Example Of Layered Process Audit In manufacturing Let’s look at an example to demonstrate the possibility of layered process audits.
Consider a large automaker that uses LPAs to improve the quality of its production line, especially in the last assembly of the vehicle’s braking system, which is an essential safety feature.
The implementation procedure and possible results could resemble this:
Goal: Determine the braking system assembly’s persistent quality problems that caused a rise in rework and customer complaints.
Action: Using a thorough checklist that examined every stage of the brake system assembly, a baseline audit was carried out.
Example Of Layered Process Audit In manufacturing
- Operators’ daily audits: The operators began by conducting daily audits with an emphasis on quick checks, such making sure brake pads and brake lines were installed correctly. Each component’s installation in accordance with the design specifications was confirmed using straightforward checklists.
- Weekly audits by supervisors: Supervisors carried out weekly audits to examine the results of the daily audits, make sure remedial measures were carried out, and confirm that all assembly processes adhered to design specifications and safety standards.
- Management’s monthly analysis: To evaluate the trend of problems, the success of the corrective measures, and whether additional training or modifications to the assembly process are required, management examined the monthly audit reports.
- Data aggregation and analysis: Information gathered from every level was examined to find trends, like the brake caliper mounting bracket’s frequent misalignment.
- Corrective measures: The training curriculum for new hires was modified to concentrate more on the areas where a high frequency of errors was noted. In order to properly fit the components and assembly equipment, the workstation arrangement was also altered.
- Feedback loop: Created an ongoing feedback loop that allowed operators to report possible problems instantly, resulting in more rapid fixes and answers.
The outcomes:
- The braking system assembly line defect rate dropped by 30% in the six months following the implementation of LPAs.
- Rework and related expenses were greatly decreased as a result of the optimized procedure and decreased error rate.
- Increased job satisfaction and improved work quality resulted from operators’ increased sense of involvement in the quality assurance process.
Layered process audit questions and checklists for manufacturers
Example Of Layered Process Audit In manufacturing During the audit process, layered process audit questions are specifically created to make sure that manufacturing activities adhere to set standards and protocols. To put it another way, they are the main component of LPA checklists.
The following advice can help you write LPA questions:
- Be succinct and clear: Questions should be direct and free of ambiguity. Accurate audits depend on having clear questions and clear responses.
- Be precise: Ask inquiries that are relevant to particular steps or sections of the production line. Being specific makes it easier to identify problems.
- Use a variety of question formats: Open-ended questions can shed light on the reasons for specific abnormalities, multiple-choice questions can evaluate adherence to conventional processes, and yes/no questions can verify basic compliance.
- Pay attention to important control points: Give top priority to inquiries concerning important facets of the production process that have a direct bearing on the safety and quality of the final product.
- Promote observational responses: Create inquiries that demand observations from auditors as opposed to their subjective assessment. This method lessens prejudice and improves the accuracy of the information gathered.
- Additionally, here’s how to create efficient layered process audit checklists using LPA questions:
- Put questions in a logical order: Sort questions according to how the process being audited operates. The checklist is easy to follow and guarantees that nothing is missed during the audit when it is organized in a progressive manner.
- Include standard answers: If appropriate, include a list of standard, acceptable answers for every inquiry. This uniformity makes it easier to compare outcomes from various auditors and across time.
- Make room for notes and observations: In order for auditors to record odd or unexpected findings that might not be addressed by the regular questions, checklists should include space for extra remarks or observations.
- Provide verification points: Include areas on the checklist where auditors can confirm that earlier corrective actions were carried out. This guarantees that every LPA reinforces compliance and progress by building on the one before it.
- Pilot the checklist: Test the checklist in a small area of the manufacturing process prior to full implementation. This test run will enable any necessary revisions and assist in identifying any gaps in the checklist’s questions or flow.
- Review and update frequently: Evaluate the checklist’s efficacy on a regular basis and update it in response to auditor comments, modifications to production procedures, or new compliance needs.
Example Of Layered Process Audit In manufacturing Manufacturers can make sure that their LPAs are strong, focused, and efficient by adhering to these recommendations.
Use L2L to streamline layered process audits.
Example Of Layered Process Audit In manufacturing Businesses wishing to enhance manufacturing processes and apply continuous improvement techniques like layered process audits can find a strong answer in the L2L Connected Workforce Platform.
Example Of Layered Process Audit In manufacturing Businesses may more efficiently plan, automate, monitor, and analyze their audits by digitizing the LPA process. L2L allows manufacturers to:
- Make and disseminate digital checklists that auditors on the production floor can readily access and amend in real time.
- The software allows you to schedule audits directly and will automatically notify the appropriate staff when an audit is due.
- To expedite the process, do the audits using mobile devices.
- Produce thorough reports as soon as possible using the information gathered throughout the audit.
- Notify pertinent parties in real time if an audit reveals a serious problem.
- Keep all the information in one location so that teams can coordinate action plans, discuss audit findings, and exchange comments.
- Monitor the execution of remedial measures.
- Maintain consistent quality and compliance standards by standardizing LPAs across various sites and facilities.
- Manufacturers can turn LPAs into a dynamic yet user-friendly tool for promoting operational excellence by utilizing L2L’s capabilities.
Why Use this Template
Example Of Layered Process Audit In manufacturing Several levels of inspection are usually used in layered process audits to make sure that manufacturing processes and procedures are being followed as planned. For the audit process to remain efficient and consistent, using a checklist is very advantageous.
The following are four excellent justifications for utilizing a template for layered process audits:
- Structure: During an audit, an LPA audit checklist guarantees that all required actions are performed and that nothing is overlooked.
- Consistency: Using a checklist also helps to standardize audits conducted by various auditors. It is simpler to compare results over time when all audits use the same questionnaire style.
- Efficiency: Auditors can work more effectively when they have a convenient list of things to look for during layered process audits.
Thoroughness: Finally, an LPA template is essential to ensuring that the audit covers all relevant topics.
