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Beacon Quality Blog

A blog on plant floor quality: IATF 16949:2016, ISO 9001:2015, layered process audits, 5S, health and safety, gemba & more. Our software, Beacon Quality, simplifies these processes with our mobile auditing solution.

How to Kick Off LPA Implementation with a Kaizen Event

Oct 02, 2018  |  Eric Stoop

The frequently referenced Learning Pyramid says an average student retains 75% of information learned through practice, compared to just 5% of what they hear in a lecture. While experts may dispute the relevance of these figures when applied to modern society, all of us can agree that we learn and retain more by doing versus being told in a classroom.

Depending on the maturity of your organization, launching or expanding a layered process audit (LPA) program can be complex and difficult to sustain.  Which is why using a whiteboard in a meeting room may not be the best choice to kick things off. 

An effective LPA program provides daily verification of high-risk processes, connecting leaders with front-line operators to develop a culture of coaching, feedback and continuous improvement. Rather than scheduling a presentation, a Kaizen event can be far more effective to get things off to a strong start, especially for plants just starting out.  

In this post, you’ll learn about Kaizen events and how they can help you get started on your LPA journey.

 

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Gemba Walk Checklist Template

Jun 25, 2018  |  Shawn Faircloth

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Mapping Layered Process Audits to Lean Manufacturing Principles

Mar 19, 2018  |  Eric Stoop

Roughly 7 in 10 manufacturers have implemented Lean manufacturing principles in their organizations, with 5S, Six Sigma and Kaizen representing the most popular strategies today.

One tool that supports these specific approaches and Lean manufacturing principles more generally is a layered process audit (LPA) program. LPAs draw auditors from all management layers and departments to verify mission-critical processes on a daily basis.

Let’s examine how LPAs align with Lean manufacturing principles, providing a structured approach to unlock the biggest benefits of this popular quality methodology.

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Creating a Gemba Walk Checklist

Oct 10, 2017  |  Eric Stoop

They say what gets measured gets managed, but what about the things you can’t measure—the ones you need to see with your own eyes to understand?

Like the workstation that could be set up for faster throughput. Or the critical calibration tool that happens to be chronically broken. Or the process that has too many steps, creating a bottleneck. In these and other situations, identifying the right solution often means going to see the source of problems firsthand.

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