Layered Process Audits
Layered Process Auditing, also known as LPA, are a proactive quality tool developed
for manufacturing management to ensure control over manual and automated processes.
LPAs improve quality, reduce scrap and rework, and increase customer satisfaction.
Layered Process Audits are performed by multiple levels of manufacturing management
at different times ensuring process steps are properly followed.
Normally Layered Process Audits are performed on high risk processes. The risk can
be identified using the Failure Mode and Effects Analysis. But, increasingly, OEMs
expect suppliers to use the process as a means of continual improvement for all
processes.
The audits are performed by multiple levels of manufacturing management including:
- Manufacturing Engineers
- Quality Engineers
- Quality Managers
- Team Leaders
- Manufacturing Supervisors
- Plant Managers
To ensure consistency, the same audit criteria is followed by each auditor. And,
to rive improvement, an audit report and audit follow up are utilized.
Plantech offers a two day performance packed workshop has you walk away with an
action plan designed to reduce Scrap, reduce Warranty Returns generated by manufacturing
errors, and improve First Time Through Capability.
Seminar Content
You will learn the DCX and General Motors QSB Layered Process Audit requirements
and you will create the necessary audit checklists to support your Layered Process
Audit Program. This workshop supports selected TS 16949:2002 and Customer Specific
Requirements. This workshop is designed to enhance your current Layered Process
Audit Program by conducting Manufacturing Process Reviews with your hourly work
groups.
Who Should Attend
Quality Managers, Quality Supervisors, Quality Engineers, Manufacturing Engineers,
Production Supervisors, Production Leaders, Quality Technicians, Maintenance Technicians,
anyone responsible for making quality improvements.
Prerequisites
Basic understanding of process documentation (process flow diagram, PFMEA, control
plan).
Seminar Materials
Each participant will receive a seminar manual.
Seminar Goals
- You will conduct a Manufacturing Process Review of your process documentation including
your Process Flow Diagram, PFMEA, Control Plan and Work Instructions of your lowest
performing manufacturing cell(s).
- You will learn how to utilize the Error-Proofing Worksheet to provide a business
case to sell your recommended improvement actions.
- You will gain the understanding of DCX and General Motors QSB Layered Process Audit
requirements.
- You will create process and error-proofing checklists tied to your Layered Process
Audit Program.
- You will create a Walk-away Action Plan that sends you back to your plant with keys-in-hand
to drive your plant's quality improvements.
Seminar Outline
Day One
- What is a Layered Process Audit
- LPA Requirements and Recommendations
- Developing the LPA Plan
- Introduction to Process Review
- Process Review Team Dynamics
- Step 1: Process Flow Diagram
- What is Zero Quality Control?
- Step 2: Potential Failure Mode & Effects Analysis
- Error-Proofing Worksheet Overview
- Step 3: Reviewing & Revising the Control Plan
- Last Step: Work Instruction Overview
Day Two
- Review and Update Process Control Documentation
- Reporting and Managing the LPA Process
- Reviewing and Approving the LPA Plan
- Implementing the LPA Plan
- Maintaining the LPA
- LPA Best Practices
- Creating your Walk-away Action Plan
Course Sequence: MPR&LPA