Layered Process Audits (LPA) - Chrysler

Date:______________Project
#______________
Item # LPA Question Expectations Y/N Corrective Action & Timing
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• 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.
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