Layered Process Audits
(LPA)

What Are Layered Process Audits (LPA)?

Layered Process Audits have become quite popular and in many cases mandatory for suppliers in the automotive industry. The effects of properly conducted layered process audits can be substanially positive. Because layered process auditing reduces the number of operator errors they have spread to industries outside of automotive.

But what are Layered Process Audits (LPA)? They are a system of audits performed by multiple layers of supervision and management to monitor key process operations, characteristics and verify process conformance on an ongoing basis. LPAs are an excellent tool for minimizing variation in your processes and error-proofing systems. They have helped many companies to progress toward a single-digit ppm. As well as meeting the zero defect goal of their customers.

Essential Components of a Layered Process Audit Program

•  Management must take ownership of the LPA process
•  Auditors Must identify and ask the right questions
•  All management layers, top to bottom, must perticipate
•  Immediate containment of nonconformances found 
•  Continual improvement must be included in the program
•  Shift, daily, weekly scheduled and performed audits

Benefits of Layered Process Audits

•  Reduces variation in processes
•  Improves & maintains operational discipline
•  Reduces scrap and eliminates waste
•  Improves communication
•  Increases associates participation
•  Improves overall quality and reduces costs
•  Stops problems from becoming nonconformances

Zero Defects and Layered Process Audits

Survey data shows excessive process input variation is the single largest cause manufacturing quality problem. This often 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 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 for the production part approval submission.

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, not on 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. 

LPA Software Is A Big Plus 

The #1 Layered Process Audit software is 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

The nice thing about the LPA ADMIN program is it is web based. This means you don't need to install it or maintain it. Everything is ready to go once you sign-up.

On-Site 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 $38.00 per person. Travel expenses not included. Call us or click here.

The Class 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

The 5 Most Common Problems Implementing Layered Process Audits

1. Implementing a Layered Process Auditing (LPA) system for the wrong reasons
  a. Doing LPA only to meet customer requirements
  b. Adding an LPA system to your Quality Management System only to meet
  TS requirements
  c. Not understanding how to measure effectiveness of your LPA system

2. Lack of leadership and ownership
  a. Leaving everything to the Quality Department
  b. The role of Manufacturing is limited to auditing
  c. Delegating implementation to people with little process knowledge

3. Implementers that don’t understand the processes at the facility
  a. Attempting to audit everything
  b. Inability to identify the high risk process areas
  c. Lack of creativity about how to audit certain key processes
  d. Lack of knowledge and deep understanding of the processes at the facility

4. Designing a system that is high-maintenance and yields low-value information
  a. Not really understanding the value and time-sensitivity of audit information
  b. Not considering who the real customers for the system are, and making it
  easy and useful for them
  c. Building a system that allows reported data to get out-dated without action
  d. Building a system where reports are not immediately available to
  management
  e. Not taking time to regularly analyze the collected data
  f. Not taking a lean approach to building an LPA system

5. Overlooking the opportunity to improve the Quality Culture of the organization
  a. Creating a system that leads to placing blame and passing judgment
  b. Creating a system that allows slow response times for corrective actions
  c. Not communicating the corrective action taken
  d. Tolerating higher levels of management not completing assigned audits

Implementing an LPA system without taking these items into account is a formula for
creating a high-maintenance system that adds cost and administrative burden to your
organization with little benefit. Avoid these mistakes, and you can be well on the way to
major cost savings, happier customers and a leaner, stronger company.

Get Help With LPA

Are you looking for assistance in developing an effective Layered Process Audit system? Would you like help evaluating the effectiveness of your current system? Do you want to gain the most benefit from your LPA system with the least cost and effort, but don't know how?

Give us a call or click here to contact us.

Back to the top of Layered Process Audits.

See our four part article on Layered Process Audits Implementation in the Article Library.

Additional Resources