Layered Process Audits (LPA) in the Automotive Industry

What is a Layered Process Audit?

Layered Process Audits (LPAs) are checks done at different levels of an organization to make sure everyone is following set processes. These audits involve looking at how work is done and talking to employees. People from various departments, not just Quality, conduct these audits. Key elements include:

Observing Manufacturing Processes:

Focus on verifying that documented processes and procedures are being followed, rather than just inspecting finished products.

Multi-Level Audits:

Typically there are 3 layers of audits conducted by different management levels:

1. Daily audits by shop floor supervisors

2. Weekly audits by middle management

3. Monthly/quarterly audits by plant managers and executives

Cross-Functional Teams:

Involves people at all levels, from junior workers to senior management, across functions like manufacturing, logistics, and maintenance.

Identifying Process Improvement Areas:

Detect and resolve process issues, before they lead to quality problems or customer complaints. Key inputs include customer requirements, risk assessments, statistical data, and trend charts on factors like rejections and rework.

Layered Process Audit Goals:

• Follow procedures consistently.
• Maintain quality standards.
• Fix deviations quickly.
• Promote continuous improvement.

Layered Process Audits help ensure that work processes are followed correctly, quality is maintained, and continuous improvement is encouraged throughout the organization.

How to Implement Layered Process Audit (LPA)?

Implementing an effective LPA program involves a systematic approach to industry best practices.
The key steps include:

1. Build a Cross-Functional LPA Team:

   Build a team with representatives from different organizational levels and functions, ensuring diverse perspectives and expertise.

2. Define Audit Scope and Objectives:

   Identify business processes, functions, and areas to be covered by the LPAs, aligning with organizational goals and quality standards.

3. Develop a Customized Audit Checklist:

   Make clear and specific questions for each audit based on the defined areas.

4. Structure Audit Layers:

   Establish three audit layers:

• • Daily Audits: Done by supervisors or team leads.
  • Weekly Audits: Done by middle management.
  • Monthly/Quarterly Audits: Done by plant managers or executives.

5. Schedule and Communicate Audits:

   Implement a scheduling system and communicate audit plans, timelines, and expectations across the organization.

6. Conduct Training:

   Provide training to all team members on conducting effective LPAs, ensuring a consistent approach and understanding of audit processes.

7. Perform Systematic Audits:

   Perform audits systematically using checklists, on-site observations, and interviews, covering product-related aspects, and manufacturing processes.

8. Document and Analyze Findings:

   Document audit findings, analyze data, and identify areas for improvement.

9. Drive Continuous Improvement:

   Establish problem-resolution processes, and ensure timely corrective and preventive actions. Continue refining the based on the data.

Key Points for Successful Layered Audit:

• Stay Organized: Follow the schedule and document results.
• Get Management Support: Ensure top leaders back the audits.
• Communicate Clearly: Keep everyone informed about the process and findings.
• Aim for Real Improvement: Use the audits to make meaningful changes.

By following these simple steps, you can implement an LPA program that helps ensure processes are followed, quality is maintained, and continuous improvements are made.

Benefits of Layered Process Audit in Automotive Quality Assurance

Implementing an effective audit program offers many benefits for organizations, especially in the automotive industry:

• Improved Safety and Reduced Incidents:

  LPAs help identify and mitigate safety risks, leading to fewer incidents and a safer work environment.

• Cost Savings:

  By catching defects early in the production process, LPAs reduce waste, scrap, rework, customer complaints, and expensive product recalls. This results in better cash flow and reduced Cost of Poor Quality.

• Improve Quality and Customer Satisfaction:

  LPAs ensure processes meet customer-specific requirements (CSRs) from automakers. This improves product quality and increases customer satisfaction.

• Continuous Improvement: 

  LPAs capture feedback from operators. This helps identify improvement opportunities, such as  5S methodology and safety behavior changes. Combining LPA data with personal interactions leads to lasting improvements.

