绿色动力_LPA

LayeredProcessAudit(LPA)分层过程审核(LPA)什么是分层过程审核?TherearetwoTypesofLayeredProcessAudits:有两种分层过程审核:ProcessControlAudits过程控制审核Error&MistakeProofingVerificationAudits防错防误验证审核LayeredProcessAudits(LPA)areasystemofauditsperformedbymultiplelevelsofmanagement.Keyprocesscharacteristicsareauditedfrequentlytoverifyprocessconformance.分层过程审核(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.分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。WhatisaLayeredProcessAudit(LPA)?什么是分层过程审核（LPA）？LPA’sassurethatdefinedmethodsandworkinstructionsareutilized,problemsolvingsolutionsareheldinplace,andallprocessissuesareidentifiedandquicklycorrected.分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.分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。•Continuousimprovementactions不断的改进行动•Communication沟通•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提高一次通过率•OverallqualityandReducescosts提高整体质量和降低成本•Maintainsdiscipline提高工艺纪律•Morale提高士气Improves提高•Buildvariationbasedonworkstandardization因为工作的标准化而产生的多样性•ReworkandPartdefects减少返工和零件缺陷•ScrapandEliminateswaste减少废品和杜绝浪费•Processerrorsandoperatormistakes减少过程和操作者错误Reduces减少LayeredProcessAuditBenefits分层审核的好处LPAImplementationApproach4phases:实施LPA的4个阶段1：DevelopyourLPAPlan发展你的LPA计划2：ReviewandApproveyourLPAPlan回顾和批准你的LPA计划3：ImplementyourLPAPlan实施你的LPA计划4：InstitutionalizeLPAProcesses建立制度化的LPA流程Phase1:DevelopYourLPAPlan编制分层审核计划UnderstandwhereLPAfitswithinyourAQPProcesses了解在我们APQP过程中那里适合LPAReview&ApproveLPAPlan&ChecklistPSOApprovalPFMEADevelopmentControlPlanDevelopmentDevelopLPAPlan&ChecklistsThemeFinalSpecsS1EndS2EndSelection(Lastenheft)PPDCSOStartSOEndS1StartS2Start&V1PostV1Review&ApproveLPAPlan&ChecklistPFMEADevelopmentControlPlanDevelopmentDevelopLPAPlan&ChecklistsToutilizeasbaselineforfutureprogramsCurrentProgramFutureProgramLayeredProcessAuditResultsToImproveexistingprocessFormaLPATeamtoimplementtheauditprocess成立一个分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。Phase1:DevelopYourLPAPlan编制分层审核计划FormanLPATeamtoImplementtheAuditProcess.Teamshouldbe…建立一个LPA团队去实施审核，团队应是：–Multi-functional:Manufacturing,Quality,Engineering,Maintenance多功能的：制造、质量、工程、维护–Multi-level:Managers,Supervisors,Inspectors,Operators多层次的：经理、主管、审查、操作者–Inclusiveofuppermanagement包括高层管理–LedbyaProcessOwner(PlantManagement)andImplementationTeamLeader由流程的Owner（工厂经理）和实施团队的Leader领导Utilizebasicprogrammanagementtechniques.利用基本的管理方法–Empowertheteamstomakedecisions.授权团队去做决定–NotifyotherManagementtoprovideimmediatesupportwhenrequested.通报相关领导在需要时立即提供支持–Schedulefrequentmeetings.定期的会议–DevelopanActionPlantoidentifyallimplementationsteps.提出行动计划来明确全部的实施步骤–ManagementteamsshouldperiodicallyreviewtheActionPlanandstatusoftheactionitems.管理团队应该定期回顾行动计划和行动状态Phase1:DevelopYourLPAPlan编制分层审核计划Machining加工Assembly装配PreventiveMaintenancetasks预防性维修任务Calibrationofgages量具的校验Technicalparameters技术参数Set-upproceduresbeingfollowed按照调整程序操作Machinesetting设备调整Processsheets工艺文件Processdocumentsbeingfollowed按文件操作Toolchangeverification换工具后的验证Productiontraceability生产的可追溯性Sustainmentof5Sworkplace文明生产５ＳGageplanbeingfollowed测具计量计划的实施Samplepartretention样件保留SPCdatacaptureandchartingＳＰＣ的有效控制Masteringofgage量具控制Error&mistakeproofingnonconformancetesting防错…………….PreventiveMaintenancetasks预防性维修任务Operationmovement作业动作Partidentification零件识别Calibrationofgages量具的校验Reworkcontrol返工控制Sustainmentof5Sworkplace文明生产５ＳProductiontraceability生产的可追溯性Processsheets工艺文件Processdocumentsbeingfollowed按文件操作Packingandlabels包装和标签Calibrationofgage量具的校验Inspectionplanbeingfollowed检测计划的实施Torquemonitoring扭矩监控VPI新品控制Error&mistakeproofingnonconformancetesting防错……………TypicalAuditElements典型审核要素Verify!Verify!Verify!DevelopAuditChecklistusingtypicalauditelementsandErrorandMistakeproofingguidelines用一些典型的审核要素和防错指导编制审核表Phase1:DevelopYourLPAPlan编制分层审核计划Checkallmistakeproofingdevicesatleastonceperday.每天至少检查一次全部防错装置Checkallcriticalmistakeproofingdevicesatleastoncepershift.每班至少检查一次关键防错装置Sendaknownnon-conformingpartthroughthesystemordevice.用一个已知的不合格零件对防错装置进行检查Documentchecksonachecklistorlog.文件检查CheckallErrorproofing–whichshouldpreventthemanufactureofnon-conformingproduct(i.e.it’sdesignedoutofthepart).检查全部的防错－防止生产出不合格品CheckallMistakeproofing–whichshoulddetectandstopthetransferofnon-conformingproduct.检查全部的防错－发现和终止不合格品的移动Checkallmistakeproofingdevicesthatmightfailorwear