Layered Process Audit (LPA) - Discipline in completely filling in the reports

M

mramirezc

We are a company that recently got our ISO/TS 16949 certification. I am the Production Manager. We are having problems with our people to mantain the discipline in filling completely the reports. I think that LPA (Layered Process Audit) could help us with this. Anybody there can tell me if this is OK, do you have any recommendations for me? Thanks a lot in advance.:confused:
 
Jen Kirley

Jen Kirley

Quality and Auditing Expert
Leader
Admin
mramirezc said:
We are a company that recently got our ISO/TS 16949 certification. I am the Production Manager. We are having problems with our people to mantain the discipline in filling completely the reports. I think that LPA could help us with this. Anybody there can tell me if this is OK, do you have any recommendations for me? Thanks a lot in advance.:confused:
Click to expand...
When I did a research project a couple of years ago I learned a lot about getting people to fill in paperwork. I found out it can be very difficult.

I don't know what your forms look like (are they complicated or unclear? A lot of data to enter--how long does it take?), and I don't know the literacy level of those who should be filling them out.

I don't know what tasks the people are not doing when they are filling out these reports or what sort of preessure they are under to return to those tasks.

I can't imagine the previous level of commitment to the filling out of these forms--is it a new thing that they may feel is a burden or valueless exersize?

Please notice how I have approached all three of the process elements: Man, Material, Machine, and arguably even the fourth element Environment, in asking questions besides what the LPA could do that you, or apparently no one else, seems to have succeeded with thus far. Please do a "5-Why" exersize and analyze the true reason(s) before taking any other action.

I will now refer you to the Reading Room, where I have written on this subject. http://elsmar.com/Forums/showthread.php?t=12122

I hope this helps!
 
Wes Bucey

Wes Bucey

Prophet of Profit
Sometimes, the process simply needs some thought and maybe a little mistake proofing.

  • Do the employees have sufficient time to complete the report or are they pressured to "produce product" (because they get bonuses for high production or they are paid on piecework)?
  • If they have sufficient time to complete the report, what do they do during the time they could complete the report? Do they goof off? Take a break? Make more product?
  • Is the report easy for ALL to complete? Are there any tricky parts which a confused employee would rather avoid thinking about?
  • Have you ASKED the folks WHY they don't complete the reports? What answers do they give? Are they valid?
In my experience (bolstered by Deming's Red Bead Experiment), the failure by employees to complete a task as laid out by management is because the task is difficult or impossible to complete in the time given, using the instructions given. Rarely have I EVER encountered a wholesale discipline problem. When I discover an INDIVIDUAL with a discipline problem, he is dealt with because of the discipline problem, NOT because of the "symptom" of refusal to perform a task.

In nearly forty years, I can't recall one instance where I ever had an employee REFUSE to do a task, although I did have some who deliberately slowed the process for a reason that had nothing to do with the difficulty of the task or the time allotted to perform the task. Almost always, the "root cause" was something which had nothing to do with the task, itself.
 
S

Sushil Kumar

Layered Audit is a very good tool

mramirezc said:
We are a company that recently got our ISO/TS 16949 certification. I am the Production Manager. We are having problems with our people to mantain the discipline in filling completely the reports. I think that LPA (Layered Process Audit) could help us with this. Anybody there can tell me if this is OK, do you have any recommendations for me? Thanks a lot in advance.:confused:
Click to expand...

Sir,
Your thinking is right. we are also using this tool. But as I think, people's interest is above all. any tool could not nothing without user's ineterst
 
