Layered Process Audit in the Automotive Industry

Layered Process Audit (LPA) is one of the methods used in the automotive manufacturing world to maintain high quality standards. This article delves into the essence of LPAs, their importance, and the specific requirements outlined by the CQI-8 guidelines from the Automotive Industry Action Group (AIAG).

Layered Process Audit (LPA) – What is it?

A Layered Process Audit (LPA) is an audit technique used in manufacturing, especially in the automotive industry, to ensure adherence to standard processes and identify areas for continuous improvement. The term “layered” refers to the multi-layered approach where audits are conducted by various levels of management and personnel within an organization.

Key Objectives

1. Consistency and Standardization: Ensuring that processes are performed consistently according to established standards.
2. Identification of Non-conformities: Detecting deviations from the standard procedures early to prevent defects.
3. Employee Engagement: Involving different layers of the organization in the auditing process to foster a culture of quality and accountability.
4. Continuous Improvement: Providing a mechanism for ongoing evaluation and enhancement of processes.

Layered Process Audit (LPA) – The Structure

LPAs are typically structured in layers, with each layer representing a different level of the organization:

• Layer 1: Daily audits conducted by team leaders or supervisors.
• Layer 2: Weekly audits performed by mid-level managers.
• Layer 3: Monthly audits conducted by senior management.

NOTE: Depending on the organization, audits may be organized into four or more layers with more accurate functions to perform those audits.

This structure ensures that multiple perspectives are applied to the auditing process, increasing the likelihood of identifying issues and fostering a culture of continuous improvement.

Layered Process Audit (LPA) CQI-8 Guidelines by AIAG

The AIAG’s CQI-8 (Continuous Quality Improvement) guidelines provide a structured approach for implementing LPAs in the automotive industry. Here are the critical requirements and recommendations of CQI-8:

1. Management Commitment and Support: Senior management must demonstrate a commitment to LPAs by providing necessary resources, training, and support.
2. Training and Competency: All personnel involved in the audit process must be adequately trained. This includes understanding audit procedures, criteria, and the importance of LPAs in quality management.
3. Audit Planning: LPAs should be planned systematically. This involves defining the scope, frequency, and responsibilities of audits at different layers.
4. Standardized Checklists: Using standardized checklists ensures consistency in the audit process. These checklists should cover critical process steps, potential failure modes, and compliance with standard operating procedures.
5. Non-conformity Management: A robust process for managing non-conformities is essential. This includes documenting issues, analyzing root causes, implementing corrective actions, and verifying the effectiveness of these actions.
6. Communication and Feedback: Effective communication channels should be established to provide feedback on audit results to all relevant stakeholders. This helps in closing the loop on identified issues and ensuring corrective actions are implemented.
7. Performance Measurement and Review: Regular review meetings should be held to assess the performance of the LPA process. This involves analyzing audit results, identifying trends, and making necessary adjustments to the audit strategy.

Layered Process Audit (LPA) – Implementing

Implementing LPAs involves such typical steps as:

• Leadership decision about LPA: the decision about implementation shall be followed by defining objectives and scopeof the processes to be audited.
• Develop LPA procedure: doing it as a workshop with different functions invited may bring a lot of expertise and accountability of everyone for doing future LPA
• Build audit team: important is to nominate different functions for performing LPA audits as they need to be trained in next steps
• Audit Schedules and Checklists: Create detailed audit schedules and checklists tailored to the specific processes and standards.
• Train Auditors: Ensure that all auditors are well-trained and understand their roles and responsibilities.
• Conduct Audits: Perform audits as per the defined schedule, using standardized checklists and documenting findings meticulously.
• Analyze and Act: Analyze audit findings, identify root causes of nonconformities, implement corrective actions, and verify their effectiveness.
• Review and Improve: Regularly review the LPA program’s performance and make improvements as needed but also some processes can be redesigned or enhanced for greater efficiency or quality.

Benefits of Layered Process Audits

• Enhanced Process Control: Ensures that processes are consistently followed, reducing variability and improving product quality.
• Early Detection of Issues: Identifies potential issues before they escalate into significant problems, reducing the cost of rework and scrap.
• Employee Engagement: Involves employees at all levels, fostering a culture of quality and accountability.
• Continuous Improvement: Provides a structured mechanism for continuous process improvement.

Let’s sum up!

Layered Process Audits, guided by the CQI-8 requirements from AIAG, play a vital role in maintaining and improving quality standards in the automotive industry. By ensuring consistent adherence to processes, identifying and addressing non-conformities early, and fostering a culture of continuous improvement, LPAs help automotive manufacturers achieve excellence in quality and customer satisfaction. Implementing a robust LPA program requires commitment, planning, and ongoing evaluation, but the benefits it brings to the organization make it a worthwhile investment.

Do you want to know more?

We invite you to the Layered Process Audit training organized by Qualitywise, where you will learn in detail all the techniques for effective problem solving. Ask about the date.

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Agata Lewkowska Ph.D.

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For people who want to know more:

CQI-8 Layered Process Audit, AIAG, 2014

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