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Layer Process Audit

Layered Process Audits (LPAs) involve conducting regular checks of critical production processes to ensure quality. They are mandated by major automakers and help achieve goals like reducing scrap. LPAs verify that proper methods, tools, and craftsmanship are used. High-risk processes should be audited at least once per shift. Audit findings must be documented, issues addressed immediately, and results reviewed by leadership. Benefits include catching issues early and driving continuous improvement. Barriers can include cultural resistance to oversight and a lack of follow-through on addressing issues found during audits.

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462 views

Layer Process Audit

Layered Process Audits (LPAs) involve conducting regular checks of critical production processes to ensure quality. They are mandated by major automakers and help achieve goals like reducing scrap. LPAs verify that proper methods, tools, and craftsmanship are used. High-risk processes should be audited at least once per shift. Audit findings must be documented, issues addressed immediately, and results reviewed by leadership. Benefits include catching issues early and driving continuous improvement. Barriers can include cultural resistance to oversight and a lack of follow-through on addressing issues found during audits.

Uploaded by

R J
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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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
LPA’s Like Preflight Checklist.
Definition
• 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 LPA’s

• LPA’s 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 non-conformances
found during audit shall be documented.
Requirements for LPA’s

• Non-conformances should be corrected


immediately.
• Audit results shall be summarized and
reviewed by plant leadership (non-
conformance 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 LPA’s

• LPA items can be added and taken away.

20% Scrap Reduction Goal


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 plant’s
objectives. Avoid putting too many items
on the audit.
• Continuously improve the audit process
(living document).
Benefits of LPA’s
• Multiple layers verifying critical processes are

20% Scrap Reduction Goal


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.
Roadblocks to LPA’s
• Culture shift in some cases to have

20% Scrap Reduction Goal


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 don’t follow through
on audit, undermining audit importance.
Roadblocks to LPA’s

Nothing done with the data

20% Scrap Reduction Goal


•

• Verification of LPA item not clear to


everyone (different interpretation of OK)

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