Background
•
•
•
Mandated by DaimlerChrysler for all tier 1
suppliers
Strongly recommended by General Motors
and Ford
The Timken Company has been utilizing
Layered Process Audits since 2004
Definition
LPA’s
Like Preflight Checklist.
•
•
•
An ongoing system of process checks that verify
proper methods, settings, tools, gages, operator
craftsmanship, error proofing devices, and other
important inputs are in place in order to achieve
optimal results.
Redundant process checks to make sure
everything is right.
Ensure multiple eyes looking at the process to
ensure the key work steps are being performed
properly.
Is Everything Ready for Take-off
Requirements for LPA’s
•
LPA’s shall be conducted for high risk
elements at a minimum of once per shift.
• Checklist of high risk items can be established using
reference items such as, customer complaints, warranty
issues, PFMEA, etc.
•
•
Audit items should be unambiguous and
specific.
LPA results should be recorded and posted
and reaction plans for non-conformances
found during audit shall be documented.
Requirements for LPA’s
•
•
•
Non-conformances should be corrected
immediately.
Audit results shall be summarized and
reviewed by plant leadership (nonconformance database)
Successive levels of plant leadership shall
perform the exact same audit as the first
level auditors and insure that first level
audits are being done.
•
•
•
LPA items can be added and taken away.
An audit item should not be deleted, unless
the risk is eliminated and verified.
LPA items should be limited to those items
critical to the process or the plant’s
objectives. Avoid putting too many items
on the audit.
Continuously improve the audit process
(living document).
20% Scrap Reduction Goal
Requirements for LPA’s
•
•
•
•
•
Multiple layers verifying critical processes are
ready to go. (Rib Angle)
Gives management a reason to be on the floor.
Makes management presence on floor
commonplace.
Ensures problem solving solutions (corrective
actions) stay in place.
Identifies problems upstream, before issue reaches
customer.
Generates continuous improvement opportunities.
20% Scrap Reduction Goal
Benefits of LPA’s
Roadblocks to LPA’s
•
•
•
Culture shift in some cases to have
associates do audits each shift and have
management looking over their shoulder.
Too many items on LPA, makes it
impossible task
Can become rubber stamp process.
Managers get busy and don’t follow through
on audit, undermining audit importance.
20% Scrap Reduction Goal
•
•
•
Nothing done with the data
Verification of LPA item not clear to
everyone (different interpretation of OK)
20% Scrap Reduction Goal
Roadblocks to LPA’s