Layered Process Audits

Layered Process Audits are a low cost strategy to get into the single digit ppm range and potentially meet the goal of zero defects to your customer. They are a tool to verify that things most important to quality are done right the first time. LPAs require various layers of supervision and plant leadership to audit processes, work instructions and errorproofing on a regular schedule to ensure compliance with documented procedures and standards.

Top leadership plays a substantial role in the implementation and ongoing success of Layered Process Audits. Many efforts have failed without management’s integration of LPAs into the plant culture.

Implementing Layered Process Audits requires different levels of support depending on prior exposure to the subject. We offer the following workshop options which can be taken alone or in combination to help you reach your specific goals:

	Content	Outcomes	Duration
Layered Process Audits-in-a-Box	A guided, do-it-yourself training and implementation kit for suppliers who have a good grasp of LPA concepts and wish to jumpstart training and implementation on their own	Low cost, self-paced implementation of LPA Site implementation team customizes forms and templates provided in Excel Leader led training and communication to the affected workforce	Up to you
On-Site Supplier Workshop	Specific to your processes/facility Utilizes hands-on examples within your facility Sample worksheets and action planning exercises aid in planning implementation	Knowledge and skill to implement Layered Process Audits Implementation plan Construction of initial audit checklists	1 day
Assessment of Current LPA System	Evaluation of your existing LPA process Recommendations for enhancing your system to meet DCX requirements	Assessment report Recommendation for improvement Debrief with leadership	1-2 days
Establishing an LPA System	Overview of LPAs and DCX’s requirements Evaluation of your facility to recommend a starting point for implementation, documentation, ownership, etc. Recommendations on audit questions, managed review, frequency, etc.	Implementation plan which considers other Quality System and manufacturing initiatives Construction of audit check sheets and compliance reports Training for top leadership and for cross-functional teams	1-5 days
Leadership Training	Targeted at plant manager and staff Ratchet-up LPA system to leverage payback Expand the reach of standardized work and LPAs	Concise training for top leadership Shared understanding of how LPAs can reduce internal and external ppm and lower costs Quality improvement action plan	1/2-1 day

For articles on LPA, click here.

Interested in LPA-in-a-Box? click here to download the PDF file describing the box’s contents or, to order a box, click here for the on-line order form.

If you are unable to access the on-line order form, please download the printable version of the LPA-in-a-Box order form, click here complete it and fax it to our office at 248.859.4350.