Zero Defects and Layered Process Audits

Survey data shows excessive process input variation is the single largest cause manufacturing quality. This often times results from a failure to reinforce process corrective actions. Or, a failure to follow the required steps and methods.

Layered process audits reduce this variation along the manufacturing line up through the ranks of plant management. This helps ensure that operators are following the process steps.

Proactive approach

The demand by customers for zero defects has never been greater than it is today, especially in the aerospace, automotive and medical device industries. The emphasis is has moved from the reactionary inspection activities to the proactive process control methods. The concept is very straightforward and effective; A potential error/problem in the process operations is found and removed before nonconforming product is made.

One of the most effective tools for proactive process control is Layered Process Audits (LPA). In fact LPA is now required for many automotive industry suppliers. Daimler Chrysler and GM have mandated LPAs. Daimler has made the LPA a requirement for their suppliers to get an approval on the Product Signoff Approval (PSO).

Multi-layers

A layered process audit system must have a documented audit structure that schedules auditors at pre-determined levels and frequency of audits. These audits focus on process operations and error-proofing and not finished product inspections.

They provide powerful information to management teams through multiple layers of auditing. The LPA checklists are living documents and a revision history kept for each checklist. A computerized document control system is needed to ensure that nothing is lost and only the current and correct checklists are being used.

Software

I recently found a terrific method for maintaining your LPA system called LPA Admin. LPA Admin provides a cost-effective, versatile solution for implementing LPAs, exceeds automotive customer requirements, and provides useful information to your management team.

LPA Admin gives you the information needed to proactively identify manufacturing system failures before they result in customer rejects, costly scrap or rework, and lost production time. Take a demo of this terrific tool by clicking here - LPA SOFTWARE

Course content

If you would like to learn more about LPA we have a course designed especially for companies wanting to increase their knowledge and control of their processes through the use of LPA techniques. It helps you determine the operations that are critical for product quality and customer satisfaction.

This course follows the CQI-8 guidelines published by AIAG for GM, Ford and Daimler Chrysler. Layered process audits are beneficial for any company regardless of the business of your company.

Many companies have substituted their ISO and TS audits with layered process audits because of the superior results.

You can have this class presented at your business for as little as $46. per person. Call us or click here.

This class is 1/2 day and includes:

·         Introduction and overview

·         What are layered process audits?

·         Planning layered process audits

·         Conducting layered process audits

·         Reviewing audit results

·         Maintaining the layered audit system

·        CEU and RU credits are awarded