Why LPA’s? LPA’s can provide low cost system for finding problems and making improvements in Safety, Quality, Delivery, Cost and Morale when used effectively. LPA’s help management: fix system problems, instill discipline, encourage work force involvement in process improvements, show appreciation for work done correctly and effectively control production systems. We started with some basic questions

What do you want this program to deliver? What are LPA’s good at addressing? Repetitive issues involving known solutions High risk / liability items involving known solutions Items easily verified without special training

Possible Targeted Items Safety Proper PPE / Guarding Completion of required daily inspections Morale Bring focus and voice to operator issues/concerns. Cost FTQ goals Quality Proper product identification Error proofing verification (i.e. the rabbit test) Improved work standardization Calibration Training Control of Non-conforming Product

Key Items for Success If plant management isn’t driving it, you won’t succeed Keep it manageable Include all functions and levels of manufacturing Phase implementation and customize to fit the organization / business you have It is not a simple roll-out and implement -- continuous monitoring and improvement is needed

Benefits Reduced OSHA injury rates Improved DMR rates Increase ability of detecting product or process problems internally Highlighted variances in set-ups and driving to improve standardization Training gaps identified Verification that process controls are being followed Bring all areas of the organization into operations

Definition Layered Process Audits is a process to ensure compliance to procedure for shop floor standards and standard work It is a series of audits done by multiple layers of an organization to reinforce standards and standard work The audits are completed by levels up to and including top plant management Results of these audits are measured for completion % and compliance %

Why do we do layered process audits? Ensure key procedures are being followed Instill the importance of following procedures on the shop floor Monitor the execution of corrective actions Ensure a high level of process control by identifying &controlling high risk/significant process elements Identify opportunity for improvements and provide a process for effective follow up Encourage people involvement in quality, leadership and shop floor

How LPA’s link in the Quality System Ensure the corrective action for previous quality issue is in place and functioning as desired Error Proofing Verification Ensure the EPV is being used and is working Control of Non-Conforming product Ensure specific CNCP procedures are being followed Standard work Ensure work being done to established standard Process control Check process control compliance to PCP Fast Response Entry criteria to FR as well as a exit criteria

How many of your plant managers do a detailed process audit weekly? Minimum Requirements How many of your plant managers do a detailed process audit weekly?

Supervisor / Team Leader Minimum Requirements Supervisor / Team Leader Daily / Weekly Manager / Engineers 1 time/week Plant Manager 1 time / month Executive Managers / Directors Quarterly / minimum Team Leader Every Shift Dept. supervisor/mgr 2 times/week Plant staff As available Every shift Team leader Weekly Department supervisor Plant staff member

Minimum Requirements

Step by step-Develop a checklist A list of high risk items to be verified during Layered Process Audits shall be established. Minimum elements to include are: Gages functioning and calibration confirmation FTQ Past corrective actions and repeat issues. Process parameters Work instructions Training effectiveness Product identification / control of non-conforming product Documentation/record completion Customer feedback Error Proofing Verification Layered Process Audits shall verify appropriate Quality documentation. Always think about high risk items!

Step by step Develop LPA work instruction and form Develop a check list of high risk items to be verified during audit process Schedule audit and visually display onsite Conduct audit and display the results Ask corrective action and follow up (report nonconforming of high risk items in Fast Response Summarize audit finding/metrics and track actions Update checklist as appropriate

Example Audit Questions Avoid non-specific LPA questions Are scrap procedures being followed? Specific LPA question Check scrap containers in line 3 and each machine’s gage stand and reject chute. Are all scrap procedures being followed for ID tag, proper containers, and location?

Example Audit Questions Avoid non-specific LPA questions Are all required quality checks being completed at this operation? Specific LPA question Review one workstation’s quality records (operation sheet and verification log). Have all required quality checks been completed correctly in last 8 hours?

Example Audit Questions Avoid non-specific LPA questions Are all machine settings correct per the operation sheet? Specific LPA question Review the set-up screen on 3 machines (Push “Set-up”, “Characteristics”, “Part Settings”). Do all 6 part settings exactly match those in the posted operation sheet?

Audit Questions

Step by Step- Conduct audit and display the results How can the visual display of findings be used?

Step by Step- Ask corrective action and follow up

Step by Step- Summarize audit finding and track

Key Learning Points-Take away LPA is a process to ensure compliance to procedure for shop floor standards and standard work LPA process involves all levels of plant management performing the same audit LPA results are measured for completion and compliance LPA is an input to Fast Response, Fast Response exit criteria include LPA Do it step by step

Key Learning Points-Step by step Develop LPA work instruction and form Develop a check list of high risk items to be verified during audit process Schedule audit and visually display onsite Conduct audit and display the results Ask corrective action and follow up (report nonconforming of high risk items in Fast Response Summarize audit finding/metrics and track actions Update checklist as appropriate