LPA Implementation Guide ~ Steps 16 through 19

The LPA Implementation Guide

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16) How should auditors be trained?- Develop and implement a Layered Process
Auditor training plan.

Reasons - LPA auditors need to understand the philosophy of layered process auditing and your LPA system. Knowing when, where, and how to complete an audit is critical to the system.
Training should ensure that auditors demonstrate the ability to record audit
results including non-conformances, containment activities, and corrective
actions.
Successful containment and the success of your LPA system depend on your
auditors understanding what to do when they discover non-conformances.

Options - A. Train everyone at once.; B. Train by layers and/or areas.
C. Train by layers by shift. D. Have auditors read the AIAG Layered Process Audit Guideline; E. Give an overview of LPA and discuss your facility's audit process.

Best Practices - Auditor training should include an overview of Layered Process
Auditing, information about how to complete audits, and sample audits for practice. Trainers must insure that auditors demonstrate the ability to record audit results
including non-conformances, containment activities, and corrective actions. Spend time to discuss the concept of corrective actions with your auditors. Auditor training should take about two hours.

17) What should nonauditing employees know about LPA?- Develop non-auditing
employee training.

Reasons - All employees need to understand the purpose of doing layered process audits.

Options - A. Train everyone at once.; B. Train by shift.; C. Train by area; D. Give an overview of LPA and discuss your facility's audit process.

Best Practices - Training for non-auditing employees is done in groups small enough that everyone feels comfortable enough to ask questions. Employees need to
understand that Layered Process Auditing will audit the process and will not be a blaming, headhunting expedition. Emphasize that LPA is designed to improve quality by reducing variation in the processes. Employee training should take about 30 minutes.

18) When should the audits begin?- Plan and decide when to begin auditing.

Reasons - It is important to wait until you have your system designed and ready to: schedule audits, handle audit data including nonconformances, containment activities, corrective actions, and reports.
Sending out auditors who are well trained and comfortable with your LPA system demonstrates the importance of LPA to improve quality throughout your facility.

Options - A. Start auditing as you are building the system.
B. Start auditing in a few pilot areas after the system is designed and built.
C. Start auditing in all areas after the system is designed and built.

Best Practices - Begin the audits when your LPA system is built and non-auditing
employees and auditors have been trained. Auditors need to be comfortable with the checklists. Your audits should follow your implementations plan in step 15. 

19) Can changes be made to the LPA system?- Evaluate effectiveness of your LPA system and make recommendations for changes.

Reasons - Your LPA system should be a dynamic, living system that adds value to your organization.

Options - A. Encourage everyone to make suggestions on how to improve your LPA system.
B. Define a documented process for how changes are reviewed and implemented.
C. Select and implement appropriate changes in a timely manner.

Best Practices - On a regular basis, ask your auditors, operators, and others how to improve your LPA system. Make changes in a timely fashion according to a documented review and implementation process.

This concludes the LPA Implementation process. Follow the implementation guide step-by-step and you should come away with a strong and effective LPA system to reduce defects.

Go to Steps 1 through 5

Go to Steps 6 through 10

Go to Steps 11 through 15