<img height="1" width="1" style="display:none" src="https://www.facebook.com/tr?id=466860936981243&amp;ev=PageView&amp;noscript=1">
Layered Process Audit Template : Download Now!

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.

Three Reasons to Invest in Manufacturing Software to Streamline Processes

Oct 07, 2015  |  Ease Inc

A few things in life are required—we simply have no choice but to do them—like paying taxes. Some quality managers would compare the often-mandatory requirement of completing layered process audits (LPAs) to calculating taxes—both are cumbersome and are easily forgotten once the requirement is met. But what if there was an effective solution to simplifying your LPA process and at the same time adding value to your organization? 

LPAs are a sub-type of process audits; and they differ from generic process audits by requiring multiple people, including management, to conduct an ongoing chain of simple verifications to ensure that a defined process is followed correctly. LPAs provide an active view into operational process conformance and corrective actions as required by many end manufacturers (such as automakers) to maintain supplier quality. When implemented correctly, LPAs can help shape your organization’s culture into one that embraces continuous improvement. This powerful audit management methodology can:

Read More >

Lean Manufacturing Principles for Tier One Automotive Suppliers

Sep 29, 2015  |  Ease Inc

U.S. auto sales are on pace to exceed 17 million units this year and could break the record of 17.4 million sold in 2000, according to Autodata Corporation. Backing these figures is the Automotive News Data Center, which reports that sales for the first eight months of 2015 outperformed sales for the same period in 2014. For example, Daimler AG posted a 6.4% increase in sales compared to 2014, Ford Motor was up 2.7% for the first eight months, and General Motors showed a 3.2% increase from the previous year.

Many automakers are running their U.S. plants with three shifts of workers and scheduling overtime, particularly factories that make pickup trucks, SUVs, and crossovers. Of course, the automakers’ success in extending this upswing depends on the ability of their suppliers to keep up with industry growth. For tier one automotive suppliers the pressure to meet demand must be carefully balanced with the ability to maintain and even improve quality. This is where lean manufacturing principles come into play.

Read More >

Beacon Layered Process Audits Featured in Automationmedia.com

Aug 19, 2015  |  Ease Inc

Automationmedia.com recently featured an article focused on Layered Process Audits written by Thomas Cutler. See the original article here or read below.

Read More >

4 Practical Ways to Maximize Your Layered Process Audits

May 05, 2015  |  Mark Whitworth


Understanding and applying key components of an LPA program are critical to success, but to maximize the short- and long-term effectiveness of an LPA, Ease has found that manufacturers should also integrate the following four key practices.

Read More >

Defining a True Layered Process Audit

Apr 21, 2015  |  Mark Whitworth

While nearly every manufacturer has employed audits to identify issues with staff output and process compliance, an LPA is distinctive in that it focuses on driving cultural change throughout an organization to improve quality and reduce failure rates. LPAs are part of a formalized system for providing constant attention to an organization’s core, high-risk processes and controls to ensure minimal variation.

Created by the Automotive Industry Action Group (AIAG) nearly a decade ago, LPAs were first applied in Daimler Chrysler and Toyota plants, and since have become required practice for most auto manufacturers. Over time the practice has spread to other manufacturing industries, but with only varying degrees of success.

Read More >

Popular Blog Posts

Sign-up for free quality management tips and best practices weekly

Recent Blog Posts

Ready to improve your quality?

REQUEST A BEACON QUALITY DEMO