Attendees will discover the low-cost strategy to improve quality and greatly reduce the number of customer rejects in your manufacturing facility. In this class, attendees will learn how build an effective Layered Process Auditing System.
This course was designed to provide a “hands-on” way of introducing and maintaining an effective layered process audit system. This course will help not only the person charged with administering Layered Process Audits, but those key resources who depend on the success of this process. Layered Process Audits involve the management and supervisors from the front line through the top administrative level. It involves gaining commitments from all levels to recognize that the organizational success depends on the direct connection between the operators (those making the products) and those who either directly or indirectly support those operations.
Purpose of the LPA audit – This is a way of introducing MBWA – management by walking around, a process found effective by the largest and most successful companies. Managers who know their processes, their people, and the ongoing issues of their organization at the grass-roots level, are in the best position to enhance quality and profitability of their organization. This is an approach that the AIAG encourages by introducing LPA systems to suppliers of the automotive industry.
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.
- Introduction – Identifying and defining the purpose of Layered Process Audits
- Value of Layered Process Auditing as a Management Tool
- Planning, starting with top management.
- The Process Owners, Planning Team and preparing the scope of LPAs
- Addressing Customer specific requirements and process prioritization
- Audit layers and developing templates for auditing and reporting
- The LPA Procedure and gaining stakeholder buy in.
- The implementation team
- Training auditors
- Communicating the LPA rollout to the process area
- Conducting the Audit
- The audit and recording findings
- Observations and personal interactions
- Top Management Review and Continuous Improvement of LPAs
- Top management LPA review
- Continuous Improvement of LPAs
Included in the 1-day training is an example audit of a selected client’s process.
We will also provide suggestions for appropriate ways to discuss the LPA system, set up an audit schedule (frequency of audits by layer), and provide a reporting example found to be effective in other organizations.