Daimler-Chrysler Layered Process Audits(2)

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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