daimler-chrysler layered process audits(2)
TRANSCRIPT
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Daimler-Chrysler Layered
Process Audits(DCX LPA)
Alberta is!er
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"oal
#atis$y Daimler-Chrysler ma!datedLPA (Layered Process Audit)
%rai!i!& o$ 'a!a&ers a!d #uerisors
#atis$y Customer #eci*c
e+uireme!ts a!d %#1,.re+uireme!ts
Co!ti!ual mroeme!t
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Co!ti!ual mroeme!t
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here are e !o
3o Layered Process Audits (LPA) arecurre!tly bei!& er$ormed
%rai!i!& has bee! started at #A4(%oday)
!ut i! Chryslers Poeray illbe&i! he! LPAs hae started
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#A4s %rai!i!&
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%rai!i!&
%rai!i!& ill be Pai!less %rai!i!& ill be 6a!ds o!
%rai!i!& ill e!comass allma!a&eme!t leels
%rai!i!& ill be comleted
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Kinda Painless
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Past 6istory
3o history o! LPA ere creati!& the li!e i! the
roerbial sa!d
Lesso!s Lear!ed ca! a!d shouldaly
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#A4s Li!e i! the #a!d
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hat are our choices1 3ot er$ormi!& LPAs
2 Pitch i! a!d &et it do!e
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%he o!ly Choice Pitch i! a!d &et it do!e a!d er$orm
LPA as re+uired
Why No Choices ?
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Daimler-Chrysler'a!dated
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4armi!&to! 'a!a&ers a!d#uerisors
Daimler Chrysler
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hat is a Layered ProcessAudit (LPA)
LPA is a! o!&oi!& system o$ rocesschec8s that eri$y roer methods9setti!&s9 oerator cra$tsma!shi9 errorroo*!& deices a!d other i!uts are i!lace to e!sure a de$ect $ree roduct
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hat is a Layered ProcessAudit (LPA)Co!ti!ued
LPAs assure that de*!ed methodsa!d or8 i!structio!s are utili:ed9roblem soli!& solutio!s are held i!lace9 a!d all rocess issues are
ide!ti*ed a!d +uic8ly corrected
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hat is a Layered ProcessAudit co!ti!ued
%o tyes o$ LPAs Auditi!& the Process itsel$
Auditi!& the ;rror Proo*!&
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1. Process Audit
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Mon Tues Wed Thurs Fri Sat Sun
Item No. Audit Area
1
2
3
4
5
1
2
3
4
Do all operators have a c lear understanding of their
jobs? Do they know the 'right' things to do are they
doing the! correctly and can they de!onstrate
These Items Are to be Checked Every
Audit
"re operator instructions acces sible at the work
stations and !ade available without disruption to
the work being perfor!ed?
Do operators undersatnd their work instructions
and is the work being perfor!ed follow the work
instructions step by step?
Do all operators perfor!ing contain!ent activities
have work instructions an d have they been trained
to the work instructions?
Section 1: !erator Instructions
"re operators filling out re#uired for!s and
docu!entation and tu rning the! into their
supervisors per their work instructions?
$s all product in the work area properly identified
with product status clearly shown per work
instructions and procedures %&( ) 21*
"re all contain!ent #uarantine and p roduct s taging
areas phys ically identified?
"re all work areas !aintained in a state of order well
organi+ed with good housekeeping?
Section ": #roduct Identi$ication% &ousekee!in' and Work!(ace r'ani)ation
$s s uspect product properly identified per work
instructions and procedure %&(*
Corrective Action Taken
A(( *uestions are to be ans+ered +ith a checkmark ,-, or no ,N, in the
corres!ondin' days bo/. Non0con$ormances are to have corrective action
recorded in the s!ace !rovided and identi$ied +ith the date MM2332--4
Please wri te the actual da tes in the corresponding
columns!
#rocess Audit:
Auditor:
Shi$t: 5555555555
LPA – Process Audit
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1
2
3
4
5
1
2
3
4
5,ave operators reviewed and s igned all orange
boundary s tandard tags -parts ?
"re corrective actions for internal #uality alerts and
concerns i!ple!ented and effective?
