1 Varadan Devanathan dvaradan@visteon.com

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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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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 today’s 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 human-

dependant tasks."

Layered Process Audits (LPA):

Murray Sittsamer, The Luminous Group

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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

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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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