CQI-8-AIAG-LPA

CQI-8LayeredProcessAuditsGuidelineLayeredProcessAuditsCQI-81Issue:1.0Dated:12/2005Replaces:N/ADated:N/AAIAGPUBLICATIONSAnAIAGpublicationreflectsaconsensusofthosesubstantiallyconcernedwithitsscopeandprovisions.AnAIAGpublicationisintendedasaguidetoaidthemanufacturer,theconsumerandthegeneralpublic.TheexistenceofanAIAGpublicationdoesnotinanyrespectprecludeanyonefrommanufacturing,marketing,purchasing,orusingproducts,processes,orproceduresnotconformingtothepublication.CAUTIONARYNOTICEAIAGpublicationsaresubjecttoperiodicreviewandusersarecautionedtoobtainthelatesteditions.MAINTENANCEPROCEDURERecognizingthatthisAIAGpublicationmaynotcoverallcircumstances,AIAGhasestablishedamaintenanceprocedure.PleaserefertotheMaintenanceRequestFormatthebackofthisdocumenttosubmitarequest.APPROVALSTATUSTheQualityRequirementsTaskForceanddesignatedstakeholdersapprovedthisdocumentforpublicationonNovember9,2005.Publishedby:AutomotiveIndustryActionGroup26200LahserRoad,Suite200Southfield,Michigan48034Phone:[phone]•Fax:[phone]AIAGCopyrightandTrademarkNotice:ThecontentsofallpublishedmaterialsarecopyrightedbytheAutomotiveIndustryActionGroupunlessotherwiseindicated.CopyrightisnotclaimedastoanypartofanoriginalworkpreparedbyaU.S.orstategovernmentofficeroremployeeaspartoftheperson’sofficialduties.AllrightsarepreservedbyAIAG,andcontentmaynotbealteredordisseminated,published,ortransferredinpartofsuchcontent.Theinformationisnottobesoldinpartorwholetoanyonewithinyourorganizationortoanothercompany.Copyrightinfringementisaviolationoffederallawsubjecttocriminalandcivilpenalties.AIAGandtheAutomotiveIndustryActionGroupareregisteredservicemarksoftheAutomotiveIndustryActionGroup.©2005AutomotiveIndustryActionGroupLayeredProcessAuditsCQI-82Issue:1.0Dated:12/2005Replaces:N/ADated:N/AFOREWORDIndustrydatashowthatmostmanufacturingqualityissuesarecausedbypoorprocesscontrolorbyafailuretofollowtheappropriateprocessinstructions.Effectivemanagementofprocesscapabilityrequirestheidentificationofsourcesofbothspecialandcommoncausevariation.Oncethesourcesareidentified,correctiveactionsdesignedtoaddressthemmustbeeffectivelyimplementedandsustained.Employeesdonotrefertoinstructionsorproceduresbeforeeverystepofaprocess;theyoftencompletetheprocessesbymemory,whichcomesfromrepeatingandpracticingeachstepmanytimesover.Oncenecessaryprocesschangesareidentified,employeesmustre-learnandadjust.However,itisveryeasyforemployeestoreturntotheold,familiarmethods.Before2005,DaimlerChryslerandGeneralMotorsrequireddifferentprocessreviewapproaches,includingdifferentapproachesforLayeredProcessAudits.ItwasrecognizedthattheLayeredProcessAuditmethodologywasnotuniquetoanyparticularcompany,hence,undertheauspicesoftheAIAG,DaimlerChryslerandGeneralMotorsdevelopedacommonapproachforLayeredProcessAudits.Oneoftheprincipalpurposesofindustrystandardpracticesistoaddresscommonlyobservedissuesthatarenotisolatedtoanyonecompany,commodity,orprocesswithintheindustry.ValidationofprocessimprovementsandcorrectiveactionsisonecommonlyobservedindustryissuethatcanbedirectlyimprovedbytheuseofLayeredProcessAudits,whicharedesignedforthisspecificpurpose.LayeredProcessAuditsrequirethatmultipleoperationallevelswithinamanufacturingfacilityreviewthesamekeyoperationalcontrolsthatensureproductquality.ControllingqualityatmultipleoperationallevelsisakeystrengthofLayeredProcessAudits.LayeredProcessAuditsCQI-83Issue:1.0Dated:12/2005ACKNOWLEDGEMENTSThefollowingindividualswereactivelyinvolvedinthedevelopmentofthisGuideline.NameCompanyJeanineGrimaudoDaimlerChryslerCorporationJerodLongGeneralMotorsCorporationTheLayeredProcessAuditteamgratefullyacknowledgestheleadershipandcommitmentofVicePresidentsPeterRosenfeldatDaimlerChryslerCorporationandBoAnderssonofGeneralMotorsCorporationaswellastheassistanceoftheAIAGindeveloping,producing,anddistributingthisGuideline.Replaces:N/ADated:N/ALayeredProcessAuditsCQI-84Issue:1.0Dated:12/2005Replaces:N/ADated:N/ATABLEOFCONTENTSLAYEREDPROCESSAUDITSGUIDELINE........................................................................................................1AIAGPUBLICATIONS.............................................................................................................................................1CAUTIONARYNOTICE.........................................................................................................................................1MAINTENANCEPROCEDURE.............................................................................................................................1APPROVALSTATUS..............................................................................................................................................1FOREWORD...............................................................................................................................................................2ACKNOWLEDGEMENTS........................................................................................................................................3INTRODUCTION.........