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QUALITY DEPARTMENT
Chris Psinas
February, 2010
Layered Audits
PURPOSE:
To provide a system to:
• verify compliance to the documented process
• instill discipline
• improve communication
• improve overall quality
SCOPE:
• Manufacturing Operations
• Shipping/Receiving
• Repair/Rework Area
• All Operations and other support functions
RESPONSIBILITY:
• Single Ownership
- Plant Manager
• Supported By
- Quality Manager
Strategic Plan - - P 2
Layered Audit Requirements
Strategic Plan - - P 3
Layered Audit Elements
(Example)
Strategic Plan - - P 5
Layered Audit Requirements cont’d
• Key Characteristics
• Part Production Date Traceability
• Supplier pass through features
• Mounting (holes, taps, etc.)
• Mounting surfaces
• Electrical connections/connectors
• Clearances
• Others as identified by customer
Strategic Plan - - P 6
Layered Audit Requirements cont’d
Strategic Plan - - P 7
Layered Audits – Quality Elements
Example
REACTION (Special Cause) Prevention (Common Cause)
PFMEA
PLANT ISSUES RPN REDUCTION
TEAMS
External- NCR’s, etc
Cross Functional
Internal Blue Cards Shainin
AUDIT THE PROCESS
P.
8 STEP (8D) Corrective • Formal Line item document
Action F. CONTROL PLANS • Items Checked daily
• Is the system working?
• 12:15p.m. Report outs M. What’s critical to
• Fast Response the process?
E.
A. AUDIT % COMPLIANCE
JOB INSTRUCTIONS • Data Collection
• Participation
- Standardized Work • Responsiveness
• Integrity
RESULTS
• Quality Improved
Strategic Plan - - P 8 • Quality Stabilized
Layered Audit Matrix
Example SHIFT DAILY WEEKLY MONTHLY QUARTERLY
OPERATIONS MGR
COPRORATE MGR
Q.A. INSPECTOR
EXECUTIVE MGR
TEAM LEADER
SUPERVISOR
PLANT MGR
OPERATOR
PRESIDENT
Q.A. MGR
TBD
PART / PRODUCT
Error Proofing Verification
First Piece Inspection
Last Piece Inspection
Standard Work Instruction Present
Operator Training Tracking Sheet
Safety Issues
PROCESS
Set-up
SPC Com pliance
Tooling Approval (Sign-off)
Quality Gate Data
SYSTEM
Preventative Maintainance
Calibration
Lot Traceability
Housekeeping
VOICE OF THE CUSTOMER
6-Panel Posted
Action Plans Updated & on-tim e
PR/R's Posted
Custom er Delivery Perform ance
C.A.R.E.
Strategic Plan - - P 9
Layered Audit Results
PART NAME:
Example PART NUMBER: SHIFT:
CUSTOMER:
DEPARTMENT: WEEK ENDING:
Wednesday
Thursday
Saturday
Tuesday
Monday
Friday
Op A
Manufacturing
Are the operators using Insulation Tape that is less than 3 months
old per the specification.
Are the parts manufactured and stored per First in First Out
(FIFO) requirements before next operation
Strategic Plan - - P 10
Layered Audit Results
Example
Strategic Plan - - P 11
Layered Audit Results
Example
DEPARTMENT:____________ LAYERED AUDIT RESULTS
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
% IN COMPLIANCE:
# OF ITEMS ON ASSESSMENT:
# OF ASSESSMENTS
TOTAL # OF ITEMS ASSESSED:
# OF ITEMS IN COMPLIANCE:
Strategic Plan - - P 12
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