Layered Process Audit

Guide to Implementing an Effective Layered Process Auditing System
1 Questions To Answer Activity Why do LPA? Decide why you're investing time to do LPA. Reasoning • Know what you expect to gain for your efforts. Options A. Meet a customer requirement B. Add to meet TS requirements C. Improve Quality throughout your organization A. Seminars B. Websites C. Books D. Coaches (proven experts) E.Lessons learned from successful companies A. People who are not busy B. Only Quality professionals C. Find people who are very busy D. Operators E. Technicians F. Setup people Best Practices Improve Quality throughout your organization for all of your customers. Understand how to measure an effective LPA system. Use all of these options to gain knowledge about LPA systems. Your Plan

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What dowe know and not know about LPA systems?

Gain knowledge about LPA systems.

• By first gaining and then applying this new-found knowledge, your company will be able to implement an LPA system correctly the first time (Note: We often find that there is never time to do a job right, but there is always time to do it over.) • Identifying a cross-functional group of people who have profoundknowledge of the manufacturing processes who will be able to relate to all aspects of manufacturing and areas of quality concerns from all shifts.

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Who should be on the implementation team?

Identify and select the Varsity team for LPA implementation. (The members you select should be chosen as if the future of the company depended upon LPA success)

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Who will own the LPA system?

Findpeople who are very busy because they are team players and doers. Choose representation from all areas Engineering, Manufacturing, Maintenance, Operators, Technicians, and Quality professionals and all manufacturing shifts. Everyone should understand why they are on the team and what is expected of them. Determine who will own • The owners should be those people who A. Quality owns the systemManufacturing owns the system and be responsible for use and interact with the system the most. B. Manufacturing owns the system with Quality supporting the system your LPA system. (This (note: Quality owning the system does not mean the has not proven to be successful). person or people who Include the group that has the maintain the system) process knowledge necessary to keep audit questions up todate. • Identifying the primary and secondary organizational units will allow you to identify the number of audits in each area and later assign audit questions. • Identifying product groupings will become very useful to sort data for reports. A. Primary Units: Department, Business, Value Streams, etc. B. Secondary Units: Workstations, Cells, Operations, etc. C. Product Groupings: Platform, ProductType, Product Grouping, etc. Primary Units: Department, Business, Value Streams, etc. Secondary Units: Workstations, Cells, Operations, etc. Product Groupings: Platform, Product Type, Product Grouping, etc.

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How will the facility be Decide how the facility organized to be audited? will be divided up to be audited.

Guide to Implementing an Effective Layered Process Auditing System
6Questions To Answer Activity What processes areas Write audit questions to are at highest risk for address all high risk quality spills? process elements. (Writing a definition for high risk for your facility will be very helpful) Reasoning • Questions for process audits should verify that the environment of the element or elements being audited are correct to produce quality products. Options A.Choose processes known by supervision, technicians, maintenance, and operators that have continual variation. B. Select areas on control plans that have a high risk priority number (RPN). C. Utilize D-6 of the 8-D process: confirmation that the fixes implemented via corrective action remain in place and working by using the same indicator (metric) that demonstrated the problem. A. Choose mistake...