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Optimizing Daimler-Chrysler Process Audits Training for Continuous Improvement

This initiative aims to fulfill Daimler-Chrysler's LPA requirements through comprehensive training for managers and supervisors, aligning with customer-specific needs and TS16949 standards. With a focus on continual improvement, the current status shows initiation of training at SRAF, poised to commence audits once training is complete. The choice is clear: engage in LPAs diligently to meet mandated standards. LPAs involve ongoing checks on processes, ensuring defect-free production and quick issue resolution. The training approach promises a painless, hands-on experience across all management levels. The proposed frequency plan and structure aim to enhance management involvement, operator feedback, and accountability. The recommended starting point is at high-risk areas, setting the groundwork for effective LPA implementation.

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Optimizing Daimler-Chrysler Process Audits Training for Continuous Improvement

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  1. Daimler-Chrysler Layered Process Audits(DCX LPA) Alberta Risner

  2. Goal • Satisfy Daimler-Chrysler mandated LPA (Layered Process Audit) • Training of Managers and Supervisors • Satisfy Customer Specific Requirements and TS16949 requirements • Continual Improvement

  3. Continual Improvement

  4. Where are we now? • No Layered Process Audits (LPA) are currently being performed • Training has been started at SRAF (Today) • Input in Chrysler’s Powerway will begin when LPAs have started

  5. SRAF’s Training

  6. Training • Training will be Painless • Training will be Hands on • Training will encompass all management levels • Training will be completed

  7. Kinda Painless

  8. Past History • No history on LPA • We’re creating the line in the proverbial sand. • Lessons Learned can and should apply

  9. SRAF’s Line in the Sand

  10. What are our choices 1. Not performing LPAs? 2. Pitch in and get it done

  11. The only Choice • Pitch in and get it done and perform LPA as required. Why No Choices ?

  12. Daimler-Chrysler Mandated

  13. Farmington Managers and Supervisors Daimler Chrysler

  14. What is a Layered Process Audit? (LPA) • LPA is an ongoing system of process checks that verify proper methods, settings, operator craftsmanship, error proofing devices and other inputs are in place to ensure a defect free product.

  15. What is a Layered Process Audit (LPA)? Continued • LPA’s assure that defined methods and work instructions are utilized, problem solving solutions are held in place, and all process issues are identified and quickly corrected.

  16. What is a Layered Process Audit? continued • Two types of LPAs • Auditing the Process itself • Auditing the Error Proofing

  17. 1. Process Audit

  18. LPA – Process Audit

  19. LPA Process Audit continued

  20. 2. Error Proofing Audit

  21. How Long Will either LPA Take? • On average 15 minutes

  22. What do we need to perform a LPA? • A pen or pencil • A Checklist • Knowledge of the Process • (A sense of humor helps) • Commitment for success

  23. LPA Frequency Plan Plant Manager-once a week Area Managers-once a week Production Supervisors-once a shift This Proposed Frequency will: Encourage Management Involvement Establish Operator Feedback Establishes Accountability

  24. Where do we start ? • Recommended starting point: At the highest point of risk.

  25. SRA LPA Audit Frequency and Structure

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