Layered
Process
Audit
分层过程审核（LPA）
What Are Layered Process Audit? 什么是分层过程审核?
Layered Process Audit(LPA) are a system of audits performed by multiple levels of management. Key process characteristics are audited frequently to verify process conformance. 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。 The purpose of Layered Process Audits is to ensure continuous conformance thereby improving process stability and first-time through capability. 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。
*第三方的遏制 *昂贵的运输成本 *管理成本 *索赔成本 *声誉 *失去市场份额 *失去业务
LPA Benefits 分层过程审核的优点
•Build variation based on work standardization 因为工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
Prevention Actions 预防行动
Employee Workshops 车间职工
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
分层过程审核应该在每班生产时由车间主管进行一次审核。工厂管理层应该在 每周执行一次审核。
Cost of Non-Conformances at Various Points
Defect found at: The Source Next Process End of Line Final Inspection End User’s Hand
13-03
16-03
19-03
51-02
10-03
22-03
25-03
28-03
31-03
34-03
37-03
49-03
43-03
40-03
Weekly 周
46-03

52-03
Layered Process Audit 分层过程审核
Proven Successful Internally 内部经过成功验证
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 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. 确定谁来执行审核。 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. 制定一个监控过程并向管理部门汇报。
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。
What is a Layered Process Audit (LPA)? 什么是分层过程审核（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、防错装置和其他输入是否到 位从而确保产品无缺陷产生。
5400
FTC一次通过率
95 90 85 80 75
1800
70 65
0 Process Layered Audits 0层过程审核
39-02 42-02
45-02 48-02 36-02 18-02 21-02 24-02 27-02 30-02 33-02
180
60 55
1-03
7-03
4-03
Facilitates 简化
Reinforces 加强
LPA Success at Kokomo Transmission Plant 逐层过程审核在KoKoMo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
Reduces 减少
Improves 提高
•First time through capability 一次通过率 •Morale 士气
•Operator training 操作员培训 •Management/operator interface 管理/操作员界面 •Safety regulations 安全法规


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 不向供应商询问我们不要的（零件） Low investment – significant quality return 低投资 – 获得显著的质量回报
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。
*3rd Party Containment *Premium Freight *Administrative costs *Warranty Costs *Reputation *Lost market share *Lost business
Note: Taken from “Layered Process Audits”, The Luminous Group, LLC
Who Performs Layered Process Audit? 谁执行分层过程审核？
Anybody can perform a Layered Process Audit. 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。 Layered Process Audit shall be performed once per shift by supervisors. Plant management shall perform the audit once per week.
*Very minor *Scrap *Minor Delay
*Repair *Significant Rework *Containment *Additional Operations *Rework *Overtime *Reschedule *Delay in delivery of Work *Added inspection