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The Automotive Industry Action Group’s CQI-8 Layered Process Audit Guideline is a great resource for learning more about what goes into. AIAG CQI LAYERED PROCESS AUDIT GUIDELINE. Check our one-day seminar on CQI 8, it provides attendees with an understanding of Layered Process Audits (LPA).

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The purpose of these Audits is to ensure continuous conformance to the process; however, it is also useful for driving continuous improvement by implementing corrective actions that correspond to Layered Process Audit nonconformances. The real downside of the LPA is the same as xudits method required or suggested by any management system standard: Reaction plans for Layered Process Audit non-conformances must be documented and must be available for reference and use by the auditor.

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Standards Subscriptions from ANSI provides a money-saving, multi-user solution for accessing standards. AIAG Organization AIAG is made up of a board of directors, an executive director, associate directors, a full-time staff, and volunteers serving on projects.

The basic approach for the Audits is an established concept; therefore, there is no guidepine advantage for any particular OEM to develop a custom approach. It is recommended that a training program for Layered Process Audit auditors be based on material in this Guideline starting with this section.


Layered Process Audit Guideline (CQI-8)

A Layered Process Audit should not be a laundry list of all requirements within a production cell or department. Once necessary process changes are identified, employees must re-learn and adjust.

Layered Audit procedure requires daily verification of quality documentation by a supervisor. Operator is using required personal protective equipment.


Purpose of This Guideline Layered Process Audits reduce variation along the manufacturing line and up through the ranks of plant management. This facilitates communication between management and the working-level team members. Audit Frequency — How often will each layer of the organization conduct the audit? Employees typically do not refer to instructions or procedures before every step of a process; they often complete the processes by memory, which comes from repeating and practicing each step many times over.

Layered Process Audits have been demonstrated to be an effective tool to ensure that key “Critical-toQuality” process steps are followed and corrective actions are sustained. However, if each customer OEM developed its own Layered Process Audit method, the effectiveness overall would be reduced. Careful analysis must be made before an item is deleted from the Layered Process Audit.

Comments Completed Audits at a frequency of once per day performed by a supervisor or lead person. Audit Items — What are we going to audit? Require that personnel from the operations level through to plant senior management validate the implementation of defined manufacturing processes.


The auditor documents the specific reaction plan proocess to contain the non-conformance. The FDA wants medical device manufactures to succeed, new technologies in supply chain managment. Program Owner Assigned to: It is very easy for them to return to the old, familiar methods. The results are recorded and reviewed regularly.

Management should review the status of all corrective actions lyered provide support and resources when necessary. Automation slashes the resources required, allowing some manufacturing sites to reallocate up to two full-time employees focused on audit scheduling and management. The concepts behind Layered Process Audits are not new.

Operators and Supervisors will conduct the Layered Process Audit daily. Therefore, the more focused the Audit check-sheet, the more effective. Effective management of process compliance requires the identification of sources of both special and common cause variation.

These are selected based on risk to product quality including lessons learned, safety, criticality of process step, or product characteristic. The reaction plan is typically documented as part of or an attachment to the Layered Process Audit checksheet. Looking Forward With Alfred Adler.