Business success relies on how it instills quality in its products and services. That’s why there are various methods and techniques on how businesses set and maintain a standard for product quality to ensure that their customers get what they want and expect from their brand. Layered process audits (LPAs) are among these quality techniques. It focuses on observing and validating product manufacturing instead of inspecting the finished product. To help you understand just how essential an LPA is to any manufacturing business, this article will explain everything you need to know about this quality technique. You will also learn how to simplify layered process audit so that you can implement it in your own business without much hardship.
What Are Layered Process Audits?
A layered process audit is a type of quality audit that focuses on manufacturing processes instead of inspecting individual products. The idea behind this quality technique is that it’s better to catch mistakes early on in the manufacturing process to be corrected before the product is completed.
This prevents issues from becoming expensive problems down the line and ensures that the finished product meets the high standards that customers expect from the brand.
LPAs are different from traditional audits in that they involve all employees in the auditing process, not just quality control staff. The goal is to help everyone understand and take ownership of the manufacturing process to prevent mistakes before they happen.
To conduct an LPA, you’ll need to:
- Create a plan that outlines the specific steps that will be audited and how often they will be checked. This can be tailored to your specific business needs.
- Train all employees involved in the auditing process to understand what’s expected of them.
- Monitor the manufacturing process to ensure that it’s meeting the standards you’ve set.
- Make changes as needed to ensure that quality is being maintained.
Why Is an LPA Important?
There are several reasons why LPAs are important for any business, but here are some of the most important ones:
- Firstly, they help reduce mistakes and improve overall work quality.
- Secondly, they help keep costs down by catching mistakes early on in the manufacturing process.
- Thirdly, they ensure that products meet customer expectations for quality.
- Fourthly, they improve communication and collaboration among employees.
- Lastly, they help businesses take control of their manufacturing processes.
How to Simplify an LPA
LPA’s can get complicated. If you’re looking to implement an LPA in your business, here are a few tips to help you get started:
- Start by creating a plan that will help simplify the entire auditing process. You can tailor this to your business and its needs.
- Train all the employees who will be doing the auditing process. That way, they will know what they will do and the outcome they need to achieve.
- Monitor the manufacturing process and make sure it meets with the set standards that you made.
- Incorporate any necessary changes to ensure quality.
An LPA can be a complex process, but you can make it simpler and easier to implement in your own business by following these tips. With an LPA in place, you can rest assured that your products are of the highest quality and meet or exceed customer expectations.
Three Steps to Starting Layered Process Audits
Starting a layered process audit usually involves three simple yet essential steps: verify your process, engage your employees, and build a culture of environment, health, safety (EHS), and quality.
Verify Your Process
Layered Process Audits (LPAs) are essential for maintaining quality in a manufacturing process. To make sure that your business is getting the most out of LPAs, you need to verify that your process works. To do this, you’ll need to:
- Create and implement a plan that outlines the steps in conducting an LPA and how often they should be done.
- Train the employees involved in the auditing process. Make sure they understand their role and what they need to do to finish the job.
- Monitor the manufacturing process. Make sure it meets the standards you’ve set.
Engage Your Employees
It’s also essential to engage your employees in the LPA process. This means more than just training them on how to conduct an audit. it’s about involving them in the process and helping them understand why LPAs are important. There are a few ways you can do this:
- Make sure everyone understands the goals of the LPA process.
- Encourage employees to ask questions and give feedback.
- Involve the employees in the auditing process itself.
Build a Culture of EHS and Quality
Finally, you need to build a culture of environment, health, safety (EHS), and quality within your organization. This means creating an LPA process that is sustainable and that everyone can buy into. To do this, you’ll need to:
- Create a system that encourages employees to report safety and quality issues.
- Make sure everyone understands the importance of EHS and quality in the workplace.
- Encourage teamwork and collaboration among employees.
By following these three steps, you can make it easier for your business to start using layered process audits.
Why Choose DataMyte?
DataMyte is an expert in productivity and performance. Our goal is to offer a connected factory solution that helps businesses take control of their manufacturing processes. We’re proud to offer a variety of services that can help you and your company, including:
- Improving communication and collaboration among employees.
- Helping businesses take control of their manufacturing processes.
- Ensuring that products meet customer expectations for quality.
If you’re looking to conduct Layered Process Audits in your business, DataMyte can help. We serve industries like Automotive OEM and supplier businesses in making the quality of their product and services better. Some offers include the following:
- Quality Planning – Advanced Product Quality Planning (APQP), Failure Mode and Effects Analysis (FMEA), Control Plan, Flow Chart, Work Instructions, Production Part Approval Process (PPAP), and Comprehensive Reporting
- Supplier Management – Data Collection, Evaluation and Escalation, Inspection Planning, Incoming and Outgoing, and Reporting Tools
- Digital Clipboard – Workflow Builder and Management, and Digital Checklist
- Gate and Tool Management
- Weld Management
- Body Shop Management
- Statistical Process Control (SPC)
- Complaint Management (Non-Conformance Management)
- And More!
These features make it easier for you to manage your LPAs. The DataMyte team is always available to help you get the most out of our product and services. To learn more about how we can help you with layered process audits, contact or check out our website today!
LPAs play an important role in any business that manufactures products. They help reduce mistakes, improve work quality, and ensure that products meet customer expectations for quality. If you’re looking to implement an LPA in your business, this article will serve as a guide to helping you accomplish that task. DataMyte can also help simplify the entire process. Check us out now!