QIP2-6分层审核.ppt

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,PSA GM Purchasing&Logistic Committee,PSA GM Purchasing&Logistic Committee,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,PSA GM Purchasing&Logistic Committee,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,PSA GM Purchasing&Logistic Committee,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,PSA GM Purchasing&Logistic Committee,Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,QIP2-6分层审核,PURPOSE,Ensure consistent application and execution of standards.,Improve built-in-quality and increase operator/leadership awareness facilitated by coaching/teaching interaction between leadership&operators,SCOPE:,Assembly Area,Manufacturing Operations,Shipping/Receiving,All Operations,Other Support Functions,责任,:,责任人,工厂,/,生产经理,突发情况的应急计划,Introduction,2,LAYERED PROCESS AUDIT,分层审核,目标,:,确保公司内部方法的统一和标准的遵守,改善制造质量，通过领导层和操作人员的辅导,/,学习交流来提高操作人员,/,领导层的质量意识,说明,范围,:,组装,区,生产操作,发运,/,接收,所有的操作,其他支持职能,RESPONSIBILITY,:,Ownership,Plant/Operations,Mgr,Contingency Plan for All Situations,BENEFITS:,Layered,Process Audits provide a system to,:,verify compliance to the documented process.,instill discipline.,improve communication,.,improve overall quality,.,Ensures a high level of process control by identifying&controlling high,risk/significant,process elements,.,Maintains proper application of standards as defined&achieved through operational readiness process.,Identify opportunities for improvement&provide a process for effective follow up,.,3,LAYERED PROCESS AUDIT,分层审核,收益,:,分层审核提供一个体系，实现：,检查实际操作同书面程序,/,过程的符合性,逐步建立组织纪律,改善交流,改善总体质量,通过识别,&,控制高风险,/,关键过程来,保证,过程控制,保持标准的正确实施,识别改善的空间,&,实现有效的跟踪,Layered Process Audit Strategy,what are we searching for?,分层审核战略，我们查找什么？,Criteria of Requirement,1 page 5-8,2,pa,ge,9-12,3 page 13-16,4 page 8,5,page 16,Auditor hints page 17,Next Requirement,LAYERED PROCESS AUDIT,分层审核,4,Process Overview Layered Audits,分层审核过程概览,Safety PPE,Standardized Work,In process,Product Checks,WPO,Visual,Mgmt.,Tool Maintenance,Process Control,Checksheets,Etc.,QSB+Key Elements,QSB+,关键要素,Layered Audit,分层审核,Performance Reviewed,in Plant Leadership Meeting,在工厂领导会议上回顾审核效果,Non-conforming info,-Countermeasures,不符合信息,应对措施,Performance,Metrics,绩效指标,Completion of audits to,schedule,按计划完成审核,Compliance,符合性,Basis of Layered Audits,分层审核基础,Group Leader Audit,团队领队审核,Shift Leader,Audit,班组领班审核,Plant Staff Audit,工厂领导审核,Team Leader Audit,小组长审核,5,LAYERED PROCESS AUDIT,分层审核,安全,PPE,标准化作业,在制品检查,WPO,可视化管理,工装维护,过程控制检查单,等等,Process explanation,6,Layered,Process Audit(LPA)is a standardized audit performed on a,regular,frequent basis by all layers of the organization to,verify adherence,to operational standards,.,LPAs,are an industry standard,.,LPAs,supplement ongoing control plan and job instruction checks,.,LPAs,shall be owned by manufacturing leadership(Team Leader Plant/Operations Manager,).,Quality,and other functions will participate and support the LPA,system.,LAYERED PROCESS AUDIT,分层审核,过程解释,分层审核是由公司所有层次人员参与的，按固定频次实施的标准化的审核。目的在于检查实际操作是否符合操作标准,LPA,是工厂标准,LPA,进度,控制计划和作业指导书检查,LPA,应该由生产部门领导层牵头（团队,领导,工厂,/,生产经理）,质量和其他职能部门参与并支持,LPA,体系,Process explanation,(continued),The,Layered Process Audit system,includes:,Schedule and tracking of audits,.,Identifying high risk items for the LPA,.,A LPA Checklist that evaluates current processes to,established,standards,.,Identification of corrective action requirements and countermeasures,.,Regular review process by senior management of the,audit results,and corrective actions,.,LAYERED PROCESS AUDIT,分层审核,过程解释（接上页）,分层审核体系包括,:,审核计划和跟踪,识别高风险问题，,LPA,覆盖这些问题,通过,LPA,检查表评估现行过程同标准的符合情况,识别纠正行动的要求和应对措施,高级经理定期检查审核结果和纠正行动,7,大家应该也有点累了，稍作休息,大家有疑问的，可以询问和交流,8,Pick