1、 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit1Layered Audit Procedure分层审核流程分层审核流程 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit2 A standardized audit performed on a regular, frequent basis by all layers of the organization to ensure we maintain proces
2、s control adherence & to reinforce the GMS vision for the entire organization. 分层审核是一种标准化的审核，它以组织结构中所有层次的定期频繁参与为基础，确保过程控制的进行，加强整个组织的全球制造系统的理念。 Ensures consistent application and execution of standards, improved built-in-quality and increased TM/leadership GMS awareness, by coaching & interaction bet
3、ween leadership &T/Ms & T/Ls. 通过培训和领导层与班组成员的互动来确保标准的应用和执行，促进质量改进，增强班组成员和领导层的全球制造系统的意识 Applicable to all Areas of GM. 适用于通用汽车所有部门 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit3Workstation GMS 工位工位GMS Detail check of one workstation process controls 工位过程控制的详细检查Quality Control 质
4、量控制质量控制 Teams important Quality systems are functioning, & previous important problem under control 班组的重要质量系统运行正常，之前的质量问题得到有效控制.Team GMS Management 班组班组GMS管理管理 Are the important team management processes under control, i.e.; BPD, TPM, Andon, 5S, Scrap, Training, etc 班组管理（业务计划部署,全员生产性维护,暗灯,工作场地布置,废料,
5、培训等）流程可控. Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit4 过程总揽过程总揽 I This Tool is being put in place to 实施分层审核是为了实施分层审核是为了:Ensure a high level of process control by identifying &controlling high risk / significant process elements. 通过识别和控制高风险或重要过程元素来确保对过程的高水平控制Maintains proper
6、 application of GMS standards. 保持对GMS标准的合理应用Identify opportunities for improvement & provide a process for effective follow up. 识别改进的机会，提供对流程的有效跟踪Confirm the effectiveness of the Audit at all levels. 加强审核制度在各个层次的有效性Involve all levels of Leadership in supporting the T/M&T/L through coaching / teachin
7、g on the shop floor. 使各级领导层都参与车间的培训/指导工作以支持班组成员和班组长 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit5 过程总揽过程总揽 II Methodology / Process 方法：Frequent assessments by all layers of the organization (T/L P/M) are performed using the layered audit checklist (班组长至工厂经理)使用分层评审检查单来对组织中的各个
8、层次进行定期评估Evaluation against established standards 使用已经确定的标准进行评估Introduction of corrective actions (countermeasures) 引入问题纠正方法及相关措施Regular review process by senior management 高层管理人员进行定期复核Results & actions tracked / visualized in each unit 在每个单元跟踪和目视化评审结果及改进情况Linked to GM-GMS (e.g. Core Requirements & O
9、perating Guidelines) 与GM-GMS相关联（例如核心需求、操作指导等） Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit6 过程总揽过程总揽 III All levels of the organization use the “Layered Audit Check Sheet”to conduct their audit. 各级人员都应使用分层评审检查单来进行评审 This Check Sheet is structured around the 5 GM-GMS principl
10、es (People Involvement, Standardization, Built-in-Quality, Short Lead Time, and Continuous Improvement). 分层评审检查单由GMS的五大原则组成（人员参与、标准化、制造质量、缩短制造周期和不断改进） The “Layered Audit Check Sheet” is comprised of 3 main sections 分层评审检查单由三部分组成:Workstation GMS base list of checks, applicable to all work stations 工位
11、GMS应用于所有工位的基本检查单Quality Focused checks are specific to operations and developed by plant, based on quality feedback, process knowledge, and problem solving 针对质量：对操作的评审是详细且明确的. 其由工厂基于质量反馈、过程知识和问题解决来加以开发Production System GMS base list of checks, applicable to all GMS management. 生产系统GMS可应用于所有GMS管理的基本检
12、查清单 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit7 过程总揽过程总揽 IV Workstation GMS section of the Layered Audit Check Sheet is Common for all workstations. 审核表中的工位审核表中的工位GMS部分对所有工适用部分对所有工适用Ensuring proper tools, gages and materials are available & used. 确保所有的工具、量具以及材料的可用性Ensuring
13、 standardized work & quality standards are understood &followed. 确保标准化工作和质量标准能够被理解和遵循Ensuring Andon system is functioning properly & follows FPS start. 确保暗灯系统的正确应用，遵循FPSEnsuring Workplace Organization & Visual Management standards are maintained (e.g. according to the plant WPO standards and Visual
14、Management policy). 确保工作场组织以及可视化管理标准的维护（遵循工厂的WPO标准和可视化管理政策）Ensuring compliance to Material Processes FIFO/Min.-Max. levels. 确保遵循物料处理先进现先出原则、最大最小量水平等Identifying open issues that require countermeasures/follow up. 识别需要对策或跟踪的公开问题 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit8 过程
15、总揽过程总揽 V The Quality Focused section is specific to each team: 针对质量的部分对不同的班组有特定的内容 Ensuring error proofing is functioning properly and identified high risk/significant process elements are controlled to prevent known problems from reoccurring . 确保问题确定的正确运行并确定高风险和显著过程元素得到控制以防止已知问题的再次发生 Ensuring requi
16、red quality inspection and / or documentation is being completed correctly. 确保必须的质量检测或文件记录的正确性 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit9 The Production System GMS section is common for all teams.生产系统生产系统GMS部分对所有的班组是通用的部分对所有的班组是通用的TPM checks are completed & updated. TPM审核
17、是全面的并且是已更新的Compliance to required quality checks.遵循必须的质量审核Conformance to Workplace Organization 5S standards.遵循工作场地组织的5S原则Proper use of Andon System. 暗灯系统的正确使用Effective problem solving & countermeasure implementation. 有效的问题解决和对策实施Effective use of layered audit process for control and follow up.分层审核在
