Layered Process Control LPC LPC Copywrite 2005 by

Layered Process Control (LPC) 逐层过程管理(LPC) Copywrite @2005 by Daimler. Chrysler 1

What Are Layered Process Control? 什么是逐层过程管理? There are two Types of Layered Process Control: 有两种逐层过程管理: § § Process Control Audits 过程控制审核 Error & Mistake Proofing Verification Audits 防错防误验证审核 Layered Process Control (LPC) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 逐层过程管理(LPC)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. 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。 Copywrite @2005 by Daimler. Chrysler 2

What is a Layered Process Control (LPC)? 什么是逐层过程管理（LPC）？ ØLPC 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、防错 装置和其他输入是否到位从而确保产品无缺陷 产生。 ØLPC’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。 Copywrite @2005 by Daimler. Chrysler 3

Who Performs Layered Process Control? 谁执行逐层过程管理？ § Anybody can perform a Layered Process Control. 任何人都能够执行逐层过程管理。 § Manufacturing management must own the process and perform audits. 生产管理部门必须领导此程序并执行审核。 § 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。 Process Control shall be performed once per shift by supervisors. Plant management shall perform the audit once per week. 过程控制管理应该在每班生产时由车间主管进行一次审核。 厂管理应该在每 周执行一次审核。 Copywrite @2005 by Daimler. Chrysler 4

Cost of Non-Conformances at Various Points Defect found at: The Source Next Process *Very minor *Scrap *Minor Delay End of Line *Repair *Containment *Rework *Reschedule of Work Final Inspection *Significant Rework *Additional Operations *Overtime *Delay in delivery *Added inspection End User’s Hand *3 rd Party Containment *Premium Freight *Administrative costs *Warranty Costs *Reputation *Lost market share *Lost business Early Detection / Prevention Note: Taken from “Layered Process Audits”, The Luminous Group, LLC Copywrite @2005 by Daimler. Chrysler 5

LPA Benefits 逐层过程审核的优点 Reduces 减少 • Build variation based on work standardization 因为 作的标准化而产生的多样性 • End-of-line inspection 线尾检验 • Part defects 零件缺陷 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 Copywrite @2005 by Daimler. Chrysler 7

LPA Success at Kokomo Transmission Plant 逐层过程审核在Ko. Mo变速箱厂的成功运用 Repair Inventory vs First Time Capability vs LPA 对比： 修理库存/一次通过率/逐层过程审核 KTP Now conducting 6700 # of LPA Checks / Week 每周LPA检查次数 100 Repair Inventory修理库存 95 FTC一次通过率 5400 90 85 80 75 1800 70 65 0 Process Layered Audits 0层过程审核 180 60 52 -03 49 -03 46 -03 43 -03 40 -03 37 -03 34 -03 31 -03 28 -03 25 -03 22 -03 19 -03 16 -03 13 -03 10 -03 7 -03 4 -03 1 -03 51 -02 48 -02 45 -02 42 -02 39 -02 36 -02 33 -02 30 -02 27 -02 24 -02 21 -02 18 -02 55 First Time Through (%)一次通过率（%) Process Layered Audit Checks KTP目前正执行6700 逐层过程审核 Weekly 周 Copywrite @2005 by Daimler. Chrysler 8

Layered Process Audit 逐层过程审核 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 Ø Not asking Suppliers to do something we are not 不向供应商询问我们不要的（零件） Ø Low investment – significant quality return 低投资 – 获得显著的质量回报 Ø Copywrite @2005 by Daimler. Chrysler 9

How does an LPA Work? 逐层过程审核是如何 作的？ Continuous Improvement Inputs LAYERED PROCESS AUDITS ARE PROCESS BASED, NOT PART BASED. 持 续 改 进 输 入 逐层过程审核是基于过程的, 而不 是基于零件的 Corrective Actions 纠正行动 Prevention Actions 预防行动 Employee Workshops 车间职 Process Audits 过程审核 PROCESS 过程 Error Proofing 防错 • 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 Copywrite @2005 by Daimler. Chrysler 10

Developing the Plan 制定计划 Form a LPA Team to implement the audit process 成立一个逐层审核团队 实施审核 Ø Develop procedure for LPA Process and Documentation 为LPA过程和文件制定程序 Ø 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 Ø Determine who will conduct audits. 确定谁来执行审核。 Ø 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 Ø Develop a monitoring process and reports for management review. 制定一个监控过程并向管理部门汇报。 Ø Copywrite @2005 by Daimler. Chrysler 11

Identify Where to begin LPA Implementation 确定从哪里开始实施LPA Review 回顾: § Customer Complaints, Quality Alerts 客户抱怨，质量警告 § First-Time Through data, Scrap Reports 一次通过数据，废品报告 § Key Characteristics and Process Capability: Cpk & Gage R&R 关键特性和过程能力：CPK与检具 R&R § PFMEA, Process Flow Diagram, Control Plan PFMEA, 过程流程图，控制计划 § Set-up Sheets, Work Instructions, Inspection Instructions 艺卡片、作业指导书、检验指导书 § Error and Mistake Proofing 防错防误 § Quality System Audits, Dock Audits, Inspection Reports 质量体系审核，货场审核，检验报告 § Rework instructions 返 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. 此区域也被用于整个制造厂学习如何实施逐层审核。 § 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。 Copywrite @2005 by Daimler. Chrysler 12

LPA - Frequency Plan 逐层过程审核-频率计划 Plant Manager 厂经理 1 X Week 每周一次 Area Management 区域管理者 2 X Week 每周两次 Production Supervisor 生产主管 1 X Shift 每班一次 • 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 Copywrite @2005 by Daimler. Chrysler 13

