Daimler-Chrysler Layered

Process Audits
(DCX LPA)
Alberta Risner

07/02/15

Goal

Satisfy Daimler-Chrysler mandated

LPA (Layered Process Audit)
Training of Managers and Supervisors
Satisfy Customer Specific
Requirements and TS16949
requirements
Continual Improvement

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Continual Improvement

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Where are we now?

No Layered Process Audits (LPA) are

currently being performed
Training has been started at SRAF
(Today)
Input in Chryslers Powerway will
begin when LPAs have started
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SRAFs Training

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Training

Training will be Painless

Training will be Hands on
Training will encompass all
management levels
Training will be completed

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Kinda Painless

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Past History

No history on LPA
Were creating the line in the
proverbial sand.
Lessons Learned can and should
apply

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SRAFs Line in the Sand

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What are our choices

1. Not performing LPAs?
2. Pitch in and get it done

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The only Choice

Pitch in and get it done and perform

LPA as required.

Why No Choices ?

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Daimler-Chrysler
Mandated

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Farmington Managers and

Supervisors

Daimler Chrysler

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What is a Layered Process

Audit? (LPA)

LPA is an ongoing system of process

checks that verify proper methods,
settings, operator craftsmanship, error
proofing devices and other inputs are in
place to ensure a defect free product.

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What is a Layered Process

Audit (LPA)?
Continued
LPAs assure that defined methods
and work instructions are utilized,
problem solving solutions are held in
place, and all process issues are
identified and quickly corrected.

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What is a Layered Process

Audit?
continued

Two types of LPAs

Auditing the Process itself
Auditing the Error Proofing

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1. Process Audit

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LPA Process Audit

Process Audit:

Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the
corresponding day's box. Non-conformances are to have corrective action
recorded in the space provided and identified with the date (MM/DD/YY)

Mon Tues Wed Thurs Fri

Item No.

These Items Are to be Checked Every

Audit

Please write the actual dates in the corresponding

columns!

Shift: __________
Sat

Sun

Corrective Action Taken

Audit Area

Section 1: Operator Instructions

1
2
3
4

Are operator instructions accessible at the work

stations and made available without disruption to
the work being performed?
Do operators undersatnd their work instructions
and is the work being performed follow the work
instructions step by step?
Do all operators performing containment activities
have work instructions and have they been trained
to the work instructions?
Do all operators have a clear understanding of their
jobs? Do they know the 'right' things to do, are they
doing them correctly, and can they demonstrate
Are operators filling out required forms and
documentation and turning them into their
supervisors per their work instructions?

Section 2: Product Identification, Housekeeping and Workplace Organization

1
2

Is all product in the work area properly identified

with product status clearly shown per work
instructions and procedures QP-9 & 21.
Are all containment, quarantine and product staging
areas physically identified?

Are all work areas maintained in a state of order, well

organized with good housekeeping?

Is suspect product properly identified per work

instructions and procedure QP-9.

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LPA Process Audit

continued

Section 3: Process Monitoring and Process Control

1

Are Process Analysis Boards (PAB) filled out

completely and correctly?

Are Process Analysis Board (PAB) charts filled out

correctly and up-to-date?

Are Process Performance Boards (PPB) maintained?

Is all required information posted on Certified

Operation Boards (COB)?

If required, are First Piece Approval tags being used

and filled out correctly?

Section 4: Customer Issues and Corrective Actions

1

Are operators aware of any customer complaints

and internal quality issues / concerns?

Are corrective actions for customer complaints

implemented and effective? (Obtain customer
complaints from the Quality Manager.)

Are corrective actions for internal quality alerts and

concerns implemented and effective?

4
5

If rework is being performed, are rework instructions

available for the operator and are they being
followed?
Have operators reviewed and signed all orange
boundary standard tags/parts?

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2. Error Proofing Audit

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Error Proofing Audit:

Only Qualified Personnel can Perform Error Proofing Verification Audits
Auditor:
All questions are to be answered with a checkmark "Y" or no "N" in the
corresponding day's box. Non-conformances are to have corrective action
recorded in the space provided and identified with the date (MM/DD/YY)

Shift: __________
Mon Tues Wed Thurs Fri

Item No.

These Items Are to be Checked Every

Shift

Sat

Please write the actual dates in the corresponding

columns!
Sun

Corrective Action Taken

Audit Area

Section 1: General
1

Are operators aware of the function and importance

of any error proofing devices at their station?

Are all error proofing verification parts identified

and maintained with due care?

Are all error proofing devices verified per work

instructions? Are the verification results recorded?

When error proofing devices fail verification checks,

are the proper employees notified? Is this contact
documented? Is there any follow up?

Is there a 'reaction step' to direct operators when

error proofing devices are not functioning? That is,
how will the known defect or potential defect be
detected in order to protect the customer in the
absence of automotic error detection?

Are all operators performing error proofing

verification checks trained to do so?

Section 1: Work Cell Specific

Will be unique for every work cell containing error
proofing.

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How Long Will either LPA

Take?

On average 15 minutes

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What do we need to
perform a LPA?

A pen or pencil
A Checklist
Knowledge of the Process
(A sense of humor helps)
Commitment for success

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LPA Frequency
Plan
Plant Manager-once a week
Area Managers-once a week
Production Supervisors-once a shift
This Proposed Frequency will:
Encourage Management Involvement
Establish Operator Feedback
Establishes Accountability

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Where do we start ?

Recommended starting point:

At the highest point of risk.

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First Layer of
Management

Supervisors

Second Layer of Plant Staff and Plant

Management
Manager

Third Layer of
Management

Corporate SRA

Mold Supervisor /
Manager

Own Department

Plating Supervis or /
Manager

Own Department

Paint Supervisor /
Manager
Assembly
Supervisor /
Manager
Quality Supervisor /
Manager
Quality Manager
Maintenance
Manger
HR Manager
Lean / Training
Coordinator
Assistant Plant
Manager
*Molding Manager
*Plating Manager
*Paint Manager
*Assembly
Manager
Plant Manager
Shipping Manager
VP of Quality
VP of Operations
Quality Systems
Engineer

1 Per Day

1 Per Day

Own Department

1 Per Day

Own Department

1 Per Day

Own Department

1 Per Day

Rotate Departments

1 Per Week

Rotate Departments

1 Per Week

Rotate Departments

1 Per Week

Rotate Departments

1 Per Week

Rotate Departments

1 Per Week

Rotate Departments
Rotate Departments
Rotate Departments

1 Per Week
1 Per Week
1 Per Week

Rotate Departments

1 Per Week

Rotate
Rotate
Rotate
Rotate

D o ck A u d its

A ssem b ly

Audit
Assignment

P a in t

Assigned
Management
Personnel

P la tin g

Assigned
Management
Category

M o ld in g

SRA LPA Audit Frequency and Structure

Departments
Departments
Departments
Departments

1 Per Week
1 Per Week
1 Per Quarter
1 Per Quarter

Rotate Departments

1 Per Quarter

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Note: * = if there is no supervisor, then the area manager shall be considered the first layer of management.
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