18、控制和跟踪中的有效应用Appropriate follow up of countermeasures for BPD, SPQRC metrics.对BPD/SPQRC的对策进行适当的跟踪Compliance to material processes- FIFO,Min/Max.遵循物料处理中的先进先出、最大最小量原则 过程总揽过程总揽 VI Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit10Plant Director 工厂总监1 Time/Month 每月一次Shift Leader/Area
19、Manager值班长/区域经理1 Group/week 每周一工段工段Supervisor(group leader)主管/工段长1 Team/week 每周一班组Team leader 班组长2 workstation/week 每周两工位 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit11Audit workstation/Team area per schedule.按计划审核工位/班组Follow standardized checklist, always study the standard
20、 and compare the standard to the work area. 遵循标准审核单，研究标准并且比较标准与实际工作区域的差异 Immediately inform all impacted team members of the audit results. 及时将评审结果通知有关的班组成员 Record all deviations on layered audit Check Sheet and post in the group area (e.g. BPD) 在分层评审检查单中记录所有差异, 并且张贴在工作场所（如:BPD墙）Identify, document &
21、 implement suggested countermeasures as soon as possible. 尽快的确认、记录、实施建议措施 Follow-up on open items, target to close in one week. Elevate problem to higher level after target date. 跟踪问题并于一周内解决，一周内不能解决的将问题向上一级汇报Choose workstation/team 选择工位/班组Conduct audit 进行审核Give feedback/Document results反馈/纪录结果Follow
22、-up跟踪 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit12 Dir, S/Mgr and Shift Leaders should prioritize their selection of a workstation/group area to audit based on plant specific issues. 值班长及以上领导应根据工厂的特点优先选择进行审核的工位和工作区域 SIP/TQC high frequency problems. SIP/QC高频率问题 GCA priority
23、 defects GCA优先缺陷 SPA (Shipping Priority Audit) Shift to shift contrast 不同班次间对比 Other areas to focus are (External-Voice of the Customer): 其他需重视的领域(客户的声音) Warranty J.D. Power Leadership should avoid auditing the same workstations/ Team areas repeatedly. 领导层应该避免对同一工位/班组进行反复的审核 Allow data to drive the
24、layered audit process deep and wide! 使用能够促进 分层审核进行的更深入更广泛的数据 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit13 Performed by Team Leader & above 班组长及以上人员执行: Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit14 Performed by all layers, plant must define specifi
25、c checks: 由所有层次实施，工厂必须进行明确且详细的审核Determine the processes within the team to be monitored based on quality data, process capabilities (including operator sensitive operations), safety, or high impact processes (process that if not followed properly could lead to a major product deficiency). 根据质量数据、处理能
26、力（包括操作员敏感性操作）、安全、高危害处理（不正确的操作导致产品的主要缺陷）等来确定班组内的程序被监控 Verify related processes / standards are documented in the standardized work, update as required 核实相关过程和标准在标准化作业中被记录，根据需要进行更新Determine appropriate method and frequency to conduct, check and update layered audit checklist 决定合适的方法和频率来进行审核和更新分层评审检查单
27、Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit15Identify quality focused Check items at the plant确定工厂内质检项目Develop method and frequency 开发方法和频次Create/update layered audit check-sheet建立/更新分层评审检查单单Communicate to all the layers of the leadership与各级领导人员交流Conduct the audits 进行审核ACri
28、tical operationKPCs process& FMEA关键操作流程Quality feedback质量反馈Update Std work更新标准化作业Group leaderEach level各层Add/removeRevise Items增删/修订B Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit16Non-conformance found?发现不合标准处？Corrective action 纠正措施Record the audit results记录审核结果Evaluate laye
29、red audit process评估分层审核流程End 结束BANo yesEach level各层Each level各层Shift leader值班长 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit17 Performed by Shift Leader & above 值班长及其以上管理人员执行: Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit18 Layered Audit Checklist 分层评审
30、检查单单分层评审检查单单Comments Section is used to document issue specifics and any immediate corrective actions taken 注释部分用于记录问题细节和所有立即采取的正确措施 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit19There are three results that can come out of the check 审核会出现三种结果审核会出现三种结果O No Deviations are Fou
31、nd 没有发现偏差没有发现偏差X Deviation Found 发现偏差发现偏差N/A Not Applicable 不适用不适用All Deviations should be recorded on the Layered Audit Checklist and described in the comments section.在分层审核单上记录所有问题并且在注释部分进行描述Any Deviations that cannot be immediately corrected must have countermeasures identified.所有不能立即修正的问题必须 确定对策
32、Reasons for non-compliance should be understood. 不遵循的原因应是可理解的Completed audit is posted previous audits are retained for 6 months. 目视化保存检查单6个月Completion and Compliance tracking charts are updated. 完成和遵循图表的跟踪应保持更新 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit20 An audit schedul
33、e is developed at each level and tracked to assure audits are completed as planned (% completed).Sample completion chart below: 各层应制定审核计划并进行跟踪以确保按照计划完成审核 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit21 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit22 Global Manufacturing System 全球制造系统全球制造系统Process Control Layered Audit23
