【文章內(nèi)容簡介】 t management shall perform the audit once per week. 工廠管理層需每周進(jìn)行一次 LPA Training Revision 2 (February 2022) 22 Process Control Audits Auditors must know the process –審核員必需懂工藝 ? Develop and use a process control audit checklist (Ref. VF213c). 建立并使用審核檢查表（參見 VF213C） ? Process control based upon top 5 RPN’s 過程控制基于 RPN值最高的 5個項目 ? Address high risk items 主要為高風(fēng)險的項目 ? Audit items are issues that would cause Customer dissatisfaction 審核項目為會引起顧客不滿意的項目 ? Process controls must link with PFEMA, Control Plan and Work Instructions 過程控制必需與 PFMEA、 控制計劃和作業(yè)指導(dǎo)書鏈接 ? Check that all logs, checklists amp。 data reports are used when required and required when used必要時檢查所有的日志、檢查表和正在使用的數(shù)據(jù)報告 ? Verify all setup parameters 驗證所有參數(shù) ? Know the process operations, materials, equipment and testing required, confirm use 了解操作過程、材料、設(shè)備和所需要的試驗，確認(rèn)使用 ? Know all inspection checkpoints 了解所有檢驗站 ? Verify barcode tags or tickets made at operation 驗證條形碼標(biāo)簽或操作中使用的標(biāo)識 LPA Training Revision 2 (February 2022) 23 Error amp。 Mistake Proofing Verification Audits防錯驗證審核 ? Verify effectiveness of error amp。 mistake proofing 防錯的有效驗證 ? Assure capability to stop defects 確保有能力消除缺陷 ? Define countermeasures to assure quality 定義確保質(zhì)量的措施 ? Performed only by qualified individuals 有資質(zhì)的人員實施 ? Must be performed at least once per day 至少每天實施一次 LPA Training Revision 2 (February 2022) 24 Error amp。 Mistake Proofing Verification Audit guidelines…防錯驗證審核概要 ? Check all mistake proofing devices at least once per day 每天至少一次檢查所有防錯裝置 ? Check all critical mistake proofing devices at least once per shift 每班至少一次檢查所有主要防錯裝置 ? Send a known nonconforming part through the system or device ? 發(fā)送一個已知不合格的零件通過該系統(tǒng)或裝置 ? Send a known conforming part through the system or device ? 發(fā)送一個已知合格的零件通過該系統(tǒng)或裝置 ? Document checks on a checklist or log ? 在檢查清單或日志上將檢查內(nèi)容書面化 ? Check all error proofing檢查所有防錯設(shè)施 ? Check all mistake proofing檢查所有防錯系統(tǒng) ? Check all proofing devices that may fail or wear檢查所有可能失效或磨損的防錯裝置 ? Check all devices for misalignment or misallocation檢查所有未校準(zhǔn)或未調(diào)整的設(shè)施 ? Check that all devices have not been switched off or disabled ? 檢查所有未切斷或未失效的設(shè)施 ? Check that devices can’t be bypassed or removed檢查所有使用的設(shè)備 LPA Training Revision 2 (February 2022) 25 Who performs Layered Process Audits?誰來實施分層審核 ? Anyone can be a Layered Process Auditor. 任何人都可以是分層審核員 ? All managers, regardless of function, can be auditors. 所有經(jīng)理（無論是什么部門）都可以是審核員 ? Manufacturing Management must own the LPA process and perform audits. 制造經(jīng)理必須是分層審核的過程所有者，并實施審核 ? Each management level should perform audits (Ref. VF213e). 各管理層都需要實施審核（參見 VF213e） ? The manufacturing supervisor SHALL verify (daily) all quality documentation is pleted by operators. 制造主管必須每天驗證所有的質(zhì)量文件都被實施 ? The manufacturing area manager SHALL verify (weekly) that supervisor verification is being pleted. 制造區(qū)域經(jīng)理必須每周驗證主管的驗證是否已完成 ? Site leadership SHALL conduct layered audits at a frequency defined locally. 工廠領(lǐng)導(dǎo)必須以一定的頻次在本廠內(nèi)指導(dǎo)分層審核 LPA Training Revision 2 (February 2022) 26 Visteon requirements: 偉世通要求 Each Plant SHALL每個工廠必須： 1. Have a documented audit structure (Ref. VF213e)有一個文件化的審核機(jī)構(gòu)（參見 VF213e） 2. Conduct daily process audits of all areas 指導(dǎo)所有區(qū)域的日常過程審核 3. Conduct daily error amp。 mistake proofing audits指導(dǎo)防錯審核 4. Document all audits 審核文件化 5. Have pliance charts (Ref. VF213d)有圖表（參見 VF213d） 6. Have reaction plans to resolve all nonconformities (Ref. VG213b)有反應(yīng)計劃解決所有不符合項（參見 VF213b） 7. Be able to show evidence of immediate corrective action, assignable root cause analysis (containment immediately) and corrective action plan within 24 、根本原因分析和在 24小時內(nèi)制定糾正措施計劃的證據(jù) 8. Have a munication procedure and documentation for resolution of nonconformities, escalation of issues for management review, and local lessons learned database建立溝通的程序文件，解決不符合項，擴(kuò)大管理評審關(guān)注焦點，并完善本地的經(jīng)驗教訓(xùn)總結(jié)數(shù)據(jù)庫。 9. Have a checklist of high risk items to be verified during audits (Ref. VF213c)有一張高風(fēng)險項目的檢查表，并在審核中得到驗證（參見 VF213c） 10. Have documentation of results reviewed by leadership 領(lǐng)導(dǎo)評審結(jié)果文件化 11. Identify customer used features listed and checked in the manufacturing process識別顧客使用的特性清單，并在制造過程中檢查 LPA Training Revision 2 (February 2022) 27 How to begin…如何開始 … Plan 策劃 Do 實施 檢查 Adjust調(diào)整 LPA Training Revision 2 (February 2022) 28 PLAN策劃 ? Form a team to develop the checklist ? 組成工作小組制定計劃 The team shall be Cross Functional : 工作小組成員來自以下職能部門 : Manufacturing, Quality, Engineering, Maintenance, etc… 生產(chǎn)、質(zhì)量、工程、維護(hù) ….等 The team shall be multilevel: 工作小組成員應(yīng)來自各個層面 ： Managers, Supervisors, Inspectors, Operators 經(jīng)理、主管、審核員、操作工 LPA Training Revision 2 (February 2022) 29 1st Layer of Management LPA Checklist LPA檢查清單管理第一層次 Yes是 No非 N/A Immediate Reaction迅速的反應(yīng)計劃 Date Closed關(guān)閉日期 Plant Specific Issues:工廠重點關(guān)注： Is Assembly Operator at Station 30 crimping part properly? (example) 裝配操作工在第 30工序的卷邊操作是正確的嗎？（舉例） Process/Operator Checks:過程操作工檢查： Are Operators following posted work Instructions at all stations? Are all operators following the process flow? Is the process following the Control plan? Are control plan checks being followed? Is the control plan linked to the PFMEA and Flow Chart and vice versa? Are the operators aware of Quality Alerts? Are Quality Alerts easily identified? Is the Quality Alert current? (Expiration date 30 day