• Process Compliance and Certification:

  LPAs help meet standards like ISO 9001, IATF 16949, ISO 45001, and ISO 14001. This ensures compliance with industry standards.

• Adopting a Quality Culture:

  Involving employees at all levels, from line workers to senior management encourages a company-wide quality effort. This promotes clear communication and a continuous improvement culture.

• Root Cause Analysis and Risk Mitigation:

  Focus on finding and fixing the root causes of defects. This helps control risks and prevent future issues.

• Measurable Performance Improvements in Processes:

  Effective audits lead to measurable benefits, such as reduced process errors, increased First Time Capability (FTC) of compliant products, and cost reduction.

Integrating Layered Process Audit Software 

Integrating LPA Software takes the process to a whole new level and makes conducting audits a breeze.
can offer a comprehensive approach to quality management, enabling organizations to:

• Improve Safety 
• Conduct Audits more effectively
• Reduce Costs
• Improve Customer Satisfaction
• Drive Continuous Improvement
• Ensure Compliance
• Cultivate a Culture of Quality

Start your Digital Layered Proces Audit journey now - Try our LPA App for free or book a demo.

 

Example of Layered Process Audit in the Automotive Industry

Assembly Line Quality Checks

Purpose: Ensure that assembly line processes meet quality standards at multiple levels within the organization.

Layer 1: Operator Self-Checks

• Frequency: Daily
• Audit Steps:
  1. Verify that each task is performed according to the work instructions.
  2. Check that all tools and equipment are in proper working condition.
  3. Ensure that the workstation is clean and organized.

Layer 2: Supervisor Audits

• Frequency: Weekly
• Audit Steps:
  1. Review operator self-check logs.
  2. Conduct random checks on product quality.
  3. Verify compliance with safety protocols.
  4. Ensure that corrective actions from previous audits have been implemented.

Layer 3: Managerial Reviews

• Frequency: Monthly
• Audit Steps:
  1. Evaluate the overall performance of the assembly line.
  2. Analyze trends from weekly audits.
  3. Check the effectiveness of implemented corrective actions.
  4. Review feedback from operators and supervisors.

Results: Better adherence to assembly procedures, early identification of issues, and improved product quality through continuous checks and improvements.

Conclusion

Layered Process Audits are essential quality management practices in the automotive industry. They offer a comprehensive approach to process compliance, continuous improvement, and risk mitigation.

The structured, multi-layered nature of LPAs allows for proactive monitoring, early defect detection, and effective root cause analysis, leading to improvements in performance.

Leveraging technology can make LPAs a breeze. Mobile2b's audit platform simplifies the entire LPA process with customizable checklists and features.

 

While LPAs require a systematic approach and commitment from all stakeholders, their benefits in driving quality, mitigating risks, and promoting a culture of continuous improvement make them an indispensable tool for organizations in the highly competitive and quality-driven automotive industry.

Layered Process Audit (LPA) FAQs

What exactly is a Layered Process Audit?

An LPA involves multiple levels of auditors, such as staff and employees, conducting the same set of audits to ensure that critical production steps adhere to established specifications. It is a methodical and organized review of a process or system.

Can you explain the CQI-8 Layered Process Audit Guideline?

The CQI-8 Layered Process Audit Guideline is a framework recommended by the Automotive Industry Action Group (AIAG) to enhance quality assurance and processes within the automotive industry. It provides a structured approach for conducting Layered Process Audits.

How many types of audits are specific to the automotive industry?

In the automotive sector, particularly under the IATF 16949 standard, there are three distinct types of audits, each with its own set of requirements, scope, and competencies. These are the Quality Management System Audit, the Manufacturing Process Audit, and the Product Audit.

What does an LPA checklist entail?

An LPA checklist is a tool used to observe and verify the manufacturing process of products. It is designed to assess various elements of the production process in stages to identify and resolve non-conformances and address issues directly at their source.