You must log in or register to reply here.
Thread starter Similar threads Forum Replies Date
K Differences between Manufacturing Process Audit & Layered Process Audit Lean in Manufacturing and Service Industries 4
K Layered Process Audit (LPA) Software IATF 16949 - Automotive Quality Systems Standard 6
Stijloor AIAG Layered Process Audit 2nd Ed. (CQI-8) is now available. IATF 16949 - Automotive Quality Systems Standard 1
H Layered Process Audit Hard Copy Records Retention Records and Data - Quality, Legal and Other Evidence 6
N LPA (Layered Process Audit) Program - Visual Shop Display Process Audits and Layered Process Audits 4
T Historical Backround of LPA (Layered Process Audit) Process Audits and Layered Process Audits 7
Celtic Warrior Consolidating results of LPA (Layered Process Audit) for Management Review Process Audits and Layered Process Audits 13
A Access Database for LPA (Layered Process Audit) questions Process Audits and Layered Process Audits 3
V Layered Process Audit Schedule example Process Audits and Layered Process Audits 2
S Layered Process Audit Examples Process Audits and Layered Process Audits 4
I Can we use layered process audit (LPA) for HR Processes? Process Audits and Layered Process Audits 9
L Layered Process Audit Basics Explained Process Audits and Layered Process Audits 5
Douglas E. Purdy Delphi CSR (Customer Specific Requirements) and LPAs (Layered Process Audit) IATF 16949 - Automotive Quality Systems Standard 3
J What is meant by number of "items"? Chrysler Layered Process Audit Question Process Audits and Layered Process Audits 10
J Layered Process Audit Examples Process Audits and Layered Process Audits 25
P Layered Process Audit & the Document Audit - Can anyone explain to me, Please? Process Audits and Layered Process Audits 2
K What is a 'layered audit'? Layered Process Audit (LPA) - A GM requirement? Process Audits and Layered Process Audits 9
A Layered Process Audit Guidelines - The AIAG's CQI-8 Process Audits and Layered Process Audits 17
R Layered Audits - Where to tie the layered audit process back to FMEA & Control Plan FMEA and Control Plans 10
Z Layered Process Audit Training - Need Powerpoint Presentation to train LPA auditors Process Audits and Layered Process Audits 5
PatMaz Layered Process Audit Procedure - Seeking an example Process Audits and Layered Process Audits 5
C DaimlerChrysler Layered Process audit experiences per the DC CSR's Process Audits and Layered Process Audits 3
C DaimlerChrysler Layered Process Audit Experiences per the DC CSR's Process Audits and Layered Process Audits 2
J What is a Layered Process Audit (LPA)? Process Audits and Layered Process Audits 22
R GM Layered Process Audit - Seeking the actual General Motors requirements Process Audits and Layered Process Audits 36
C Layered Process Audit required by Chrysler - Is it as 'great' as Chrysler says it is? Process Audits and Layered Process Audits 28
T Simple Layered Process Audit format - What are you using? Required resources & time? Process Audits and Layered Process Audits 20
A Layered Process Audits for Medical Device Manufacturing? ISO 13485:2016 - Medical Device Quality Management Systems 7
D Layered Process Audits - FCA 9.2.2 - Exemption Clause? IATF 16949 - Automotive Quality Systems Standard 5
J Requirements for Layered Process Audits including Maintenance, Shipping, Receiving IATF 16949 - Automotive Quality Systems Standard 4
J Layered Process Audits using Kamishibai Board Process Audits and Layered Process Audits 3
P Interesting Discussion IATF 16949:2016 Clause 9.2.2.3 and Layered Process Audits IATF 16949 - Automotive Quality Systems Standard 18
S Help explaining LPA (Layered Process Audits) IATF 16949 - Automotive Quality Systems Standard 4
V QSB Layered Process Audits GM/OPEL Customer and Company Specific Requirements 3
R Layered Process Audits Procedure of Form Process Audits and Layered Process Audits 3
A LPA's (Layered Process Audits) for Non-Production Support Processes Process Audits and Layered Process Audits 13
C Handling Repeated Non-Conformities when doing Layered Process Audits Process Audits and Layered Process Audits 11
automoto Implementation of Layered Process Audits (LPA) Process Audits and Layered Process Audits 7
L Layered Process Audits: Efficiency, quality, safety or all the above? Process Audits and Layered Process Audits 11
L Having faith in your Layered Process Auditors - Pencil whipping audits Process Audits and Layered Process Audits 8
Q Layered Process Auditing (LPA) for a service provider Process Audits and Layered Process Audits 4
A Definition Layered Process Audits - What are Layered Process Audits? Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 12
H LPA's (Layered Process Audits) - Evaluation of Effectiveness Process Audits and Layered Process Audits 22
J LPAs (Layered Process Audits) and TS 16949 Clause 8.2.2.2 - Quick Question Process Audits and Layered Process Audits 20
J Evaluating and Reporting the Results of Layered Process Audits Document Control Systems, Procedures, Forms and Templates 9
M The Difference between Process Audits and Layered Audits General Auditing Discussions 5
F Tell me about Layered Process Audits (LPA) Process Audits and Layered Process Audits 2
A Layered Process Audits - Getting Results? Show me the data! Process Audits and Layered Process Audits 11
J Does anyone have a procedure that covers Layered Process Audits Process Audits and Layered Process Audits 1
J Layered Process Audits vs. Internal System Audits Process Audits and Layered Process Audits 17

Similar threads

Top Bottom