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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A method to verify that quality documentation instructions, control plans, etc.

Auditor validates error-proof devices by “running a rabbit. An audit with results that are reviewed by site leadership on a regular basis. It is recommended that a training program for Layered Process Audit auditors be based on material in this Guideline starting with this section. Completed lessons audita forms that reflect Layered Audit results, nonconformance process updates.

Customer-specific requirements should be referenced and wudits customer contacted before deleting any Layered Process Audit item. An audit where non-conformances are noted and addressed at a later time or after a certain number auditd been accumulated. Audit frequency depends on personnel management level, not on availability. Layered Process Audits require that multiple operational levels within a manufacturing facility review the same key operational controls within the reviewer’s span of authority that ensure product quality.

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CQI-8 | Layered Process Audit Guideline

Layered Audit issues are used to update companywide processes. Operator is using required personal protective equipment. Operations managers must ensure the following: Examples of common cause variation might include an inadequate FMEA for the manufacturing process.

However, if each customer OEM developed its own Layered Process Audit method, the effectiveness overall would be reduced. These are selected based on risk to product quality including lessons learned, safety, criticality of process step, or product characteristic. Customer specifics may require particular audit frequencies. An audit typically planned for processes and procedures conducted by people. So, what does that kind of commitment look like?


CQI – 8 : Layered Process Audit Guideline

Layered Audit procedure requires daily verification of quality documentation by a supervisor. Layerec Process Audits are conducted by the designated team members. Where appropriate, Standardized Work is verified though Layered Audits. Effective management of process compliance requires the identification of sources of both special and common cause variation. Layered Process Audits conducted in manufacturing layefed are owned by Manufacturing Management. Root causes are then determined and appropriate questions are incorporated into the audits for recurring non-conformances.

In my experience we are moving backwards away from Lean and the Toyota Production System when we go from gemba guudeline to any formalized ‘audit’ process. For example, a line supervisor may conduct the Audit on a daily basis, while the plant manager may conduct the Audit once per month.

The presence and involvement of leadership on the plant floor makes quality visible, elevating it as a priority for everyone. If the document is revised or amended, you will be notified by email. This guideline is designed to provide a common framework of the definitions and standard approaches that can be adopted by any automotive OEM or supplier to an OEM, at any depth in the supply chain any tier. This verification is not focused on the items that an Audit is to verify. The real downside of the LPA is the same as any method required or suggested by any management system standard: Typical Steps for Developing and Implementing Audits A cross-functional team identifies existing key process steps to audit.

They can be developed to be operation-specific, process-specific, department-specific, product line-specific, etc. Inspector Plant Manager Q. Earn CEUs and certification. Layered Audit tracking forms, posted Audit results, management review notes, action items, or meeting agenda. Focus on key processes and process steps identified as requiring special attention from multiple levels of plant personnel to ensure compliance due to their criticality to customer satisfaction.


Completed Audits are performed by managers demonstrating their assessment of manufacturing, quality documentation, process parameters, systems, and customer activities. Validation of process improvements and corrective actions is one commonly observed industry issue that can be directly improved by the use of Layered Process Audits, which are designed for this specific purpose.

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Taking the Step from Gemba Walks to Layered Process Audits | Quality Digest

One of the principal purposes of industry standard practices is to address commonly observed issues that are not isolated to any one company, commodity, or process within the industry. Please refer to the Maintenance Request Form at the back of this document to submit a request.

These “auditors” do not need Quality Management System auditor training since they are not Quality Management System auditors. To be most effective, Layered Process Audits should audjts relatively short in duration.

Layered Process Audit Guideline (CQI-8)

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Reinforce manufacturing process updates typically implemented as a result of a corrective action.