the station to be audited based on the,LPA schedule,根据,LPA,计划选择需要审核的工位,Follow LPA,Check sheet,依据,LPA,检查表进行审核,Immediately inform all,Team members about the audit results.,立即将审核结果通知给所有小组成员,Record all deviations on LPA Check sheet and Countermeasure sheet.,在,LPA,检查表和应对措施表中记录发现的偏差,Assign target close date&champion,给出问题关闭时间,&,负责人,Implement suggested countermeasures as soon as possible.,尽快实施建议的应对措施,Follow-up on open items,make sure to close by target close date,.,跟踪立项问题，确保问题如期关闭,Elevate problem to higher level after target Close date.,如果超过关闭期则将问题向上升级,Perform Management review.,管理层回顾评审,Choose the,Workstation,选择工位,Conduct the Audit,实施审核,Give feedback&document results,给出反馈,&,书面结论,Follow-up,跟踪,Process explanation,(continued),过程解释（接上页）,LAYERED PROCESS AUDIT,分层审核,9,LPA results are documented on LPA Check sheet,The intent is to have a single page LPA Check sheet form that is manually completed on production floor.The back side of the form is available to write down the non-compliance comments.,Establish LPA Check sheet questions from the high risk items,A LPA Check sheet should have two common sections(Workstation and Manufacturing System)and one section(Quality Specific),that is customized to a specific Product Line or Area of the Plant.,Workstation and Quality Specific sections of the LPA Check sheet shall be completed by all auditors.The Manufacturing System section shall be completed by the site leadership only.,A,LPA Check sheet should be created for each unique processing area,LPA Check sheet,10,LAYERED PROCESS AUDIT,分层审核,在,LPA,检查表中记录,LPA,结果,要建立一个单页的,LPA,检查表，在生产车间手动填写。检查表背面可以书写对发现的不符合的意见,针对高风险问题建立,LPA,检查问题表,LPA,检查表要有,2,个共同的部分（工位和生产体系）和适用于工厂的特殊生产线和区域的,1,个特殊部分（质量特性）,所有,审核,人员都要填写,LPA,检查表的工位和质量特性部分。生产体系部分只能由生产现场领导层填写,每个加工区域都要有,LPA,检查表,LPA,检查表,Section#1:1,部分：,COMMON Workstation Questions,、,一般的工位问题,Section#3:3,部分,COMMON Manufacturing System,Questions,一般的生产体系问题,Section#2:2,部分：,UNIQUE Quality Focused,Questions,质量问题,In this Example the Manufacturer would have(4)four unique one page audit forms/files,to cover all processes.,在这个例子中，这家供应商有,4,个单页审核表,/,文件，覆盖所有的过程,(Example,例,),LPA Check sheet,(continued)LPA,检查表（接上页）,HEADER:,Enter the System Name,Product line or an area of the Plant,表头：输入体系名称生产线或者工厂区域,Molding,成型,Paint/Coating,油漆,/,镀层,Assembly,组装,Warehouse/Shipping,仓储,/,运输,11,LAYERED PROCESS AUDIT,分层审核,Header&Work Station Specific,表头,&,工位特性,(Example,例,),LPA Check sheet,(continued)LPA,检查表（接上页）,Has the team member been qualified to requirements of the job and is this documented?,团队成员是否符合岗位要求的资质？是否有记录？,12,LAYERED PROCESS AUDIT,分层审核,Quality Specific&Manufacturing System,质量特性,&,生产体系,(Example,例,),LPA Check sheet,(continued)LPA,审核表（接上页）,13,LAYERED PROCESS AUDIT,分层审核,High risk items shall be identified and included in the audit.,They,should be,organized in 3 main sections:,Workstation Specific 5S,Workplace organization,Safety,Ergonomic list of checks,applicable to all workstations,Quality Focused checks,are specific to operations and developed by,product line or area,based on quality,feedback(internal/external),process knowledge,and problem,solving,Manufacturing System Specific Flexibility Charts up to date,Workplace Organization being followed,Process Control Plan up to date and followed,Material properly identified,Fast Response meeting are taking place and Exit Criteria is being followed in a proper way,Call for help system working,Business Metrics on the Shop Floor posted and up to date,Layered Audit being performed and actions are being implemented,etc.list of checks applicable to an area/department/plant,14,Development of high risk items for auditing,LAYERED PROCESS AUDIT,分层审核,识别高风险问题并纳入到审核中,问题应该分为,3,个主要方面：,工位特性,5S,工位,组织,，安全，人机工程,检查表，适用于所有的工位,质量特性,用于检查操作问题，由生产线,/,区域的人员根据质量反馈（内外部），对过程的了解，和问题解决方法开发检查项,生产体系特性,岗位能力矩阵图更新，遵守工位组织，过程控制计划更新并遵守，材料识别恰当，快速反应会正常召开并遵守退出标准，求助系统正常运行，商务指标张贴在车间并及时更新，实施分层审核，落实行动计划等。