Zero Defects - Layered Process Audits Training

Course Duration: 2 Days - 8 Hours/day

This two day performance packed workshop has you walk away with an action plan designed to reduce Scrap, reduce Warranty Returns generated by manufacturing errors, and improve First Time Through Capability. You will learn the DCX and General Motors QSB Layered Process Audit requirements and you will create the necessary audit checklists to support your Layered Process Audit Program. This workshop supports selected TS 16949:2002 and Customer Specific Requirements. This workshop is designed to enhance your current Layered Process Audit Program by conducting Manufacturing Process Reviews with your hourly work groups.

Learning Objectives

  • You will conduct a Manufacturing Process Review of your process documentation including your Process Flow Diagram, PFMEA, Control Plan and Work Instructions of your lowest performing manufacturing cell(s).
  • You will learn how to utilize the Error-Proofing Worksheet to provide a business case to sell your recommended improvement actions.
  • You will gain the understanding of DCX and General Motors QSB Layered Process Audit requirements.
  • You will create process and error-proofing checklists tied to your Layered Process Audit Program.
  • You will create a Walk-away Action Plan that sends you back to your plant with keys-in-hand to drive your plant's quality improvements.

Course Outline

Day One

  • What is a Layered Process Audit
  • LPA Requirements and Recommendations
  • Developing the LPA Plan
  • Introduction to Process Review
  • Process Review Team Dynamics
  • Step 1: Process Flow Diagram
  • What is Zero Quality Control?
  • Step 2: Potential Failure Mode & Effects Analysis
  • Error-Proofing Worksheet Overview
  • Step 3: Reviewing & Revising the Control Plan
  • Last Step: Work Instruction Overview

Day Two

  • Review and Update Process Control Documentation
  • Reporting and Managing the LPA Process
  • Reviewing and Approving the LPA Plan
  • Implementing the LPA Plan
  • Maintaining the LPA
  • LPA Best Practices
  • Creating your Walk-away Action Plan

Who Should Attend

Quality Managers, Quality Supervisors, Quality Engineers, Manufacturing Engineers, Production Supervisors, Production Leaders, Quality Technicians, Maintenance Technicians, anyone responsible for making quality improvements.

Course Materials

Each participant will receive a seminar manual.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.


Basic understanding of process documentation (process flow diagram, PFMEA, control plan).

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