Quality & Industrial Performance: Layered Process Audit
Quality & Industrial Performance: Layered Process Audit
RESPONSIBILITY:
• Ownership
Plant/Operations Mgr
Criteria of Requirement
1 – page 5-8
2 – page 9-12
3 – page 13-16
4 – page 8
5 – page 16
Auditor hints – page 17
Next Requirement
•Safety – PPE
•Standardized Work
•In process
Product Checks
•WPO,Visual Mgmt. Plant
•Tool Maintenance Staff Audit
•Process Control
Checksheets Shift Leader
•Etc. Audit
QSB+ Key Elements
Group Leader Audit
Layered Audit
Performance Reviewed
in Plant Leadership Meeting Non-conforming info
- Countermeasures
• Quality and other functions will participate and support the LPA system.
• Ensuring proper safety and ergonomic practices and PPE are being followed.
• Ensuring proper tools, gages and materials are available & used.
• Ensuring standardized work & quality standards are understood & followed.
Verification that special process audits are performed shall be included as applicable.
(e.g. CQI 9, 11, 12, Weld Audit, Chrome Audit, Paint Process Audit)
Criteria of Requirement
1 – page 20-22
2 – page 20-21
3 – page 23
Auditor hints – page 24
• Monthly, the site leadership (Plant Manager) shall conduct Layered Process
Audits and review audit results and corrective actions.
• Quarterly, CEO shall audit and verify that previous levels LPA and process
specific audits have been performed.
Plant
PlantManager
Manager
11time
time/ month
/ month
Manager / Management
Manager / Engineerssupport staff
1 1time/week
time/week
Supervisor
Supervisor / Team
/ Team LeaderLeader
DailyDaily
/ Weekly
(Example)
Shaded in
Red if Not
Completed
Criteria of Requirement
1 – page 26
2 – page 26-27
3 – page 28-29
4 – page 30
Auditor hints – page 31
NC N = Deviation Found
Y = Meets Standard
If the item is Corrected
Immediately
• All questions answered “N” on the LPA Check Sheet that cannot be resolved
immediately will be entered on the Countermeasure Sheet as an open item.
• The Countermeasure Sheet will be updated and signed off as issues are
resolved.
(Example)
Target Complete
Item # Date Location Problem Description Owner Countermeasure date Initials Date
New option Side marker lamp, parts don't Re-layout work station to include one
4 7/7/08 005R have a standard marked location. TL1 shift's requirement of lamps. 7/28/08 JC 7/26/08
tool for installing drainplugs is different
from standard, TM used replacement get standard tool from store, replace at
6 7/7/08 005R without informing TL TL1 workstation 8/3/08 RS
Criteria of Requirement
1 – page 33
2 – page 34-35
Auditor hints – page 36
100% 47 50
90% 43 43 45
80% 40
70% 35
60% 27 30
24
50% 23 22 25
20 19
40% 20
16 16
14
30% 15
20% 10
10% 5
0% 0
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
% IN COMPLIANCE: 88% 68% 95% 96% 97% 84% 95% 95% 94% 95% 95% 89%
# OF ITEMS ON ASSESSMENT: 20 15 20 30 20 10 20 25 20 20 20 20
# OF ASSESSMENTS 20 9 28 15 20 10 20 20 20 20 20 20
TOTAL # OF ITEMS ASSESSED: 400 135 560 450 400 100 400 500 400 400 400 400
# OF ITEMS IN COMPLIANCE: 353 92 533 434 386 84 380 477 376 381 378 357
NON CONFORMANCES 47 43 27 16 14 16 20 23 24 19 22 43
1st Week 2nd Week 3rd Week 4th Week 1st Week 2nd Week 3rd Week 4th Week 1st Week 2nd Week 3rd Week 4th Week
STARTED ON THE
INSTRUMENT PANEL LINE
AUDIT AUDIT
CONDUCTED BY: FREQUENCY:
Supervisors Daily
- AUDIT NOT COMPLETED
Team Leaders Daily
100% 30
27
90%
25
80%
70%
20
60%
50% 14 14 15
40%
8 8 10
30% 7
20% 4
3 5
10% 2 2
1
0
0% 0
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
JAN FEB MAR APR MAY JUNE JUL AUG SEP OCT NOV DEC
% ISSUES CLOSED: 85% 67% 89% 100% 86% 75% 60% 65% 92% 95% 36% 37%
TOTAL # OF NON CONFORMANCES: 47 43 27 16 14 16 20 23 24 19 22 43
TOTAL # OF CLOSE ISSUES: 40 29 24 16 12 12 12 15 22 18 8 16
TOTAL # OF OPEN ISSUES 7 14 3 0 2 4 8 8 2 1 14 27