检查清单适用于区域,/,部门,/,工厂,审核识别并覆盖高风险问题,The,Workstation Specific section,of the Layered Audit Check Sheet is used by all levels of the organization.This section looks at things such as:,Ensuring proper safety and ergonomic practices and PPE are being followed.,Ensuring proper tools,gages and materials are available&used.,Ensuring,standardized work,&quality standards are understood&followed.,Ensuring Andon system is functioning properly.,Ensuring Workplace Organization&Visual Management standards are maintained(e.g.according to the plant WPO standards and Visual Management policy).,Ensuring compliance to Material Processes FIFO/Min.-Max.levels.,15,Development of high risk items for auditing,(Continued),LAYERED PROCESS AUDIT,分层审核,分层审核检查表的工位特性部分适用于所有层次的检查人员。这一部分主要检查以下方面（例）,:,确保合适的安全和人机工程，遵守,PPE,要求,确保合适的工装，检具和材料可用并在使用,确保标准化作业,&,质量标准被理解并遵守,确保,Andon,系统运行正常,确保遵守工位组织,&,可视化管理标准（例如：遵守工厂的,WPO,标准和可视化管理制度）,确保符合材料过程,FIFO/,最小,最大高度等,审核覆盖高风险的问题（接上页）,The,Quality,Focused section,(used in production areas),covers all important quality issues for specific area/plant and is also used by all levels of the organization to support the team member,Ensuring control of identified significant process elements which can impact,Warranty,Customer(Internal/External),Specific items,regarding corrective action implementation to customer concerns.(e.g.,error proofing,verification,use of fixture added to complete,standardized work,Ensure,error proofing,is functioning properly and identified high risk/significant process elements are controlled to prevent known problems from reoccurring,Ensure required quality inspection and/or documentation is being completed.,16,LAYERED PROCESS AUDIT,分层审核,Development of high risk items for auditing,(Continued,）质量部分（在生产区域使用）覆盖特定区域,/,工厂的所有重大质量问题并且所有层次人员使用这一部分来支持操作人员：,识别出对以下方面有影响的过程并确保其受控：,保修,客户（内部,/,外部）,客户问题纠正,行动相关,的问题（例如：防差错检查，夹具使用等纳入到标准化作业中）,确保防差错正常运行，并且识别出的高风险,/,关键过程受控，预防已知问题复发,确保实施质量检查并,/,或做记录,审核覆盖高风险的问题（接上页）,In addition to the Workstation Specific and Quality Focused sections,Managers/Directors/CEO also review an area/department using the,Manufacturing System Specific audit,for things such as:,(Note:Supervisor/Group Leader/Team Leader are not required to complete this portion of the Layered Audit.),Completion of safety talks&tours,Compliance to Process Control Plans,Conformance to Workplace Organization standards,Proper use of the Andon System,Effective Problem solving&countermeasure implementation,Effective use of Layered Process Audits process for control and follow up,Verification that special process audits are performed shall be included as applicable.(e.g.CQI 9,11,12,Weld Audit,Chrome Audit,Paint Process Audit),）,17,LAYERED PROCESS AUDIT,分层审核,Development of high risk items for auditing,(Continued),除工位特性和质量特性部分外，经理,/,总经理,/CEO,也要使用生产体系特性审核某个区域,/,部门，需要检查例如,：（注：检查员，小组长,/,团队领导不要求做这一部分的分层审核）,进行安全问题交流和现场视察,符合过程控制计划,符合工位组织标准,正确使用,Andon,系统,实施有效的问题解决方法,&,应对措施,有效利用分层审核进行控制和跟踪,检查特殊过程审核的实施情况（例如,CQI9,11,12,焊接审核，镀铬审核，油漆过程审核等）,审核覆盖高风险的问题（接上页）,Auditor hints,-Verify if the LPA procedure define,：,-Frequency,-who shall perform the LPA,-how to conduct the LPA(standard method),-how to record and treat issues,Examples of fields in the LPA check sheet form:,Workstation,-PPE:the team member is using all the posted Personal Protective Equipment,-Work Instructions(for example:Standard Operation Sheet,Job Element Sheet).,-Proper tools,gages and materials available and used.,LAYERED PROCESS