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    Line Walk Audit Methodology

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    mougib soltani
    This document defines the methodology for planning, executing, and evaluating LPA line walk audits at COFICAB production sites and ADCs. It outlines a multi-level audit approach involving team leaders, engineers, managers and plant managers. Audits are to occur daily/weekly at minimum for level 1 auditors and monthly for level 2. Audit checklists evaluate parameters against compliance and require corrective actions for deviations. Audit scores are rated on a color scale and follow-up is required for low scores. The document also establishes qualifications for LPA auditors and an annual evaluation process.

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    © All Rights Reserved
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    Line Walk Audit Methodology

    Uploaded by

    mougib soltani
    217 views4 pages
    This document defines the methodology for planning, executing, and evaluating LPA line walk audits at COFICAB production sites and ADCs. It outlines a multi-level audit approach involving team leaders, engineers, managers and plant managers. Audits are to occur daily/weekly at minimum for level 1 auditors and monthly for level 2. Audit checklists evaluate parameters against compliance and require corrective actions for deviations. Audit scores are rated on a color scale and follow-up is required for low scores. The document also establishes qualifications for LPA auditors and an annual evaluation process.

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    This document defines the methodology for planning, executing, and evaluating LPA line walk audits at COFICAB production sites and ADCs. It outlines a multi-level audit approach involving team leaders, engineers, managers and plant managers. Audits are to occur daily/weekly at minimum for level 1 auditors and monthly for level 2. Audit checklists evaluate parameters against compliance and require corrective actions for deviations. Audit scores are rated on a color scale and follow-up is required for low scores. The document also establishes qualifications for LPA auditors and an annual evaluation process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    217 views4 pages

    Line Walk Audit Methodology

    Uploaded by

    mougib soltani
    This document defines the methodology for planning, executing, and evaluating LPA line walk audits at COFICAB production sites and ADCs. It outlines a multi-level audit approach involving team leaders, engineers, managers and plant managers. Audits are to occur daily/weekly at minimum for level 1 auditors and monthly for level 2. Audit checklists evaluate parameters against compliance and require corrective actions for deviations. Audit scores are rated on a color scale and follow-up is required for low scores. The document also establishes qualifications for LPA auditors and an annual evaluation process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    Reference : 10.61.01.

    34
    Effective date : 11.04.2022/02
    LPA - Line Walk Audit Methodology Type of document: Instruction
    Page :3/3

    SUBJECT :

    This document defines:

    • The methodology of planning, execution, and evaluation of LPA line walks audits.
    • Selection, qualification, and evaluation of LPA internal auditors.

    APPLICATION FIELD :

    This instruction is to be used in all COFICAB production sites and ADCs

    USED BY :

    RESPONSIBLE: Plant Quality

    PARTICIPANTS: Production, Quality, and Logistic Processes

    ANNOTATIONS DEFINITION:
    LPA- Layered Process Audits

    I. CHANGE HISTORY

    REVISION DATE VERSION MODIFICATION MODIFIED BY


    21/10/2021 V01 First emission Ciprian Tarsala

    V02 Modifying note at 2. LPA/line walk program and


    11/04/2022 Ciprian Tarsala
    frequency

    II. APPROVAL MATRIX


    DEPARTMENT POSITION

    Corporate Process Control & Monitoring Manager Corporate Quality

    Corporate Product Quality & Safety Assurance Manager Corporate Quality

    Corporate Quality System Supervisor Corporate Quality

    Corporate QEHS Manager Corporate Quality


    ODR:10/5269

    This document is the property of Group COFICAB

    It cannot be transmitted or duplicated by any means

    whatsoever without its prior authorization.


    Reference : 10.61.01.34
    Effective date : 11.04.2022/02
    LPA - Line Walk Audit Methodology Type of document: Instruction
    Page :3/3

    1. Type of LPA’s/ line walk audits and objective


    The Layered Process Audits (LPA)/Line walk are audits realized by different layers (level) of the plant:
    • Layer 1: Team Leaders and Engineers
    • Layer 2: Plant Manager and Managers

    The LPA objective is to ensure that the procedures, work instructions, Product/ Process Controls and Poka-
    Yoke are in place, known and respected to mitigate any risk on product/ process Quality and consequently
    on customer satisfaction.

    Note1: It is at the plant level decision to add additional levels whenever needed.
    Note 2: the LPA/line walk audit must be used also by the designated plant PSCR in order to comply with VDA
    product integrity manual requirements related to line walk audits .

