OK - I know what the GM and DCX deffinition of an LPA is. We've been doing them here since they've been required. But I think we are doing a bad job with them and would like to improve the format.

Before you tell me to do a search - I've looked through all of the LPA threads ever started on here and can't seem to find too many examples. Lots of links to training presentations or to customer requirements. But not too many examples of the audit forms.

So please, if you think you have a good format for doing the LPA's, post it here. I know myself and many others will really appreciate it!

:thanx: in advance!

May want to review this thread as well, appears to be along the same vein

ISO/TS 16949 Manufacturing Audits - Check List Questions - 8.2.2.2

Related Layered Process Audit (http://Elsmar.com/Forums/search.php?do=process&titleonly=1&query=layered+audit) discussion threads.

Marc - thanks for posting the search. I have already gone through all of those threads. The problem is that a lot of them were started before anyone really knew what LPAs were. Now that we've all been doing them for 1+ year, I'm hoping some folks have tweaked their systems a bit and have some good examples.

Good point. I'd like to see some good 'current' examples as well.

Attached is the LPA checklist we use - these are the questions we ask for all identified processes. They are in an automated database so it's kinda hard to see what is happening. There are 3 radial buttons; Yes, No, N/A for every question. If the evidence is not compliant and No selected, an action item is initiated to get the issue fixed. At month-end, we analyze the action items for systemic problems and issue corrective action as necesary. The blank areas are there for us to add specific items to the audit depending on the product that is running; this goes for the customer specific requirements too.

We use these forms and a computer data base. A daily calender is also used to dictate to the auditors the audit area or process.
Jeff.

...But not too many examples of the audit forms.
So please, if you think you have a good format for doing the LPA's, post it here.

In the past threads, the original poster has often asked for sample questions. However, the wording of questions is specific to the procedures and practises of the facility and all you can do is list potential topics. This time the question is format.

Our LPA system is Access-based, with linked databases for questions, scheduling, reporting, etc. Although the attachment below is an audit report, the matching checklist is nearly identical. The key is to keep the audits specific to a part & process and quick (15 min average).

The format includes the question, references for the requirement and what the auditor should look for to determine conformance. If a non-conformance is found, the specific reason or cause is noted in the report.

B.G. Wiehle

The key is to keep the audits specific to a part & process and quick (15 min average).


This is where I think we're going wrong - our LPA's are not process or part specific. It's a generic checklist used at each press or welder. Your audit report seemed fairly generic - are specific questions added depending on the part/process?

on a side note...we're almost neighbours...we're in Milton ON (ok not quite neighbours...) and I have relatives that are in the Mitchell area.

Your audit report seemed fairly generic - are specific questions added depending on the part/process?

This was one complete checklist -- the audit itself was targeted at a particular process (injection molding, aka pressing) and part (KJ shock mounts).

Different checklists apply to other processes and, where applicable, a separate checklist will audit error-proofing features at a process. Assembly processes tend to have more variety in the questions and requirements. Although not evident in this checklist, often the PFMEAs are also mined for questions.

Each shift (level 1), our supervisors are assigned an audit. Weekly (level 2), other management, including the plant manager, are assigned audits. The checklists for the 2 audit frequencies are the same but by rotating programs and processes we avoid duplicating audits (same process/part/shift).

Targeting programs and processes this way has supposedly also made it easier to generate and report LPA metrics to the customer.

B.G. Wiehle

anyone else have any other examples or comments?

Hi all !
I1m not a quality professional, and trained for audits. However here are my opinions or thoughts.
What I would like to achieve by a layered audit:
-shoop flor involvment
-leadership involvment
- graphical or numerical scoring of results to see a trend
- comparison of audit results done by different shifts, supervisors etc
- actions, due dates, responsable ( I dont't like to include here daily actions, for that I have a separate meeting, with list every morning, so here on this level, I would include only important actions, maybe weekly)
- when the audit is not anymore value added
I made one example, of what I'm thinking about, see below.
Daily sheet would be filled up by shift or group leaders, weekly by me, and can be added more for manegers. There is a scoring system included, which has to be agreeded and communicated to all involved persons.
There is a graphical representation where you can see shift results, compare shifts, you can add to the graph a trend line for overall score, and you can make one for weekly results.
That's my view, I don't know if it fits here or not, that's why I didn't post earlier. The graph is not perfect, but this is just for example.
BR
György

Here is an example of the LPA Checklist that we are currently using. I have been working on making it more value added. I think this can be done by making specific questions per department. Example: Manufacturing Engineer should be checking Poke Yoke activities and verifiying that they are working properly per the process. :cool:
Hope that helps.

Welcome to the cove
:bigwave:

Do you use the same questionnaire for each layer?

Is this limited to new projects as the responsible is "Launch Coordinator"?

If it is for all levels I think nit is to detailed for the worker levels

Thanks for sharing

Thank-You for the warm Welcome...:D

Currently we do not use the worker level.
The following is the schudule:
CEO - 1 a month
Directors - 1 a month
Plant Manager - 2 a month
Mfg. Eng - 2 a month
Quality Eng. - 2 a month
Floor auditors - 2 a week
Floor supervisors - 2 a week

We use MDR's, (material defency reports) External, and Internal customer complaints. We then list these as the priority for that month. Each area has a choice between 4 different process.

We do currently use a Launch Tracker for new products.:o
This has saved us tons of time and missed communications.
:thanx:

Thanks for sharing this information.

I have managed a LPA system in the past. One thing we did is reduce the number of questions and limit the time to do the audit to 10-15 minutes.

How much time does the auditor need to complete the audit ?

We also had issues with the clerical and administrative time need to manage the LPA process (collecting completed forms, tabulating results, tracking corrective actions, scheduling, auditor travel/vacations).

How do you manage the adminstrative part of the LPA process ?

The audit takes about 15-20mins.
Our work centers are very visual and most information is easily available.

We usually share this between manufacturing and quality.
After each audit the auditor logs audit information onto a log. These logs are located in 3 areas of manufacturing.
The audit checklist is then turned into to me; I collect for 1 month. At the end of the month I give to the quality clerk who enters into a database.

I only schedule the CEO and Directors everyone else is required to schedule themselves.

Every Monday I remove the 3 logs and place items into an action tracker. The champion of the corrective action is then required to enter in the corrective action on the tracker by the due date. Every Tuesday the tracker is sent out with part due items in red to every auditor, auditee, champions and the Plant manager.

This system has been working pretty good. Please let me know if you have more questions.

I found a great article by the Luminous Group:
Best Practice to Make Layered Process Audits Meaningful.
You can get re-prints by contacting:
248-538-8677

Thanks.

Other resources that I found are at http://www.layeredprocessaudits.com

Here is an example of the LPA Checklist that we are currently using. I have been working on making it more value added. I think this can be done by making specific questions per department. Example: Manufacturing Engineer should be checking Poke Yoke activities and verifiying that they are working properly per the process. :cool:
Hope that helps.

I like the layout of this form you have provided. This provides a good start and could be applied to most industries, big or small. Where I am working we have an operator performing the audits and the section that guides them on where to look and what to do if there is a non-conformance found really is helpful.