Daimler-Chrysler Layered Process Audits (DCX LPA)

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Daimler-Chrysler Layered Process Audits(DCX LPA)

• Alberta Risner

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Goal

• Satisfy Daimler-Chrysler mandated LPA (Layered
  Process Audit)
• Training of Managers and Supervisors
• Satisfy Customer Specific Requirements and
  TS16949 requirements
• Continual Improvement

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Continual Improvement
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Where are we now?

• No Layered Process Audits (LPA) are currently
  being performed
• Training has been started at SRAF (Today)
• Input in Chryslers Powerway will begin when LPAs
  have started

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Training

• Training will be Painless
• Training will be Hands on
• Training will encompass all management levels
• Training will be completed

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Kinda Painless
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Past History

• No history on LPA
• Were creating the line in the proverbial sand.
• Lessons Learned can and should apply

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What are our choices

• Not performing LPAs?
• Pitch in and get it done

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No Choice

• Pitch in and get it done
• Perform LPA as required

Why No Choices ?
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Daimler-Chrysler Mandated
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What is a Layered Process Audit? (LPA)

• LPA is an ongoing system of process checks that
  verify proper methods, settings, operator
  craftsmanship, error proofing devices and other
  inputs are in place to ensure a defect free
  product.

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What is a Layered Process Audit (LPA)?
Continued

• LPAs assure that defined methods and work
  instructions are utilized, problem solving
  solutions are held in place, and all process
  issues are identified and quickly corrected.

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What is a Layered Process Audit?
continued

• Two types of LPAs
• Auditing the Process itself
• Auditing the Error Proofing

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1. Process Audit
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LPA Process Audit
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LPA Process Audit continued
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2. Error Proofing Audit
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(No Transcript)
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How Long Will either LPA Take?

• On average 15 minutes

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What do we need to perform a LPA?

• A pen or pencil
• A Checklist
• Knowledge of the Process
• (A sense of humor helps)
• Commitment for success

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LPA Frequency Plan
Plant Manager-once a week
Area Managers-once a week
Production Supervisors-once a shift
This Proposed Frequency will
Encourage Management Involvement Establish
Operator Feedback Establishes Accountability
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SRA LPA Audit Frequency and Structure