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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.

Comparing the Costs of Manual vs. Automated Layered Process Audits

Dec 04, 2018  |  Eric Stoop

PricewaterhouseCoopers estimates that by 2020, Industry 4.0 digital transformation initiatives will deliver nearly 4% in annual cost reductions for both the aerospace and automotive industries.

One area manufacturers are automating is internal audits, including the layered process audits (LPAs) required by several original equipment manufacturers (OEMs). These daily checks of high-risk processes are a best practice for reducing defects, but they’re also time-consuming when tracking a large volume of audits manually.

Given the understandable scrutiny on costs, the question for auto and aerospace manufacturers becomes whether paper-based or spreadsheet-based LPAs actually cost less than automation. Here we discuss various costs to consider, including administration, implementation and quality costs—as well as hidden costs that should figure into your decision.

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How to Talk to Your Quality Director About LPA Software

Nov 06, 2018  |  Joe Bollard

Layered process audits (LPAs) are mandatory for automotive suppliers and growing in popularity in the aerospace industry due to its effectiveness in improving quality at the process level. However, you may find that an effective LPA program isn’t easy to manage when done manually through spreadsheets, resulting in administrative burden.

Maybe you’re doing ok scheduling these high-frequency audits, but people are just checking the box during the process checks (if they complete them at all). Or maybe you’re bogged down in reporting, and it’s taking too long to find and fix problems.

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