Layered Process Audits Guideline
Layered Process Audits
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The Quality Requirements Task Force and designated stakeholders approved this document for publication on November 9, 2005.
Published by: Automotive Industry Action Group 26200 Lahser Road, Suite 200 Southfield, Michigan 48034 Phone: (248) 358-3570 • Fax: (248) 358-3253
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1Issue: 1.0 Dated: 12/2005 Replaces: N/A Dated: N/A
Layered Process Audits
Industry data show that most manufacturing quality issues are caused by poor process control or by a failure to follow the appropriate process instructions. Effective management of process capability requires the identification of sources of both special and common cause variation. Once the sources are identified,corrective actions designed to address them must be effectively implemented and sustained. Employees do not refer to instructions or procedures before every step of a process; they often complete the processes by memory, which comes from repeating and practicing each step many times over. Once necessary process changes are identified, employees must re-learn and adjust. However, it is very easyfor employees to return to the old, familiar methods. Before 2005, DaimlerChrysler and General Motors required different process review approaches, including different approaches for Layered Process Audits. It was recognized that the Layered Process Audit methodology was not unique to any particular company, hence, under the auspices of the AIAG, DaimlerChrysler and General Motors developed acommon approach for Layered Process Audits. One of the principal purposes of industry standard practices is to address commonly observed issues that are not isolated to any one company, commodity, or process within the industry. Validation of process improvements and corrective actions is one commonly observed industry issue that can be directly improved by the use of Layered Process Audits, whichare designed for this specific purpose. Layered Process Audits require that multiple operational levels within a manufacturing facility review the same key operational controls that ensure product quality. Controlling quality at multiple operational levels is a key strength of Layered Process Audits.
Issue: 1.0 Dated: 12/2005 Replaces: N/A Dated: N/A
Layered Process Audits...