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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A Layered Process Audit should not be a laundry list of all requirements within a production cell or department. Layered Process Audits require that multiple operational levels within a manufacturing facility review the same key operational controls that ensure product quality. Cqk-8 gaps between a real gemba walk and a ‘formal audit’ process are not trivial.

Do not replace regular Quality Management System audits conducted by internal or external dedicated auditors. MON Are the first piece inspection sheets completed daily by all shifts? This verification is not focused on the items that an Audit is to verify. Error-proofing is added to an operation. Measure and encourage work process pgocess. It is recommended that a training program for Layered Process Audit auditors be based on material in this Guideline starting with this section.

Ask questions, exchange ideas and best practices, share product tips, discuss challenges in quality improvement initiatives. Gemba walks are gudieline essential strategy for getting managers out of their offices to experience shop floor processes up close. 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.

This could be part of the Quality Management System layerwd. The ongoing review of Layered Process Audit results should be structured in such a way that systemic issues within the organization can be identified and corrected across the entire organization. Evidence that customer quality concerns are addressed in xx days. The information is not to be sold in part or whole to layersd within your organization or to another company.



Customer-specific requirements should be referenced and the customer contacted before deleting any Layered Process Audit item. Layered Process Auddits, when implemented as described in this Guideline, address all these issues. Are the results of all required dimensional inspections recorded on form zzzz-1? Evidence that customer delivery requirements have been met. Multiple levels of plant personnel audit the manufacturing process to the same questions; delegating is not acceptable. Employees typically do not refer to instructions or procedures before every step of a process; they often complete the processes by memory, which comes from repeating and practicing each step many times over.

Root causes are then determined and appropriate questions are incorporated into the audits for recurring non-conformances.

Layered Process Audit Guideline (CQI-8)

They can be developed to be layrred, process-specific, department-specific, product line-specific, etc. The reaction plan is typically documented as part of or an attachment to the Layered Process Audit checksheet. Managers often can learn much about the manufacturing processes from operators, and operators guidelime learn much about what is important to customer satisfaction from managers. Therefore, if an Audit continually shows very high compliance, the questions may need to be re-evaluated or the focus changed as part of the maintenance of the Audits.

Audit check-sheet, Audit work instructions, internal corrective actions. Therefore, organizations should plan their Layered Process Audit frequency considering the type of audit items.

An audit with results that are reviewed by site leadership on a regular basis.


Examples of common cause variation might include an inadequate FMEA for the manufacturing process. You can download and open this file to your own computer but DRM prevents opening this file on another computer, including a networked server.

Whether the reference is intentional or not, LPAs and gemba walks share clear similarities. An audit that requires measuring parts or other cqk-8 characteristics.

Already Subscribed to this procdss. 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. Our focus is to continuously improve business processes and practices involving trading partners throughout the supply chain. Typical Steps for Developing and Implementing Audits A cross-functional team identifies existing key process steps to audit.

Helps manufacturers by focusing on problems and problem resolution in real time. Calibration not expired for gauge xxx.

AIAG CQI – CQI Layered Process Audit Guideline (Secured file – cannot be printed)

Managing the items is a necessary part of an effective Layered Process Audit program. Record of the completion of tool change-over steps. Areas audited are appropriate to the span of authority of the level of person auditing. Inspector Plant Manager Q. Customers who mandate Layered Process Audits in one form or another will audit this compliance themselves, have the audit conducted by an approved third party, or require documentation from the organization showing Layered Process Audit process compliance.