Reduce process non-conformance with Layered Process Audits (LPA)

Improve quality metrics, customer satisfaction, and profits by getting more things right the first time.

Consistently meeting or exceeding the requirements set by your company, customers, and quality standards is the foundation of your business. This criteria is in place for a reason, and failing to adhere to these standards results in inflated scrap and rework costs, increased customer complaints, and preventable costly accidents. How do you ensure process requirements are met or exceeded the first time around?

Implement or improve your Layered Process Audit system.

What is a Layered Process Audit?

A layered process audit is a structured set of process verifications conducted by various employees within an organization, from quality engineers to plant leadership. It is called a “layered” process audit because all levels of management are involved in the audit.The purpose of this quality strategy is to confirm everything is done right the first time by providing consistent attention to high risk processes, ensuring adherence to procedures and standards of core processes.

What does LPA do for you?

  • Know when your process is correct—build confidence and engagement in your processes.
  • Know when your process is not correct—immediately detect occurrence of non-conformance.
  • If your process is incorrect, take corrective action—make the right changes to prevent costly mistakes.
  • Capture and analyze this information—create a culture of continuous improvement.

The Luminous Group has led hundreds of companies in process improvement. We have been around since 1999, and each of our consultants has more than 30 years of experience in their field. We are recognized by the Automotive Industry Action Group (AIAG) as the thought leader in Layered Process Audit practices and implementation, and we take pride in applying our expertise by providing a fresh set of eyes to examine processes in large and small design and manufacturing companies.

We will meet you where you are.

Whether you are new to LPA, exploring options to improve your current system, or seeking a training engagement, we will find an approach to fit you. We will design a custom LPA strategy after assessing your unique situation. The result is an effective, highly targeted approach with immediate results. We will help you uncover which questions to ask and how to ask them to get more things done right the first time.Our experience with LPA in design and manufacturing industries allows us to execute your strategy quickly and effectively with little cost and large impact on quality conformance in your core processes.

Why reduce non-conformance?

  • Minimize scrap and rework costs
  • Strengthen customer satisfaction
  • Increase conforming parts per shift
  • Prevent costly accidents

About implementing LPA.

Implementing an effective Layered Process Audit program is a low-cost, easy to follow practice to reduce and eliminate process non-conformance. With minimal effort and a painless adjustment to quality practices, non-conformance can become a thing of the past. The ROI for implementing LPA with The Luminous Group is large and immediate. Our expertise promotes a quick and effective execution of your personalized LPA strategy.

Get started improving your LPA system today.

Contact us today to learn more about Layered Process Audits. Simply fill out the contact form or give us a call.

For information about approach and ROI, read our case studies. To learn more about implementation, download our 14 step guide to implementing LPAs.

“We are pleased to say that after a year, there have been no repeats of the original non-conformance. The inclusion of operators in the workshop lent good perspective to what was really happening. The timeline forced us to get everything done in a shorter amount of time than if we had tackled the issue on our own. We look forward to working with The Luminous Group again in the future.”

John Sidorenko
Quality Control General Supervisor, Delphi

“I learned a lot watching your style of cutting through some of the cloudy issues to get to the heart of the matter. You always know what questions to ask and have a very tactful way of getting the answers. You were also very helpful in pushing things through management, keeping the project focused on the objective and staying within the timeline. It’s obvious you have a lot of experience as well as a talent for analyzing a process to find ways to streamline it.”

Jim Tarpley
Induction Manager, Industrial Steel Treating Company