2. 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

3. 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

4. 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

5. 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

6. 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

7. 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 %

8. 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

9. 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

10. 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?

11. 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

12. Minimum Requirements

13. 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!

14. 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

15. 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?

16. 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?

17. 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?

18. Audit Questions

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

20. Step by Step- Ask corrective action and follow up

21. Step by Step- Summarize audit finding and track

22. 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

23. 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