Layered Process Audit Examples

[jmurph01]

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!

in advance!

 

[IEGeek - 2006]

Re: Layered Process Audits - Looking for examples

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

 

[Marc]

Re: Layered Process Audits - Looking for examples

Related Layered Process Audit discussion threads.

 

[jmurph01]

Re: Layered Process Audits - Looking for examples

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.

 

[Marc]

Re: Layered Process Audits - Looking for examples

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

 

[Valeri]

Re: Layered Process Audits - Looking for examples

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.

 

[jeffb]

Re: Layered Process Audits - Looking for examples

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.

 

[bgwiehle]

Re: Layered Process Audits - Looking for examples

...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

 

[jmurph01]

Re: Layered Process Audits - Looking for examples

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.

 

[bgwiehle]

Re: Layered Process Audits - Looking for examples

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