Layered Process Auditing

  • Delivery Option: On-Site Only
  • Subject Category: Auditing
  • Cost: $450
  • Number of Days: 1

Course Summary

Attendees will discover the low-cost strategy to improve quality and greatly reduce the number of customer rejects in your manufacturing facility. In this 1-day (8 hour) class, attendees will learn how build an effective Layered Process Auditing System.

Target Audience

Managers of operational areas who are expected to be the owners of Layered Process Audits, personnel involved in System Improvement along with Development Team leaders and Supervisory personnel. LPA has direct application to ISO/IATF 16949 and this course is recommended for anyone involved in quality planning or involved in the implementation of ISO/IATF 16949 and third-party auditors.

Prerequisites

Attendees should be familiar with IATF 16949 and basic audit techniques.

Course Objectives

The latest CQI-8 manual takes from the experience of OEMs and Tier One suppliers to deliver a roadmap for effective Layered Process Audit implementation, to provide a reduction in variation along the manufacturing line all the way up through the ranks of plant management. For organizations who feel they are not benefiting from Layered Process Audit it provides suggestions to improve their checksheets and other key aspects of their Layered Process Audit system. The updated guideline explains how Layered Process Audits can be used as management tools to verify that work is done according to established standards, emphasize the importance of those standards, and identify opportunities for continuous improvement.

Benefits

The main reason a facility should implement an effective LPA system is to enhance their competitive advantage. Good LPA systems will identify variations in high risk processes that could lead to the production of non-conforming products. It will also help identify error-proofing systems that become ineffective over time. With appropriate containment measures, this prevents bad product from shipping and reduces or eliminates customer rejections.

Agenda

Background and Purpose
1.0 What are Layered Process Audits
1.1 Typical Steps for Developing and Implementing Layered Process Audits
1.2 Scope of Use of Layered Process Audits
1.3 The Benefits of Layered Process Audits
1.4 Everyone Is an Auditor
1.5 Layered Process Audits and the IS/IS NOT Tool
2.0 Guidance for Planning Layered Process Audits
2.1 Audit Items
2.2 Audit Layers
2.3 Audit Frequency
2.4 Audit Non-Conformance Reaction
2.5 Audit Ownership
3.0 Conducting Layered Process Audits
3.1 Discipline in Conducting Audits
3.2 Recording Results
3.3 When a Non-Confomance is Found
3.4 Corrective Action Plans
4.0 Reviewing Layered Process Audit Results
5.0 Maintaining Layered Process Audits
5.1 Managing the Items on a Layered Process Audit
5.2 Adding Corrective Actions to Layered Process Audits
5.3 Auditing Compliance to Layered Process Audit Requirements

Materials

The Automotive Industry Action Group (AIAG) LPA Guideline is used as the reference material for this class. Copies of the guideline can be obtained through AIAG via their website www.aiag.org. Membership in AIAG has its benefits; if your company is not a member of AIAG, QC Training Services can provide manuals at additional cost.
In order to have the highest likelihood of success with this class, we encourage the students to obtain their reference materials as soon as possible in order to have plenty of time to familiarize themselves prior to the class date.