LAYERED AUDITS

© 1998 General Motors Corporation. All rights reserved.

006/02/20 QSB WORKSHOP REV. 11 (02/18/03) 1
 LAYERED AUDITS
PURPOSE:
To provide a system to:
- verify compliance to the documented process
- instill discipline
- improve communication
- improve overall quality
SCOPE:
• Assembly Area
• Manufacturing Operations
• Shipping/Receiving
• Repair/Rework Area
• All Operations and other support functions

RESPONSIBILITY:
• Single Ownership
- Plant Manager
• Supported By
- Quality Manager
© 1998 General Motors Corporation. All rights reserved.
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 REQUIREMENTS:

• Layered Audits shall be conducted for manufacturing and

assembly of high risk items at a minimum of once per shift.

• Frequency of Layered Audits based on production volume or level of

risk
associated with process.

• Layered Audits supplement ongoing control plan and job instruction

checks.

• A check list of high risk items to be verified during Layered Audits

shall be established.

• Elements should be considered in developing the check list. (Example)

© 1998 General Motors Corporation. All rights reserved.

006/02/20 QSB WORKSHOP REV. 11 (02/18/03) 3
 (Example)
Elements

 Utilization of manufacturing assists (as applicable)

 Gages functioning and calibration confirmation
 Stacking / packing techniques
 Build / manufacturing techniques
 Visual aids presence and content
 Process parameter setting
 Job instructions
 Correct product identification
 Process steps adhered to
 Required inspections completed
 Torque monitoring (if applicable)
 Product dimensions or visual inspection
 Documentation / record completion
 Quality Gates (as applicable)
 Customer feedback

© 1998 General Motors Corporation. All rights reserved.

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REQUIREMENTS (continued):

• Layered Audits results shall be recorded.

• Non-conformities shall be addressed immediately

• Reaction plan(s) for non-conformities detected during Layered

Audits shall be documented and available for use.

• Corrective actions shall be documented.

• Results shall be summarized and reviewed by the

manufacturing site leadership.

• Layered Audit documentation shall be compiled in the

Lessons Learned (key strategy) database.

© 1998 General Motors Corporation. All rights reserved.

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REQUIREMENTS (continued):

• Customer used features shall be identified, listed and checked in

the manufacturing process with emphasis on:

- Supplier pass through features

- Mounting (holes, taps, etc.)
- Electrical connections/connectors
- Mounting surfaces
- Clearances
- Missing/wrong brackets
- Incorrect parts
- Others as identified by customer

© 1998 General Motors Corporation. All rights reserved.

006/02/20 QSB WORKSHOP REV. 11 (02/18/03) 6
REQUIREMENTS (continued):

• The following is an example of a Layered Audit with three levels

of management involved in the process:
- The manufacturing supervisor shall verify (daily) all quality
documentation is completed by operators.
- The manufacturing area manager shall verify (weekly) that
supervisor verification is being completed.
- Site leadership shall conduct layered audits at a
frequency defined locally.

© 1998 General Motors Corporation. All rights reserved.

006/02/20 QSB WORKSHOP REV. 11 (02/18/03) 7
 QUALITY ELEMENT: LAYERED AUDIT

Example
REACTION (Special Cause Prevention (Common Cause) GMPT model
PFMEA
CUSTOMER CONCERNS RPN REDUCTION
External- PRR’s, etc TEAMS
Cross Functional
Internal Shainin
AUDIT THE PROCESS

8 STEP Corrective P. -Formal Line item document

Action CONTROL PLANS --Items Checked daily
F. -- Is the system working?
-12:15p.m. Report outs What’s critical to
-Fast Response M. the process?
E. AUDIT % COMPLIANCE
A. JOB INSTRUCTIONS -Data Collection
-Participation
-Standardized Work -Responsiveness
-Integrity

RESULTS
-Quality Improved
-Quality Stabilized

© 1998 General Motors Corporation. All rights reserved.

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 LAYERED AUDIT MATRIX (Example)

O P E R A T IO N S M A N A G E R

CO PRO RATE M ANAG ER

SHIFT DAILY WEEKLY M ONTHLY QUARTERLY

E X E C U T IV E M A N A G E R
PLANT M ANAG ER
Q .A . IN S P E C T O R

Q .A . M A N A G E R
TEAM LEADER

S U P E R V IS O R
O PERATO R

P R E S ID E N T

TBD
PART / PRODUCT
Err or Pr oofing V e rification
Fir s t Pie ce Ins pe ction
Las t Pie ce Ins pe ction
Standard Work Ins tr uction Pre s e nt
Ope r ator Training Tr ack ing She e t
Safe ty Is s ue s

PROCESS
Se t-up
SPC Com pliance
Tooling Appr oval (Sign-off)
Quality Gate Data

SYSTEM
Pre ve ntative M aintainance
Calibr ation
Lot Trace ability
Hous e k e e ping

V OICE OF THE CUSTOM ER

6-Pane l Pos te d
Action Plans Update d & on-tim e
PR/R's Pos te d
Cus tom e r De live r y Pe r form ance
C.A.R.E.

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(Example)

PART NAME:
PART NUMBER: SHIFT:
CUSTOMER :
DEPARTMENT: WEEK ENDING:

Wednesday

Thursday

Saturday
Tuesday
Monday

Friday
Op 10 Broach
Is runout (column #2) within spec (20 lights)
Has perpendicularity been gaged (402-3537)? Spec is 20 lines
Is there any broach tear? (Check one part from each broach)

Op 20 Olofssons
Is the ID on size (columns #2 & 3)?
Is the ID run out within specifications?
Is the ID taper (between columns 2 & 3) within specification?

Op 30 Hones
Has the ID-Micro been checked and the Micro Log completed?

* Entire Department
Are operators verification sheets completed daily by all shifts?
Are the tagging procedures being followed?
Are any Temporary Alert Notices posted that have expired?

© 1998 General Motors Corporation. All rights reserved.

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(Example)
PART NAME:
PART NUMBER: SHIFT:
CUSTOMER:
DEPARTMENT: WEEK ENDING:

Wednesday

Thursday

Saturday
Tuesday
Monday

Friday
Op A Assembly
Are the builders checking rotation & marking parts (touch point)?
Have the 8-hole sprags been inspected for presence of 8-holes
and identified with orange marker?
Are bar code labels attached to shipping container in correct
location?
Are shipping containers checked for actual count?

Machining Operations Total Non-Conforming Items

Assembly Total Non-Conforming Items

LIST ANY QUALITY OR MANUFACTURING CONCERNS ON ALL OPERATIONS.

© 1998 General Motors Corporation. All rights reserved.

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 (Example)

DEPARTMENT LAYERED AUDIT RESULTS

ITEMS NOT IN COMPLIANCE

ITEM NUMBER OF OCCURANCES

© 1998 General Motors Corporation. All rights reserved.

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 (Example)

DEPT.____________ LAYERED AUDITS RESULTS

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

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:
# OF ITEMS ON ASSESSMENT:
# OF ASSESSMENTS
TOTAL # OF ITEMS ASSESSED:
# OF ITEMS IN COMPLIANCE:

© 1998 General Motors Corporation. All rights reserved.

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