Daimler-Chrysler Layered Process
Audits
(DCX LPA)
Alberta Risner
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6/28/2016
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
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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
Training
Training
levels
Training
will be Painless
will be Hands on
will encompass all management
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.
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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
corresponding day's box. Non-conformances are to have corrective action
recorded in the space provided and identified with the date (MM/DD/YY)
Shift: __________
Mon Tues Wed Thurs Fri
Item No.
These Items Are to be Checked Every
Audit
Sat
Please write the actual dates in the corresponding
columns!
Sun
Corrective Action Taken
Audit Area
Section 1: Operator Instructions
1
2
3
4
5
Are operator instructions accessible at the work
stations and made available without disruption to
the work being performed?
Do operators undersatnd their work instructions
and is the work being performed follow the work
instructions step by step?
Do all operators performing containment activities
have work instructions and have they been trained
to the work instructions?
Do all operators have a clear understanding of their
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
documentation and turning them into their
supervisors per their work instructions?
Section 2: Product Identification, Housekeeping and Workplace Organization
2
Is all product in the work area properly identified
with product status clearly shown per work
instructions and procedures QP-9 & 21.
Are all containment, quarantine and product staging
areas physically identified?
3
Are all work areas maintained in a state of order, well
organized with good housekeeping?
4
Is suspect product properly identified per work
instructions and procedure QP-9.
1
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LPA Process Audit
continued
Section 3: Process Monitoring and Process Control
1
Are Process Analysis Boards (PAB) filled out
completely and correctly?
2
Are Process Analysis Board (PAB) charts filled out
correctly and up-to-date?
3
Are Process Performance Boards (PPB) maintained?
4
Is all required information posted on Certified
Operation Boards (COB)?
5
If required, are First Piece Approval tags being used
and filled out correctly?
Section 4: Customer Issues and Corrective Actions
1
Are operators aware of any customer complaints
and internal quality issues / concerns?
2
Are corrective actions for customer complaints
implemented and effective? (Obtain customer
complaints from the Quality Manager.)
3
Are corrective actions for internal quality alerts and
concerns implemented and effective?
4
5
If rework is being performed, are rework instructions
available for the operator and are they being
followed?
Have operators reviewed and signed all orange
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
corresponding day's box. Non-conformances are to have corrective action
recorded in the space provided and identified with the date (MM/DD/YY)
Shift: __________
Mon Tues Wed Thurs Fri
Item No.
These Items Are to be Checked Every
Shift
Sat
Please write the actual dates in the corresponding
columns!
Sun
Corrective Action Taken
Audit Area
Section 1: General
1
Are operators aware of the function and importance
of any error proofing devices at their station?
2
Are all error proofing verification parts identified
and maintained with due care?
3
Are all error proofing devices verified per work
instructions? Are the verification results recorded?
4
When error proofing devices fail verification checks,
are the proper employees notified? Is this contact
documented? Is there any follow up?
5
Is there a 'reaction step' to direct operators when
error proofing devices are not functioning? That is,
how will the known defect or potential defect be
detected in order to protect the customer in the
absence of automotic error detection?
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Are all operators performing error proofing
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?




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A pen or pencil
A Checklist
Knowledge of the Process
(A sense of humor helps)
Commitment for success
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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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First Layer of
Management
Supervisors
Second Layer of Plant Staff and Plant
Management
Manager
Third Layer of
Management
Corporate SRA
Mold Supervisor /
Manager
Own Department
Plating Supervisor /
Manager
Own Department
Paint Supervisor /
Manager
Assembly
Supervisor /
Manager
Quality Supervisor /
Manager
Quality Manager
Maintenance
Manger
HR Manager
Lean / Training
Coordinator
Assistant Plant
Manager
*Molding Manager
*Plating Manager
*Paint Manager
*Assembly
Manager
Plant Manager
Shipping Manager
VP of Quality
VP of Operations
Quality Systems
Engineer
1 Per Day
1 Per Day
Own Department
1 Per Day
Own Department
1 Per Day
Own Department
1 Per Day
Rotate Departments
1 Per Week
Rotate Departments
1 Per Week
Rotate Departments
1 Per Week
Rotate Departments
1 Per Week
Rotate Departments
1 Per Week
Rotate Departments
Rotate Departments
Rotate Departments
1 Per Week
1 Per Week
1 Per Week
Rotate Departments
1 Per Week
Rotate
Rotate
Rotate
Rotate
Dock Audits
Assembly
Audit
Assignment
Paint
Assigned
Management
Personnel
Plating
Assigned
Management
Category
Molding
SRA LPA Audit Frequency and Structure
Departments
Departments
Departments
Departments
1 Per Week
1 Per Week
1 Per Quarter
1 Per Quarter
Rotate Departments
1 Per Quarter
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Note: * = if there is no supervisor, then the area manager shall be considered the first layer of management.
6/28/2016