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    Layer Process Audit

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    BAla
    The document discusses Layered Process Audits (LPAs), which involve conducting regular checks of critical production processes to ensure quality. LPAs are mandated by automakers like DaimlerChrysler and recommended by GM and Ford. They involve verifying proper methods, tools, and craftsmanship at multiple stages to achieve optimal results. LPAs must check high-risk items daily, use unambiguous checklists, record and address nonconformances, and have successive management levels conduct audits. Benefits include catching issues early and driving continuous improvement, while roadblocks can include cultural resistance, too many audit items, and lack of follow-through.

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    Layer Process Audit

    Uploaded by

    BAla
    94 views8 pages
    The document discusses Layered Process Audits (LPAs), which involve conducting regular checks of critical production processes to ensure quality. LPAs are mandated by automakers like DaimlerChrysler and recommended by GM and Ford. They involve verifying proper methods, tools, and craftsmanship at multiple stages to achieve optimal results. LPAs must check high-risk items daily, use unambiguous checklists, record and address nonconformances, and have successive management levels conduct audits. Benefits include catching issues early and driving continuous improvement, while roadblocks can include cultural resistance, too many audit items, and lack of follow-through.

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    LPA

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    The document discusses Layered Process Audits (LPAs), which involve conducting regular checks of critical production processes to ensure quality. LPAs are mandated by automakers like DaimlerChrysler and recommended by GM and Ford. They involve verifying proper methods, tools, and craftsmanship at multiple stages to achieve optimal results. LPAs must check high-risk items daily, use unambiguous checklists, record and address nonconformances, and have successive management levels conduct audits. Benefits include catching issues early and driving continuous improvement, while roadblocks can include cultural resistance, too many audit items, and lack of follow-through.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    94 views8 pages

    Layer Process Audit

    Uploaded by

    BAla
    The document discusses Layered Process Audits (LPAs), which involve conducting regular checks of critical production processes to ensure quality. LPAs are mandated by automakers like DaimlerChrysler and recommended by GM and Ford. They involve verifying proper methods, tools, and craftsmanship at multiple stages to achieve optimal results. LPAs must check high-risk items daily, use unambiguous checklists, record and address nonconformances, and have successive management levels conduct audits. Benefits include catching issues early and driving continuous improvement, while roadblocks can include cultural resistance, too many audit items, and lack of follow-through.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 8

    Background

    Mandated by DaimlerChrysler for all


    tier 1 suppliers
    Strongly recommended by General
    Motors and Ford
    The Timken Company has been
    utilizing Layered Process Audits
    since 2004

    Definition
    LPAs Like

    Preflight Checklist.

    An ongoing system of process checks that


    verify proper methods, settings, tools, gages,
    operator craftsmanship, error proofing
    devices, and other important inputs are in
    place in order to achieve optimal results.
    Redundant process checks to make sure
    everything is right.
    Ensure multiple eyes looking at the process to
    ensure the key work steps are being
    performed properly.

    Is Everything Ready for Take-off

    Requirements for LPAs

    LPAs shall be conducted for high risk


    elements at a minimum of once per shift.
    Checklist of high risk items can be established using
    reference items such as, customer complaints,
    warranty issues, PFMEA, etc.

    Audit items should be unambiguous and


    specific.
    LPA results should be recorded and
    posted and reaction plans for nonconformances found during audit shall be
    documented.

    Requirements for LPAs

    Non-conformances should be
    corrected immediately.
    Audit results shall be summarized and
    reviewed by plant leadership (nonconformance database)
    Successive levels of plant leadership
    shall perform the exact same audit as
    the first level auditors and insure that
    first level audits are being done.

    Requirements for LPAs

    LPA items can be added and taken


    away. An audit item should not be
    deleted, unless the risk is eliminated
    and verified.
    LPA items should be limited to those
    items critical to the process or the
    plants objectives. Avoid putting too
    many items on the audit.
    Continuously improve the audit process
    (living document).

    20% Scrap Reduction Goal

    Multiple layers verifying critical processes


    are ready to go. (Rib Angle)
    Gives management a reason to be on the
    floor. Makes management presence on floor
    commonplace.
    Ensures problem solving solutions
    (corrective actions) stay in place.
    Identifies problems upstream, before issue
    reaches customer.
    Generates continuous improvement
    opportunities.

    20% Scrap Reduction Goal

    Benefits of LPAs

    Roadblocks to LPAs

    Culture shift in some cases to have


    associates do audits each shift and have
    management looking over their shoulder.
    Too many items on LPA, makes it
    impossible task
    Can become rubber stamp process.
    Managers get busy and dont follow
    through on audit, undermining audit
    importance.

    20% Scrap Reduction Goal

    Nothing done with the data


    Verification of LPA item not clear to
    everyone (different interpretation of
    OK)

    20% Scrap Reduction Goal

    Roadblocks to LPAs

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