What Is Layered Process Audits !!
Realized This Requirements In 2005 Dc Cust. Spec. Reqt.
Suzuki Is Also Asking For The Same.
Top Management Is Expected To Perform This Audit Also.
Any Dc Guys On The Forum !! Guide Us Please.

These attachments explain it pretty well

Also - In more simpler terms...

Do your outputs for one process equal your inputs for the next process?

Just some thoughts....

Welcome
See also these discussions
Layered Process Audit required by Chrysler - Is it as 'great' as Chrysler says it is? (http://elsmar.com/Forums/showthread.php?t=8521)

GM Layered Process Audit - Seeking the actual General Motors requirements (http://elsmar.com/Forums/showthread.php?t=9427)

Simple Layered Process Audit format - What are you using? Required resources & time? (http://elsmar.com/Forums/showthread.php?t=8472)

for more info.
If you look at the bottom of the page there are lonks to similar threads.

Thanks ! But what is "layered".
Joher

You are correct - LAYERED process auditing is something specific - not just regular old process auditing. I don't know much about it - I'm not in the automotive industry anymore.

Did you look at the other threads? There are 5 or 6 right at the bottom of this screen.

I don't know about Chrysler or Suzuki, but GM has a program called layered
audits. The gist is as follows:

* Shop floor people (operators and/or supervisors) audit process details, daily or weekly
* Next level of management audits the audits, weekly or monthly
*Top management audits the middle management, monthly or quarterly

There are some differences from traditional audits here:

1) These audits may not be independent. The idea is to have people auditing
their own areas, and then have their bosses audit them.

2) Expectation is that there will be a detailed audit checksheet, with
very specific criteria. E.G. the injection molding dept will audit the barrel temps and pressures against the setup sheet for each machine once a day

If this sounds like the right program, I may be able to dig up a training
presentation on it. (It's part of what GM calls Quality System Basics).

best of luck

Brad Pritts

Thanks BRAD - good knowledge shared by you.
Joher.

Thanks ! But what is "layered".
Joher
See Chrysler's Customer Specifics dated February 2005 on the IAOB web site.
The perform a return on investment for the cost of the specified Powerway Software, the manhours to do what it sez.

The All Knowing and Ancient One

Bob, you sent this to me last week:

4.2.1.9.1 Layered Process Audits

Organizations supplying production parts or components to DaimlerChrysler shall conduct Layered Process Control Audits on all manufacturing and assembly lines that produce production parts or components for DaimlerChrysler. These shall include all error-proofing operations.

Organizations shall provide evidence of compliance to the following requirements:

• Audit process shall involve multiple levels of management, from line supervisor up to top
management.

• Top management at plant shall conduct process control audits at least once per week. Delegation of this activity will not be accepted with the exception of extenuating
circumstances.

• The organization shall have a documented audit structure with auditor level and frequency of inspection.

• Process control audits shall be conducted at least once per shift for build techniques and craftsmanship related processes.

• Error Proofing Audits shall be conducted at least once per day.

• Compliance charts shall be completed once per quarter and maintained for the life of the program. The following metrics should be included:
o audit completion by all auditing layers
o By-Item percentage conformance by area

• Reaction plans shall be in place to immediately resolve all non-conformances.

• The organization shall show evidence of immediate corrective action, containment (as required), and root cause analysis (as required).

• Communication Procedure is required to address reoccurring non-conformances. Specific areas of focus shall include the following:
o Resolution of non-conformances
o Escalation of issue for management review
o Lessons learned

Marc:
As you can notice I'm getting older.

As you can notice I'm getting older.As are we all are.

GM's internal requirement (at least in Powertrain) is very similar to D-Cs CSR, and I'd be very surprised if GM dosen't extend this to their supply base in the not too distant future. Used wisely it can be an effective program, of course it can also be a supreme waste of time if not.

One of my Quality Leaders has said the following about layered audits.

If your layered audits are always compliant 100% the audit is doing you no good anymore. It's time to re-evaluate your process and 'up the bar' on the requirements. (Line Side Reviews help give new challenges to the Layered Audit Process)

The audit will act as a bit of a reminder for a while as well as an auditing tool, until all requirements are met consistently.

Some items will probably always be on the layered audit checklist.

Example: Always telling your kid to clean up their room. After months of auditing (nagging) their room is always clean. Next start telling your kid to line up their socks and underwear in the drawers.

Cheers!

Jen

Hi guys.

GM does require layered audits in their Quality System Basics (QSB). However they seem to be enforcing this requirement along with the rest of the QSB with problem suppliers such as CS1 or CS2. They expect all suppliers to utilize the principals of QSB.

We are having a 2 day QSB workshop in a few weeks so maybe later I can post what we are doing for layered audits.

cac

Hi Brad
I was reading your comments on the Layered audits, I need to implement these into our Company as per GM :frust: . I would appreciate any info on your training presentation. :truce:

Dear everybody,
So glad to meet all of you here .I am from a company in china .I just want to know what is a cqi-8 layered process audit guideline ? Pls kindly advise.
thanks and best regards.

Hi Amy,

Since you are new here, let me guide you on how to use the search function. It is located along the blue bar below your log-in area.

When you click it, a box will appear. Just type cqi 8 and it will guide and bring you along the next few steps. There are some 12 threads which should contain more than what you want.

Regards.

Hi everyone, I'm new here. Attached pls find our complany LPA structure, can anyone tell me whether it meets GM requirements or not?

No. it is not LPA. LPA should be implemented by leader/supervisor/manager. and the frequency is different.

:thanx:These attachments explain it pretty well

Also - In more simpler terms...

Do your outputs for one process equal your inputs for the next process?

Just some thoughts....

regards
norman

:thanx:

regards
norman

Careful guys. Layered Process Audits are not the same as Process Audits. It can get confusing when first being introduced to all of this though.

Careful guys. Layered Process Audits are not the same as Process Audits. It can get confusing when first being introduced to all of this though.

True, but (unfortunately) the AIAG folks who wrote the CQI9 (?) guide seem to think otherwise.........

We are required by our customer to perform LPA's - to be honest it has been a struggle to get this put into place. Getting the "layered" audit concept in place took a while, we put into our internal procedure who was able to audit at each level. We also report on the LPA activity during our monthly Quality Meeting by % completed by each level. It took a while before our front line leadership saw this activity as having any value. At first they were doing it just because it was required. Now that they are doing the LPA I am finding less nonconformities during internal audits of their processes.


I have attached the procedure we have in place as well as an example of a check sheets were use in a production area.