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Layered Process Audit Examples

G

gszekely

#12
Re: Layered Process Audits - Looking for examples

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
 

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I

ILumbert - 2007-8

#13
Re: Layered Process Audits - Looking for examples

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.
 

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Howard Atkins

Forum Administrator
Staff member
Admin
#14
Re: Layered Process Audits - Looking for examples

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
 
I

ILumbert - 2007-8

#15
Re: Layered Process Audits - Looking for examples

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.:eek:
This has saved us tons of time and missed communications.
:thanx:
 

Kales Veggie

People: The Vital Few
#16
Re: Layered Process Audits - Looking for examples

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 ?
 
I

ILumbert - 2007-8

#17
Re: Layered Process Audits - Looking for examples

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

ILumbert - 2007-8

#18
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
 
S

sberg

#20
Re: Layered Process Audits - Looking for examples

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.
 
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