Layered Process Audits: Efficiency, quality, safety or all the above?

L

longhorn man

#1
Should an LPA be designed to improve the efficiencies, quality, safety, or all the above?
 
Elsmar Forum Sponsor
#3
Re: Layered process Audits:effeciency, quality, safety or all the above

Typically, LPAs should be focused on those items that are critical to quality (QTC) only! By adding the other stuff, they lose their focus and tend to become paper and pen exercises that the employees see no value in.
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#4
Re: Layered process Audits:effeciency, quality, safety or all the above

It should be focused on mainting the quality system, with an emphasis on weak areas. Think of all the things normally hectically done prior to prepare for a surveillence audit - and strectch out monitoring and maintaining those things to prevent such a flurry of activity, plus some chronic problems, and you have a good bird's eye view of what you LPAs should be covering.
 

Kales Veggie

People: The Vital Few
#5
Re: Layered Process Audits: Effeciency, quality, safety or all the above

Should an LPA be designed to improve the efficiencies, quality, safety, or all the above?
It is about minimizing risk to your customer and your company. The most important part of rolling out an LPA process is identifying the risks of "non conforming material" getting to your customers.

Inputs to create a LPA questionnaire include:

- PFMEA / Control plan
- Recent customer concerns
- List of Poke Yoke in your process

On your question:

1) Quality = for sure,

2) Safety = depends on company, culture and process. (a question like: are all operators wearing the required PPE? is useless in my opinion).

3)Efficiencies = probably not.

Do not implement LPA just because your customer tells you to. Make it really work for your company and your process/cell.
 

Jim Wynne

Staff member
Admin
#6
Re: Layered Process Audits: Effeciency, quality, safety or all the above

It is about minimizing risk to your customer and your company. The most important part of rolling out an LPA process is identifying the risks of "non conforming material" getting to your customers.

Inputs to create a LPA questionnaire include:

- PFMEA / Control plan
- Recent customer concerns
- List of Poke Yoke in your process

On your question:

1) Quality = for sure,

2) Safety = depends on company, culture and process. (a question like: are all operators wearing the required PPE? is useless in my opinion).

3)Efficiencies = probably not.

Do not implement LPA just because your customer tells you to. Make it really work for your company and your process/cell.
Good advice, I think, except perhaps for #2. If the LPA is about mitigating risks to the customer, and operator injury could have a negative effect on throughput, checking for proper use of protective equipment should be considered.
 

Ajit Basrur

Staff member
Admin
#7
Re: Layered Process Audits: Effeciency, quality, safety or all the above

I feel LPA brings in a spirit of senior involvement for improving quality systems.
 

Stijloor

Staff member
Super Moderator
#8
Re: Layered Process Audits: Effeciency, quality, safety or all the above

I feel LPA brings in a spirit of senior involvement for improving quality systems.
Ajit,

I have not met many executives that are very excited about LPA's. :nope:
If this was a "voluntary" type activity, LPA's would not happen.

It is just for that reason that LPA's have been forced by automotive customers upon their suppliers to get these people out of their corner offices hoping that they will develop some kind of understanding and appreciation of what's really going on on the shop floor.

Stijloor.
 

Ajit Basrur

Staff member
Admin
#9
Re: Layered Process Audits: Effeciency, quality, safety or all the above

Ajit,

I have not met many executives that are very excited about LPA's. :nope:
If this was a "voluntary" type activity, LPA's would not happen.

It is just for that reason that LPA's have been forced by automotive customers upon their suppliers to get these people out of their corner offices hoping that they will develop some kind of understanding and appreciation of what's really going on on the shop floor.

Stijloor.
Thats true Jan and I feel sorry for that. I strongly feel that if LPA is seriously followed (not waiting for the customer to point out), the quality systems ought to get improved. :tg:
 

Stijloor

Staff member
Super Moderator
#10
Re: Layered Process Audits: Effeciency, quality, safety or all the above

Thats true Jan and I feel sorry for that. I strongly feel that if LPA is seriously followed (not waiting for the customer to point out), the quality systems ought to get improved. :tg:
Ajit,

Great point and I agree with your comment! :agree1:
I just wished it was different....

Jan.
 
Thread starter Similar threads Forum Replies Date
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 Having faith in your Layered Process Auditors - Pencil whipping audits Process Audits and Layered Process Audits 8
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
J Internal Process Auditing - Auditor Unhappy - Wants Layered Process Audits Process Audits and Layered Process Audits 13
T Does Delphi's requirement for layered process audits only apply to their products? Process Audits and Layered Process Audits 15
Crusader Layered Process Audits - Recommended Reading? Process Audits and Layered Process Audits 24
R Layered Audits - Where to tie the layered audit process back to FMEA & Control Plan FMEA and Control Plans 10
D Layered Process Audits? Are they required by TS16949? Process Audits and Layered Process Audits 13
B Defining Top Management for Layered Process Audits Process Audits and Layered Process Audits 9
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 5
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
Q Layered Process Auditing (LPA) for a service provider Process Audits and Layered Process Audits 4
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
M Layered Process Audit (LPA) - Discipline in completely filling in the reports Process Audits and Layered Process Audits 3
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

Similar threads

Top Bottom