Layered Process Audits (LPA) - Chrysler

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Start Up / Shut Down Layered Process Audit Things for you to consider: 1. Modify the Start Up / Shut Down LPA to your plant processes/needs 2. Instruct people on role: First line - Use normal LPA Top Management - use Start Up / Shut Down LPA 3. Drive the LPA schedule 30 days before shut down 30 days after shut down 4. Use it at your own discretion 58
Date:______________Project #______________ Item # LPA Question Expectations Y/N Corrective Action & Timing 1 2 3 4 5 • SHIFT DOWN / START OF PRODUCTION All questions are to be answered with a "Y" for yes (acceptable or compliant), or "N" for no (unacceptable or non-compliant) in the status box. Non-compliances are to have corrective action with timing recorded in the space pro ided Assumptions for using this document: - Intent of these questions is that the operator is performing a new operation. - Normal LPA is being followed. O i f t i i i l MANPOWER TURNOVER & RE-LEARNING Do you know the percentage of new Operators for the process? Percentage: % Is there a documented process for training new operators, and are records of training kept? Have Control Plan frequencies and sample sizes been increased to reflect the increased risk of nonconformances during the learning curve period? Is the process unchanged since the operator last performed the task? Are the operators following the posted operator instructions, and are the work insrtuctions up-todate? Management has a clear perspective of the number of new operators on each job. This needs to drive training plan and an enhanced control plan during the learning curve period. Untrained operators pose risk to assembly. Only certified operators are allowed to perform specific tasks without backup. The risk of nonconformances is highest as operators are learning a process. Inspection frequencies should be increased to compensate. Operators require education of process changes or deviations that could effect their job. Confirm operators are following the correct operator instructions. 59
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Layered Process Audit (LPA) 1
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• Knowledge Objectives Be able to
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1. Layered Process Audits are: a. A
Page 7 and 8: 7. Which of the following is not a
Page 9 and 10: DFMEA LPA PRODUCTION DEMONSTRATION
Page 11 and 12: Supplier Interface - LPA is Chrysle
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Page 19 and 20: LPA Benefits Reduces Improves Facil
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Page 23 and 24: Form LPA Team LPA Plan Form a Team
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Page 27 and 28: Example: LPA Plan 27
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Page 35 and 36: Making Questions Specific (Example
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Page 39 and 40: 3. LPA Implementation LPA Implement
Page 41 and 42: LPA Structure & Frequency Plant Man
Page 43 and 44: Train Auditors Training of Employee
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Page 47 and 48: LPAs used as a training tool - new
Page 49 and 50: Example: 4. Monitor & Adjust Plan 4
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Page 53 and 54: 5. Summary The LPA is an audit of
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Layered Process Audits (LPA) - Chrysler

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