V. QUESTIONS? 有问题吗？ by DaimlerChrysler, Version 1.1 October 2005

Layered Process Audit (LPA) 逐层过程审核(LPA)

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