Layered_Process_Audits_

Layered Process Audits
1.0 Purpose
This work instruction defines the requirements for Layered Process Audits (LPA) to ensure that all
customer requirements are met.
2.0 Scope
3.0 Responsibility
The Plant Manager is responsible for
∙Developing the plant LPA schedule,
∙Identifying and training LPA auditors,
∙Ensuring that LPA’s are executed as required,
∙Tracking and reporting LPA completion and results,
∙Ensuring corrective actions for LPA nonconformances are documented and implemented,
∙Including LPA results in Plant Management Reviews,
4.0 Process
4.1 LPA shall be executed in layers;
4.1.1 Support staff and direct reports to Functional Managers.
4.1.1.1 Line supervisors perform the Standardized Work Audit (SWA) instead of the LPA.
The SWA focuses on critical Quality and Product Safety characteristics at each
operation.
4.1.2 Functional Managers.
4.1.3 Plant Manager
4.1.4 VP/General Manager, Corporate staff and Directors
4.2 Minimum frequency:
4.2.1 VP/ General Manager, Corporate Staff and Directors: Once per quarter. .
4.3 Document and Implement Corrective Action for Issues:
4.3.1 If a nonconformance is identified, the auditor immediately executes and documents the
corrective action on the LPA checklist.
4.3.2 After completing the audit, the auditor immediately documents any additional or incomplete
corrective actions on the LPA Audit Findings List.
4.3.3 The auditor must notify the area supervisor of any audit findings and obtain the supervisor’s
signature on the completed audit form. The auditor and/or supervisor must inform team
members of findings.
4.3.4 The Plant Manager ensures that corrective actions are implemented and closed in a timely
manner.
4.3.4.1 The LPA Audit Findings List should be displayed for weekly leadership review to
ensure corrective actions are completed in a timely manner.
4.3.4.2 Leadership analyzes/reviews the frequency of findings and adjusts the checklist
and/or frequency to assure high risk issues are being found and corrected.
4.3.5 Repetitive findings or systemic issues found in the LPA system may be escalated to the Fast
Response Board and prevented from future occurrence by utilizing the team problem solving
approach.
4.4 LPA Completion:
4.4.1 The LPA Auditor documents their completion of the audit on the audit schedule.
4.4.2 The auditor turns the completed checklist into Quality immediately upon completion of the
audit.
4.5 Lessons Learned:
4.5.1 If any Lessons Learned are identified by the findings or their corrective actions; the Quality
Manager or a designated corrective action owner will document the lesson in the Lessons
Learned database.
5.0 Records/Logs
6.0 References。