$f rework is being perfor!ed are rework instructions
available for the operator and are they being
followed?
$s all re#uired infor!ation posted on .ertified
/peration 0oards ./0?
Section 6: Customer Issues and Corrective Actions
"re operators aware of any custo!er co!plaints
and internal #uality issues - concerns?
"re corrective actions for custo!er co!plaints
i!ple!ented and effective? /btain custo!er
co!plaints fro! the %uality anager*
"re &rocess &erfor!ance 0oards &&0 !aintained?
$f re#uired are irst &iece "pproval tags being used
and filled out correctly?
Section 7: #rocess Monitorin' and #rocess Contro(
"re &rocess "nalysis 0oards &"0 filled out
co!pletely and correctly?
"re &rocess "nalysis 0oard &"0 charts filled out
correctly and uptodate?
LPA Process Audit continued
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2. Error Proofin Audit
Error #roo$in' Audit:
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Mon Tues Wed Thurs Fri Sat Sun
Item No. Audit Area
1
2
3
4
5
A(( *uestions are to be ans+ered +ith a checkmark ,-, or no ,N, in the
corres!ondin' days bo/. Non0con$ormances are to have corrective action
recorded in the s!ace !rovided and identi$ied +ith the date MM2332--4
Please wri te the actual da tes in the corresponding
columns!
Error #roo$in' Audit:
Only Qualified Personnel can Perform Error Proofing Verification Audits
Auditor:
Shi$t: 5555555555
Corrective Action Taken
"re all operators perfor!ing error proofing
verification checks trained to do so?
6ill be uni#ue for every work cell containing error
proofing*
Section 1: Work Ce(( S!eci$ic
These Items Are to be Checked Every
Shi$t
"re operators aware of the function and i!portance
of any error proofing devices at their station?
Section 1: 8enera(
"re all error proofing verification parts identified
and !aintained with due care?
"re all error proofing devices verified per work
instructions? "re the verification results recorded?
6hen error proofing devices fail verification checks
are the proper e!ployees notified? $s this contact
docu!ented? $s there any follow up?
$s there a 'reaction step' to direct operators when
error proofing devices are not functioning? 7hat is
how will the known defect or potential defect be
detected in order to protect the cus to!er in the
absence of auto!otic error detection?
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6o Lo!& ill either LPA %a8e
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hat do e !eed toer$orm a LPA
A e! or e!cil A Chec8list
=!oled&e o$ the Process
(A se!se o$ humor hels)
Commitme!t $or success
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LPA 4re+ue!cyPla!Plant Manager-once a week
Area Managers-once a week
Production Supervisors-once a shift
This Proposed Frequency will:
Encourage Manageent !nvolveent
Esta"lish #perator Feed"ack
Esta"lishes Accounta"ility
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here do e start
ecomme!ded starti!& oi!t>At the hi&hest oi!t o$ ris8
S9A #A A dit F d St t
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S9A #A Audit Fre*uency and Structure
Assi'ned
Mana'ement
Cate'ory
Assi'ned
Mana'ement
#ersonne(
Audit
Assi'nment M
o ( d i n '
# ( a t i n '
# a i n t
A s s e m b (
3 o c k A u d
3old 8upervisor -
3anager /wn Depart!ent 1 &er Day
&lating 8upervisor -
3anager /wn Depart!ent 1 &er Day
&aint 8upervisor -
3anager /wn Depart!ent 1 &er Day
"sse!bly
8upervisor -
3anager
/wn Depart!ent 1 &er Day
%uality 8upervisor -
3anager /wn Depart!ent 1 &er Day
%uality 3anager 9otate Depart!ents
3aintenance
3anger 9otate Depart!ents
,9 3anager 9otate Depart!ents
:ean - 7raining
.oordinator 9otate Depart!ents
"ss istant &lant
3anager 9otate Depart!ents
;3olding 3anager 9otate Depart!ents
;&lating 3anager 9otate Depart!ents;&aint 3anager 9otate Depart!ents
;"sse!bly
3anager 9otate Depart!ents
&lant 3anager 9otate Depart!ents
8hipping 3anager 9otate Depart!ents