1、 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)1 LAYERED AUDITS 分层审核分层审核 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)2PURPOSE目的目的:To provide a system to保证系统:-verify compliance to the documented process-确保按文
2、件标准生产/装配-instill discipline-培养规范行为-improve communication-增加交流-improve overall quality-提升整体质量LAYERED AUDITSSCOPE:范围范围 Assembly Area组装场地 Manufacturing Operations制造场所 Shipping/Receiving发运/接收场地 Repair/Rework Area返修/返工场地 All Operations and other support functions所有生产和其他相关支持区域 1998 General Motors Corporat
3、ion.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)3RESPONSIBILITY职责职责:The Manufacturing Plant Manager is responsible for implementation and execution of this procedure.生产工厂经理负责执行和完成该程序。The Manufacturing Quality Manager is responsible for supporting the implementation of this procedure.
4、生产质量经理负责支持执行该程序。1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)4REQUIREMENTS要求要求:Layered Audits shall be conducted for manufacturing and assembly of high risk items at a minimum of once per shift.分层审核针对高风险项目的生产和装配至少每班进行一次。Frequency of Layered Audits based
5、 on production volume or level of risk associated with process.分层审核的频次因依据所审核内容的数量及风险级别进行确定。Layered Audits supplement ongoing control plan and job instruction checks.分层审核需要是当前控制计划和操作指导书的补充和完善。A check list of high risk items to be verified during Layered Audits shall be established.应建立一份需进行分层审核的高风险项目检
6、查列表。Elements should be considered in developing the check list.(Example)应在建立列表时考虑到以下一些相关内容，且该列表应是灵活的。1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)5Elements要素要素(Example)Utilization of manufacturing assists (as applicable)利用生产协助（如适用）Gages functioning and
7、calibration confirmation 运用量具及刻度确认 Stacking/packing techniques 堆叠/包装技术 Build/manufacturing techniques 制造/生产技术 Visual aids presence and content 目视检查控制 Process parameter setting 建立过程参数 Job instructions 工作指示 Correct product identification 正确的产品识别 Process steps adhered to 严格遵守的过程步骤 Required inspections
8、completed 完成所要求的监察 Torque monitoring (if applicable)扭矩监控（如适用）Product dimensions or visual inspection 产品尺寸或视觉检查 Documentation/record completion 文件/记录完整 Quality Gates (as applicable)质量门（如适用）Customer feedback 客户反馈 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/
9、03)6REQUIREMENTS(continued)要求要求:Layered Audits results shall be recorded.分层审核结果应记录。Non-conformities shall be addressed immediately,and corrective action documented 不合格情况应立即汇报，并记录纠正措施。Reaction plan(s)for non-conformities detected during Layered Audits shall be documented and available for use.对分层审核中发
10、现的不一致情况应记录以备进一步使用。Corrective actions shall be documented.所有已采取的改进措施应该进行记录。1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)7 Results shall be summarized and reviewed by the manufacturing site leadership.审核结果应汇总并由上级生产管理者检查。Layered Audit documentation shall b
11、e compiled in the Lessons Learned(key strategy)database.各级审核结果应最终进行整理，并将其中的内容记录入Lessons learned（key strategy)数据库中。1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)8REQUIREMENTS(continued):Customer used features shall be identified,listed and checked in the
12、manufacturing process with emphasis on:客户的使用特征应在能分解到各生产过程中，并且对这些使用特性进行重点的识别、列出、及检查：-Supplier pass through features 供应商通过率指标-Mounting(holes,taps,etc.)装配特性（孔，螺孔，等）-Electrical connections/connectors 电气连接/接头-Mounting surfaces 安装表面-Clearances 间隙-Missing/wrong brackets 丢失/装错的支架-Incorrect parts 错误的零件-Other
13、s as identified by customer 顾客提出的其他要求 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)9 The following is an example of a Layered Audit with three levels of management involved in the process:以下是三级管理层参与生产过程分层审核的一个例子。-The manufacturing supervisor shall verif
14、y(daily)all quality documentation is completed by operators.现场制造监督者（班组长）核查所有由操作工填写完成的 质量记录（每天）。-The manufacturing area manager shall verify(weekly)that supervisor verification is being completed.现场区域经理应该核查所有现场制造监督的质量记录（每 周）。-Site leadership shall conduct layered audits at a frequency defined locally
15、.生产制造负责人应该定期进行分区域的分层审核工作。Records shall be maintained per local procedures.以上所以分层审核记录应相应的分别保存在各区域。1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)10QUALITY ELEMENT:LAYERED AUDITREACTION(Special CauseCUSTOMER CONCERNSExternal-PRRs,etcInternal8 STEP Correctiv
16、e Action-12:15p.m.Report outs-Fast ResponseP.F.M.E.A.CONTROL PLANSWhats critical tothe process?PFMEARPN REDUCTIONTEAMSCross FunctionalShaininJOB INSTRUCTIONS-Standardized WorkAUDIT THE PROCESS-Formal Line item document-Items Checked daily-Is the system working?AUDIT%COMPLIANCE-Data Collection-Partic
17、ipation-Responsiveness-IntegrityRESULTS-Quality Improved-Quality StabilizedPrevention(Common Cause)ExampleGMPT model 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)11LAYERED AUDIT MATRIX (Example)1998 General Motors Corporation.All rights reserved.02023-1
18、-9 QSB WORKSHOP REV.11 (02/18/03)12 (Example)PART NAME:PART NUMBER:SHIFT:CUSTOMER:DEPARTMENT:WEEK ENDING:MondayTuesdayWednesdayThursdayFridaySaturdayOp 10Broach Is runout(column#2)within spec(20 lights)Has perpendicularity been gaged(402-3537)?Spec is 20 lines Is there any broach tear?(Check one par
19、t from each broach)Op 20Olofssons Is the ID on size(columns#2&3)?Is the ID run out within specifications?Is the ID taper(between columns 2&3)within specification?Op 30Hones Has the ID-Micro been checked and the Micro Log completed?*Entire Department Are operators verification sheets completed daily
20、by all shifts?Are the tagging procedures being followed?Are any Temporary Alert Notices posted that have expired?1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)13PART NAME:PART NUMBER:SHIFT:CUSTOMER:DEPARTMENT:WEEK ENDING:MondayTuesdayWednesdayThursdayFri
21、daySaturdayOp AAssembly Are the builders checking rotation&marking parts(touch point)?Have the 8-hole sprags been inspected for presence of 8-holes and identified with orange marker?Are bar code labels attached to shipping container in correct location?Are shipping containers checked for actual coun
22、t?Machining Operations Total Non-Conforming ItemsAssembly Total Non-Conforming ItemsLIST ANY QUALITY OR MANUFACTURING CONCERNS ON ALL OPERATIONS.(Example)1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)14(Example)DEPARTMENT LAYERED AUDIT RESULTS ITEMS NOT IN COMPLIANCE ITEM NUMBER OF OCCURANCES 1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)15(Example)1998 General Motors Corporation.All rights reserved.02023-1-9 QSB WORKSHOP REV.11 (02/18/03)16Layered Audits 分层审核