    2. LPA/Line walk program and frequency


    The LPA/Line walk program audits is defined internally (at plant level) as the following at a minimum:

    MINIMUM PROCESS MACHINE


    LAYER RESPONSIBLE
    FREQUENCY COVERAGE COVERAGE
    Team Leaders
    LEVEL 1 Daily/ Weekly Weekly Weekly
    Engineers
    Managers
    LEVEL 2 Monthly Monthly Monthly
    Plant Manager

    Note: Level 1- bunching and braiding process due to the amount of machines, the frequency to cover
    all machines is two weeks.

    The frequency of LPA audits shall be increased in the following cases:

    • New manufacturing process/product


    • High level of nonconformance (i.e., ppm, FTQ)
    • Claims related issues

    3. LPA execution, evaluation and follow-up


    a. LPA Execution:
    For each process there is a defined checklist divided into two parts:

    Part to be evaluated:

    • Parameter that needs to be evaluated


    • Type of the control to be applied (visual or by measurement)
    • Compliance (yes/no or n/a)

    Reaction to correct a deviation:

    This document is the property of Group COFICAB

    It cannot be transmitted or duplicated by any means

    whatsoever without its prior authorization.


    Reference : 10.61.01.34
    Effective date : 11.04.2022/02
    LPA - Line Walk Audit Methodology Type of document: Instruction
    Page :3/3

    • Problem
    • Causes
    • Correction, corrective and preventive actions
    • Responsible
    • Status

    b. LPA Evaluation:
    𝑻𝒐𝒕𝒂𝒍 𝑸𝒖𝒆𝒔𝒕𝒊𝒐𝒏𝒔 𝒂𝒏𝒔𝒘𝒆𝒓𝒆𝒅 𝒀𝑬𝑺
    𝑺𝒄𝒐𝒓𝒆 𝟏𝟎𝟎% = ∗ 𝟏𝟎𝟎
    𝑻𝒐𝒕𝒂𝒍 𝑸𝒖𝒆𝒔𝒕𝒊𝒐𝒏𝒔 𝑨𝒏𝒔𝒘𝒆𝒓𝒆𝒅

    EVALUATION RESULT
    RATING REACTION
    in %
    Immediate corrections to be implemented to reach
    [100, 90] A – GREEN
    the 100%
    • Immediate corrections to be implemented for
    the Star Question*
    • Corrective action plan is required (problem
    resolution) inside check list with clear
    ]90,80] B – YELLOW
    responsible and deadline of the action. The
    effectiveness of the action implemented will
    be checked in the following audit after the
    action is closed.
    A follow up audit is mandatory to be performed in the
    < 80 C – RED
    next day.

    * Star Question-If the answer is nonconform the evaluation result is downgraded to B

    c. LPA Follow-up:
    At minimum, on an annual basis, a full review of the LPA Program shall be evaluated
    considering the following:
    • LPA Audit Program Realization Rate:

    𝑇𝑜𝑡𝑎𝑙 𝑟𝑒𝑎𝑙𝑖𝑧𝑒𝑑 𝑎𝑢𝑑𝑖𝑡𝑠


    𝐿𝑃𝐴 𝑅𝑒𝑎𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 % = ∗ 100
    𝑇𝑜𝑡𝑎𝑙 𝑃𝑙𝑎𝑛𝑛𝑒𝑑 𝑎𝑢𝑑𝑖𝑡𝑠

    • Pareto of the recurrent nonconformities and the actions to address them.

    4. LPA auditors’ competences


    a. Qualification:
    • Understanding of IATF 16949, ISO 9001 requirements related to the scope of the
    audit
    • Understanding of applicable CSRs and other customer requirements
    • Understanding of the technical understanding of the relevant manufacturing
    processes to be audited
    • Understanding product requirements to be audited

    This document is the property of Group COFICAB

    It cannot be transmitted or duplicated by any means

    whatsoever without its prior authorization.


    Reference : 10.61.01.34
    Effective date : 11.04.2022/02
    LPA - Line Walk Audit Methodology Type of document: Instruction
    Page :3/3

    • Understanding of relevant measuring and test equipment to verify product


    conformity.

    b. Evaluation:
    The Quality manager of the plant is responsible for the annual evaluation of internal LPA auditors and
    give feedback to HR.

    The checklist for the internal auditors’ evaluation is to be created at plant level and reviewed whenever
    needed.

    The HR department is responsible for the qualification of internal LPA’s auditors, retain evidence of
    qualification and the list of internal LPA auditors.

    To maintain the qualification, each internal LPA auditor shall perform at least 1 LPA audit per year.

    This document is the property of Group COFICAB

    It cannot be transmitted or duplicated by any means

    whatsoever without its prior authorization.

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