The Automotive Industry Action Group’s CQI-8 Layered Process Audit Guideline is a great resource for learning more about what goes into. AIAG CQI LAYERED PROCESS AUDIT GUIDELINE. Check our one-day seminar on CQI 8, it provides attendees with an understanding of Layered Process Audits (LPA).
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For lean manufacturing experts, this specific quote might bring to mind gemba walks, a method where leaders observe and solve problems on the shop floor.
CQI – 8 : Layered Process Audit Guideline by AIAG –
Whether the reference is intentional or not, LPAs and gemba walks share clear similarities. Could this be why companies doing gemba walks have an easier time with LPA programs, despite their complexity?
Gemba walks are an essential strategy for getting managers out of their offices to experience shop floor processes up close. Other similarities between gemba walks and LPAs include: Both practices involve multiple layers of management who participate auudits different times.
Gemba walks and LPAs open the door to conversation and coaching, rather than focusing on punishing mistakes. The presence and involvement of leadership on the plant floor makes quality visible, elevating it as a priority for everyone. LPAs complement gemba walks by providing: LPAs let you correct problems and log corrective measures on the spot, so you only have to send larger issues to the corrective action system.
By uncovering issues internally before they become customer problems, suppliers can expect as much as a percent reduction in returns. Although organizations with mature lean programs are primed for LPAs, the most important ingredient for success is a genuine commitment to improving quality.
CQI-8 Layered Process Audit Guideline
Any expert will tell you that doing LPAs audiits to check a box will never give you the same results as when you believe in their ability to truly improve quality. So, what does that kind of commitment look like? For many companies, making these audits work requires an automated LPA system to handle scheduling, data analysis, and checklist management. Many aerospace suppliers see the benefits of LPA in the auto industry, but they are reluctant to do it themselves because of the administrative overhead.
Automation slashes the resources required, allowing some manufacturing sites to reallocate up to two full-time employees focused on audit scheduling and management. An automated LPA platform makes it simple to: What you decide to do with these insights is where the real work lqyered.
CQI – 8 : Layered Process Audit Guideline
With nearly 25 years of management, technology, and entrepreneurial experience, Mark Whitworth specializes in architecting global, cloud-based software platforms and developing partnerships to help clients enhance performance, control and flexibility throughout the production and process life cycle. I have no doubt that Mr.
Whitworth believes there is value in making the required LPA approach as useful as possible.
The subheading of the article is probably accurate: Wentowrth’s approach to the LPA is no doubt a natural progression of internal auditing. I don’t mean to denigrate Mr. Wentworth’s work in any way. It makes the auditor adn the audit host’s job a lot easier, but it doesn’t improve business.
The LPA will not provide you with the value that a true gemba walk culture will provide you. The gaps between a real gemba walk and a ‘formal audit’ process are not trivial. In my experience we are moving backwards away from Lean and the Toyota Production System when we go from gemba walks to any formalized ‘audit’ process. The real downside of the LPA is the same as any method required or suggested by any management system standard: This is all waste.
It also tends to result in far fewer ‘walks’ than when the walks are done because the manager knows first hand how useful they are. When true gemba walks are being done the ‘objective evidence’ is seen in the continual improvement of the key metrics of quality, delivery, delivery, cost and employeee engagement. Regardless of whether the findings come from a true gemba walk or a formal audit.
AIAG CQI – CQI Layered Process Audit Guideline (Secured file – cannot be printed)
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