Course Description

Get more things right the first time by reducing process non-conformance with Layered Process Audit (LPA).

Layered Process Audit (LPA) – 8 Hours

Layered Process Audits (LPA) are a strategy to ensure that things most important to quality are done right the first time.  LPAs can be applied to verify any defined process within an organization. In a manufacturing realm, various layers of supervision and plant leadership audit, or verify, settings, conformance to work instructions and effectiveness of error proofing on a regular schedule to ensure compliance with established procedures and standards.

This workshop helps participants see how LPA fits within their current daily management practices and helps them grow a problem prevention mind-set.  Activities in the workshop will help participants create and implement LPA questions that are effective and meaningful, so that the daily verifications have an impact.

Site leadership should attend or at least kick-off and wrap-up this one-day workshop.

Upon completion of this workshop participants will be able to:

• Understand the value and impact of LPA
• Lead or participate in the rollout of a plant’s LPA program
• Select processes and process elements that would benefit from LPA
• Write LPA questions and checksheets that help ensure more things are processed correctly the first time
• Conduct process verifications utilizing LPA checksheets
• Explain to others how LPA supports quality and other KPIs

By applying the knowledge and skills conveyed in this workshop, Layered Process Audits will provide multiple benefits for manufacturing operations:

1. Reduce variation in production (human, equipment, tooling, etc.)
2. Reduce scrap, rework and customer issues
3. Reduce end-of-line and 3rd-party inspection
4. Improve safety
5. Improve customer quality scorecards
6. Increase improvement suggestions from operators

Implementing Layered Process Audits utilizes current adult learning methodologies including:  discussion, and practice with debrief on real-world work applications.  Maximum of 16 participants per session.  The training agenda is typically as follows:

• Introduction
  • It’s a management tool to prevent problems
  • The value of LPA
  • LPA definitions and Industry requirements (CQI-8)
• LPA Implementation Process
  • Top Leadership planning
  • Deployment and writing sample LPA questions
  • Practice conducting an LPA audit
  • Management review of findings and effectiveness
• Summary and action planning

This course is available in the following formats:

• Onsite Training: Available for groups wanting an in-person experience
• Live Virtual Sessions: Delivered online with real-time interaction, ideal for remote teams
• Hybrid Approach: Maximize flexibility by blending real-time online interaction with occasional in-person experiences