EXAMPLE: LPA FREQUENCY AND STRUCTURE 举例： 逐层过程审核频率与结构 Copywrite @2005 by Daimler. Chrysler 14

Example: Frequency Chart Compliance Matrix for Supervisors 举例: 主管执行频次矩阵图 生产 主管周LPA检查计划安排表 X X X Note: Example Illustrates that 3 rd Shift Not Being Audited Per the Rotation Matrix – Unacceptable Condition! 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! 每 9天对每条线轮流每班进行审核. 在你 作的那班中, 用差号标明已经完成了审核. Copywrite @2005 by Daimler. Chrysler 15

Example: Frequency Chart Compliance Matrix for Plant Manager 举例: 厂经理执行频次矩阵图 PLANT MANAGER 厂经理周LPA检查计划安排表 Weekly Audit Rotation 9 Weeks to Rotate Through all 9 Production Lines 周审核循环 9周内循环审核所有9条 生产线 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. Copywrite @2005 by Daimler. Chrysler 16

LPA Checklist Development Copywrite @2005 by Daimler. Chrysler 17

LPA 检查表的制定 Copywrite @2005 by Daimler. Chrysler 18

LPA Checklist Development OPERATION or PROCESS LPA CHECKLIST QUESTION 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. 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. . MOLDING HEAT STAKE ASSEMBLY SHIPPING CORRECTIVE ACTION Verify that the operators are documenting flash removal on operator inspection form. Notify department supervisor. 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. 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 Notify Assembly Supervisor Inform Quality Inspector to begin containment. 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 Notify Materials Manager Inform Quality Inspector to begin containment and initiate a C. A. R. . Copywrite @2005 by Daimler. Chrysler 19

Develop Audit Checklist. 制定审核检查表 - Process Control Audit Checklist. 过程控制审核检查表 Ø - Error & Mistake Proofing Verification Audit Checklist. 防错防误验证审核检查表 Ø Consider: 考虑到: Ø Ø Questions must be concise and specific. 提问必须简明具体 Phrase questions so a “no” always indicates a nonconformance. 使用简单提问, 使用“不”来表明一个不符合. Questions should include complete identification of operation, equipment, documentation, etc… 提问应该包含对操作、设备、文件等的完整说明。 Reaction to non-conformances must assure immediate response. 对不符的响应速度必须及时。 Copywrite @2005 by Daimler. Chrysler 21

Making Questions Specific (Example #1) 使问题具体(举例#1) 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. What什么 ? How如何 ? Improved Question 改进提问: Inspection Log Book: Verify QAFM 250092 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QAFM 250092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). Why 为什么? Copywrite @2005 by Daimler. Chrysler 22

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. ) Copywrite @2005 by Daimler. Chrysler 23

Customer Review & Approval 客户审核与批准 Ø Your Customer shall review & approve LPA Plan with supplier (Required only for High & Medium Risk Parts) prior to the PSO visit. For low risk parts, suppliers shall approve their own LPA plan. 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。 Ø The LPA Plan shall include (at a minimum) LPA计划应至少包括： • LPA Roll-Out timing plan LPA滚动计划 • Frequency/Schedule & Structure Chart 频次/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) 包括实施迅速反应计划的区域/部分的检查清单 • Non-conformance corrective action procedure 对不符合的更正行动程序 • Schedule of management reviews for LPA results LPA结果的管理检查进度 • 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的最终LPA范围的规定 Copywrite @2005 by Daimler. Chrysler 24

Train Auditors 培训审核员 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. 审核员必须理解LPA策略和目的。 • Review checklist and reactions with auditors. 和审核员共同分析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快速作出响应。 • EMPV Auditors shall be qualified to perform error and mistake proofing verification. EMPV审核员具备执行防错防误验证的资格。 • Perform a practice audit where appropriate. 在适用的时候执行一次审核实践。 Copywrite @2005 by Daimler. Chrysler 25

Notify Workforce 通知操作 人 § Explain why the LPA is being implemented. 解释为什么LPA在被执行。 § 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 作地点执行审核时，将LPA活动和对结果的期望 通知给操作 人。 § Encourage workforce feedback. 鼓励操作 人进行反馈。 § Communicate LPA results frequently. 经常对LPA的结果进行交流。 Copywrite @2005 by Daimler. Chrysler 26

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，来按时完成审核并提供资 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- 管理层的审核将发现问题， 但是以后管理层的审核会发现改 进。 - Develop and apply Lessons Learned to improve audit. - 制定并运用吸取的教训来改进审核。 Copywrite @2005 by Daimler. Chrysler 27

Develop a Monitoring Process and Reports for Management Review. 制定一个监控流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. • 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核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 (4. 2. 1. 9. 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 Copywrite @2005 by Daimler. Chrysler 28

Manufacturing Location Summary Indicators 制造地点总结指示器 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可审核项的数量指的是LPA检验表上项目数乘以当月 这些项目被检查的次数. Copywrite @2005 by Daimler. Chrysler 29

Manufacturing Location Summary Indicators 制造地点总结指示器 Supplier Name 供应商名称: Supplier Location 供应商地点: Copywrite @2005 by Daimler. Chrysler 30

Layered Process Audit 逐层过程审核 Summary 总结 Ø Ø Ø 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家来批准LPA的计划和演示。 The LPA checklist is a living document. 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程序的实施。 The Customer shall review LPA as part of corrective action(s) for quality issues. 客户将检查LPA, 这也是解决质量问题所采取纠正行动的一部分。 Copywrite @2005 by Daimler. Chrysler 31