AUDIT,分层审核,审核注意事项,-,检查,LPA,程序是否定义了：,-,审核频率,-,谁做,LPA,-,如何做,LPA(,标准的方法,),-,如何记录和处理问题,LPA,检查表部分示例,工位,-PPE:,小组成员都佩戴了个人防护装备,-,作业指导书（例如：标准化操作表，岗位要素表等）,-,合适的工装，检具和材料可用并在使用,18,Auditor hints,(Continued),Quality Focused,-Specific Controls are in place in order to protect the customer and they are effective,-Ensure control of significant process elements which can impact areas such as Customer Satisfaction,PPM,Warranty.,-Ensure control of high risk elements including:Operator/Process Sensitive Operations,Key Process Control Operations/Checks,Mandatory Assembly Sequence Operations.,Manufacturing System,系,-Visual Management:conditions out of target were identified and theres an action plan,-Errors Proofing Verification activity is being performed,-Flexibility Chart is up to date,-Verify that auditor understood the questions,LPA check list filled in properly:follow a team/group leader in a LPA.Verify if they use the Standard Method.,LAYERED PROCESS AUDIT,分层审核,审核注意事项（接上页）,质量特性,-,有特殊控制用以保护客户，有效性,OK,-,确保影响例如客户满意度，,PPM,保修等方面的关键过程的各要素受控,-,确保高风险要素受控，包括：操作人员,/,过程敏感的操作，关键过程控制操作,/,检查，强制组装顺序的操作等。,生产体系,-,可视化管理：识别超出目标的问题，建立行动计划,-,实施防错检查,-,岗位能力矩阵图更新,-,检查审核员是否理解问题，,LPA,检查表是否正确填写：在,LPA,时跟随一个小组长,/,团队领队，检查他们是否使用标准化的方法,19,Levels and schedule,what are we searching for?,层次和计划，我们查找什么？,Criteria of Requirement,1 page 20-22,2,p,age,20-21,3 page 23,Auditor hints page 24,Next Requirement,Prev.,Requirement,LAYERED PROCESS AUDIT,分层审核,20,Define the organization levels to perform audits.,Define audits frequency for each level of the organization.,Layered Process Audits levels&frequency:,Daily,the manufacturing supervisor or Team Leaders/team members shall perform audits(in all shifts).,Weekly,the manufacturing area manager or Management Support Staff (i.e.Engineering,Maintenance,Quality)shall audit&verify that supervisor or Team Leader verification is being completed.,Monthly,the site leadership(Plant Manager)shall conduct Layered Process Audits and review audit results and corrective actions.,Quarterly,CEO shall audit and verify that previous levels LPA and process specific audits have been performed.,Scheduling and tracking,LAYERED PROCESS AUDIT,分层审核,确定什么层次的人员做审核,确定每个层次人员的审核频率,分层审核人员层次,&,审核频率,生产检查员或者小组长,/,团队领队每天做审核（覆盖所有班次）,生产区域经理或者管理支持人员（例如：工程师，维护人员，质量人员等）每周审核，并检查生产检查员或小组长是否按要求做了审核,工厂领导（工厂经理）每月做分层审核，检查审核结果和纠正行动,CEO,每季度检查之前层次人员是否做了分层审核和过程特殊审核,计划和跟踪,21,Supervisor/Team Leader,Daily/Weekly,Manager/Engineers,1 time/week,Plant Manager,1 time/month,Executive,Managers,/Directors,Quarterly/,minimum,Supervisor/Team Leader,Daily,Manager/Management support staff,1 time/week,Plant Manager,1 time/month,CEO/Executive,Managers,/Directors,Quarterly/,minimum,(Example),Scheduling and tracking,(continued),22,LAYERED PROCESS AUDIT,分层审核,Supervisor/Team Leader,Daily/Weekly,Manager/Engineers,1 time/week,Plant Manager,1 time/month,Executive,Managers,/Directors,Quarterly/,minimum,检查员,/,团队领队,每天检查,经理,/,管理支持人员,每周,1,次,工厂经理,每月,1,次,CEO/,执行经理,/,总经理,/,至少每季度审核,(Example,例,),Scheduling and tracking,(continued),计划和跟踪（接上页）,23,LAYERED PROCESS AUDIT,分层审核,The example at the right is another way to ensure each station within a work area is evaluated at a minimum,on a monthly basis(including containment activities,rework areas and material handling).This chart is used by all auditors to determine which stations have not yet been audited and requires the auditor to write down their name,date,and shift for the stations they chose for the audit.,The goal is to audit each work station where a team member is present one time each month.,右边的例子是另一种方法，来确保某个工作区域内的每个工位至少每月审核一次（包括遏制行动，返修区域和材料处理）。审核人员可以使用这张表找出哪些工位还没做审核，已做的审核要求审核员填写他们的姓名，审核日期，和选择的什么班次。,目的在于每月对所有的工位做一次审核。,(Example,示例,),Scheduling and tracking,(continued),计划和跟踪（接上页）,24,