Varadan Devanathan dvaradan@visteon.

com

Layered Process Audits (LPA):

Driven by TS 16949 Customer Specific Requirements Focused on Improving Compliance to Quality Systems Most issues are due to non-compliance than system adequacy

Technology 20% of solution Culture 80% of solution

Sustained Longer Term Improvements

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Layered Process Audits (LPA):

Driven by demands for zero defects and
aggressive cost-reductions, the need for control of manufacturing processes has never been greater, especially in the automotive industry. In todays business environment suppliers cannot rely on inspection of parts and remain cost competitive. Instead, the focus is swinging to the basics of proactive process control, for both automatic and humandependant tasks."

Murray Sittsamer, The Luminous Group

Layered Process Audits (LPA):

LPA is a quality improvement process involving multiple layers of management. Key process & product characteristics are audited more frequently to verify process conformance. Ensure continuous conformance thereby improving process stability and first-time through capability. LPA is a dynamic process Creating Compliance Culture
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The Layered Process Audit is a tool that:

Reduces variation (both assignable and common cause) Prevents process errors and operator mistakes Improves and maintains discipline Initiates Continuous Improvement actions Reduces rework Reduces scrap and eliminates waste Improves communication Instills and improves standardization Improves overall Quality and reduces cost. Meets Customer Requirements
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Why perform Layered Process Audits?

Reduce errors, reduce scrap, increase first time through, reduce waste, etcb Encourage work process standardization. Increase interaction between plant management and line operators. Improve product quality + customer satisfaction.
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Why perform Layered Process Audits?

Reduce errors, reduce scrap, increase first time through and therefore reduce cost. Encourage work process standardization. Reinforce key process steps, including customer requirements. Increase interaction between plant management and line operators. Improve product quality + customer satisfaction. To become or remain ISO/TS 16949:2002 certified, suppliers must meet all of the Customer Specific Requirements.
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Types of Layered Process Audits:

Process Control Audits Error & Mistake Proof Verification Audits

Who performs Layered Process Audits?

Anyone can be a Layered Process Auditor All managers, regardless of function, can be auditors Manufacturing Management must own the LPA process and perform audits Each management level should perform audits Plant Manager shall perform periodic audits
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PLAN

Leadership commitment is a MUST

Top Down Approach

Form a team (CFT & multi level) to develop the checklist Develop a LPA plan to include (at a minimum):
Frequency/Schedule & Structure Chart Auditor Training Plan Checklists Nonconformance Reaction Plan Schedule of management reviews for LPA results
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Remember Layered Process Audits are PROCESS BASED, not part based!

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DO

Make LPA process a part of your Quality System Include checklist and tracking forms in document control system Enter results in local lessons learned database. Communicate to your workforce about the LPA process Plant leadership shall review summarized results during Management Review.

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Remember

Improvements driven by the LPA process shall be measured, monitored, and reported to management. Error & Mistake proofing verification shall be done by qualified employees Management must physically perform the audit; this is not a desk audit.

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Check

Review audit results frequently Conduct internal review of LPA Review effectiveness of follow-up actions Verify that corrective actions prevent recurrence of the checklist item Plant leadership shall review summarized audit results in Management Review
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ADJUST

Adjust the audit schedule New auditor, remember the advantage of fresh eyes. Error proofing audits - at the beginning of the shift Process audits - at different times of the shift. Adjust training to meet new needs Evaluate training effectiveness of auditors Adjust checklists and forms Evaluate training effectiveness of auditors Adjust checklists and forms Update to include new processes, operations, equipment, or error & mistake proofing devices.
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Layer Process Audit (LPA) : Tool is quality improvement process involving multiple layers of management

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Layer Process Audit (LPA) Check Sheet

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Layer Process Audit (LPA) : Compliance Chart

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