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