Beacon Quality Blog

This layered process audit checklist template is intended to help automotive and aerospace suppliers get started with LPAs. Note that this LPA checklist is a starting point for ideas, and should be customized to the specific department, work area and process being audited.

As you create your own LPA checklist, try to limit it to 10 questions that take no longer than 10 minutes to answer. Questions should be:

• Objective: Use yes or no questions where yes means pass and no triggers mitigation or corrective action.
• Specific: Avoid terms like “properly” or “correctly.”
• Concise: People who are not process experts should be able to easily answer the questions.

 The LPA checklist is an editable Excel spreadsheet that you can alter to your specific needs. Directly download, and start using today! Note: Make sure to ‘scale to 1 page’ when printing in ‘landscape’ format for ease of use.

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Failure modes and effects analysis (FMEA) is a core tool for reducing automotive and aerospace manufacturing risks. And yet, companies routinely waste 80% of the potential value of the FMEA process.

Particularly for manufacturers on the lower end of the maturity spectrum, FMEAs are simply a theoretical exercise for maintaining a certification or meeting customer requirements. These manufacturers may fill out an FMEA and even add a few countermeasures, but ultimately it’s just another form to file away and forget about.

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It’s an open secret that many automotive and aerospace manufacturers have unacceptably high defects and costs. And where defects are on the rise, quality costs aren’t far behind.

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In 2016, General Motors (GM) instituted a new supplier quality program called Built in Quality Supply (BIQS), representing a major departure from its previous Quality Systems Basics (QSB) program.

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Every day we glean insights from signals that show when a change is coming or we need to take action.

The smoke alarm goes off when you’re cooking, alerting you to turn down the burner. Your engine starts making a funny noise weeks before your car breaks down. That old injury starts to ache just before a storm front moves in.

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The cost of ineffective corrective action can be astronomical when you consider the monetary and reputational impact of delayed problem-solving. On a small scale, repeat problems—even minor errors—send a message to customers that you just don’t care to get it right.

And when poor problem-solving leads to more significant quality escapes? You could be looking at $10,000 per minute from the customer in line stoppage charges, or even a $10 million dollar recall.

To ensure corrective actions reduce risk, automotive and aerospace suppliers need to avoid key mistakes around measuring effectiveness, root cause analysis and tracking closure.

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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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Pareto’s Law, also known as the 80/20 rule, tells us that 20% of inputs are responsible for 80% of results. Even when it’s not an even 80/20 split, the idea that a few factors drive a large proportion of outcomes applies to many business processes and everyday situations.

Like how a majority of complaints often result from a few key defects. Or how 20% of our time accounts for 80% of our productivity, with the remaining 80% spent on meaningless tasks.

In the automotive and aerospace industries, organizations can use a range of tools to leverage the 80/20 rule for bigger, faster quality improvements. Pareto management is the most obvious of these, but manufacturers should also apply the rule to performance metrics, risk management and audits.

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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.

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