Daimler-Chrysler Layered Process

Audits
(DCX LPA)

Alberta Risner

1 11/17/2019
Goal

 Satisfy Daimler-Chrysler mandated LPA

(Layered Process Audit)
 Training of Managers and Supervisors
 Satisfy Customer Specific Requirements
and TS16949 requirements
 Continual Improvement

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Continual Improvement

3 11/17/2019
Where are we now?

 No Layered Process Audits (LPA) are

currently being performed
 Training has been started at SRAF
(Today)
 Input in Chrysler’s Powerway will begin
when LPAs have started

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 Training

 Training will be Painless

 Training will be Hands on
 Training will encompass all management
levels
 Training will be completed

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Kinda Painless

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Past History

 No history on LPA
 We’re creating the line in the proverbial
sand.
 Lessons Learned can and should apply

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 What are our choices

 Not performing LPAs?

 Pitch in and get it done

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 No Choice

 Pitch in and get it done

 Perform LPA as required

Why No Choices ?

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Daimler-Chrysler Mandated

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What is a Layered Process
Audit? (LPA)
 LPA is an ongoing system of process
checks that verify proper methods,
settings, operator craftsmanship, error
proofing devices and other inputs are in
place to ensure a defect free product.

11 11/17/2019
What is a Layered Process
Audit (LPA)? Continued

 LPA’s assure that defined methods and

work instructions are utilized, problem
solving solutions are held in place, and all
process issues are identified and quickly
corrected.

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What is a Layered Process
Audit? continued
 Two types of LPAs
 Auditing the Process itself
 Auditing the Error Proofing

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1. Process Audit

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 LPA – Process Audit
Process Audit:

Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the
Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun
These Items Are to be Checked Every
Item No. Audit Area Corrective Action Taken
Audit
Section 1: Operator Instructions
Are operator instructions accessible at the work
1 stations and made available without disruption to
the work being performed?
Do operators undersatnd their work instructions
2 and is the work being performed follow the work
instructions step by step?
Do all operators performing containment activities
3 have work instructions and have they been trained
to the work instructions?
Do all operators have a clear understanding of their
4 jobs? Do they know the 'right' things to do, are they
doing them correctly, and can they demonstrate

Are operators filling out required forms and

5 documentation and turning them into their
supervisors per their work instructions?

Section 2: Product Identification, Housekeeping and Workplace Organization

Is all product in the work area properly identified
1 with product status clearly shown per work
instructions and procedures QP-9 & 21.
Are all containment, quarantine and product staging
2 areas physically identified?
Are all work areas maintained in a state of order, well
3
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organized with good housekeeping?
Is suspect product properly identified per work
4 instructions and procedure QP-9.
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 LPA Process Audit continued

Section 3: Process Monitoring and Process Control

Are Process Analysis Boards (PAB) filled out
1 completely and correctly?
Are Process Analysis Board (PAB) charts filled out
2 correctly and up-to-date?
3 Are Process Performance Boards (PPB) maintained?
Is all required information posted on Certified
4 Operation Boards (COB)?
If required, are First Piece Approval tags being used
5 and filled out correctly?
Section 4: Customer Issues and Corrective Actions
Are operators aware of any customer complaints
1 and internal quality issues / concerns?
Are corrective actions for customer complaints
2 implemented and effective? (Obtain customer
complaints from the Quality Manager.)

Are corrective actions for internal quality alerts and

3 concerns implemented and effective?

If rework is being performed, are rework instructions

4 available for the operator and are they being
followed?
Have operators reviewed and signed all orange
5 boundary standard tags/parts?

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2. Error Proofing Audit

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Error Proofing Audit:
Only Qualified Personnel can Perform Error Proofing Verification Audits
Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the
Please write the actual dates in the corresponding
corresponding day's box. Non-conformances are to have corrective action Shift: __________ columns!
recorded in the space provided and identified with the date (MM/DD/YY)
Mon Tues Wed Thurs Fri Sat Sun
These Items Are to be Checked Every
Item No. Audit Area Corrective Action Taken
Shift
Section 1: General
Are operators aware of the function and importance
1 of any error proofing devices at their station?
Are all error proofing verification parts identified
2 and maintained with due care?
Are all error proofing devices verified per work
3 instructions? Are the verification results recorded?
When error proofing devices fail verification checks,
4 are the proper employees notified? Is this contact
documented? Is there any follow up?
Is there a 'reaction step' to direct operators when
error proofing devices are not functioning? That is,
5 how will the known defect or potential defect be
detected in order to protect the customer in the
absence of automotic error detection?
Are all operators performing error proofing
6 verification checks trained to do so?
Section 1: Work Cell Specific
Will be unique for every work cell containing error
proofing.

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How Long Will either LPA
Take?
 On average 15 minutes

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What do we need to perform
a LPA?
 A pen or pencil
 A Checklist
 Knowledge of the Process
 (A sense of humor helps)
 Commitment for success

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21 11/17/2019
 LPA Frequency Plan
Plant Manager-once a week
Area Managers-once a week

Production Supervisors-once a shift

This Proposed Frequency will:

Encourage Management Involvement

Establish Operator Feedback
Establishes Accountability

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 SRA LPA Audit Frequency and Structure

Dock Audits
Assembly
Molding

Plating

Paint
Assigned Assigned
Management Management Audit
Category Personnel Assignment
Mold Supervisor /
Own Department 1 Per Day
Manager

Plating Supervisor /
Own Department 1 Per Day
Manager
First Layer of
Supervisors Paint Supervisor /
Management Own Department 1 Per Day
Manager
Assembly
Supervisor / Own Department 1 Per Day
Manager
Quality Supervisor /
Own Department 1 Per Day
Manager
Quality Manager Rotate Departments 1 Per Week
Maintenance
Rotate Departments 1 Per Week
Manger
HR Manager Rotate Departments 1 Per Week
Lean / Training
Rotate Departments 1 Per Week
Coordinator
Assistant Plant
Second Layer of Plant Staff and Plant Rotate Departments 1 Per Week
Manager
Management Manager *Molding Manager Rotate Departments 1 Per Week
*Plating Manager Rotate Departments 1 Per Week
*Paint Manager Rotate Departments 1 Per Week
*Assembly
Rotate Departments 1 Per Week
Manager
Plant Manager Rotate Departments 1 Per Week
Shipping Manager Rotate Departments 1 Per Week
VP of Quality Rotate Departments 1 Per Quarter
Third Layer of VP of Operations Rotate Departments 1 Per Quarter
Corporate SRA
Management Quality Systems
Rotate Departments 1 Per Quarter
Engineer

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Note: * = if there is no supervisor, then the area manager shall be considered the first layer of management.
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