Compare the following process audit questions, asking which would be more effective at preventing defects:
Question A: Does the operator know how to handle non-conforming material?
Question B: Can the operator describe each step of the non-conforming material process according to the quality manual?
Clearly, Question B is more likely to identify errors that result in defective product reaching the customer—the main goal of layered process audit (LPA) requirements for General Motors (GM) and Fiat Chrysler suppliers. These high-frequency audits focus on how products are made, and are also gaining traction in industries like aerospace as a best practice for minimizing variation, defects and quality costs.
