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Beacon Quality Blog

A blog on plant floor quality: IATF 16949:2016, ISO 9001:2015, layered process audits, 5S, health and safety, gemba & more. Our software, Beacon Quality, simplifies these processes with our mobile auditing solution.

Slideshare: The Compelling and Immediate ROI of Layered Process Audits

Apr 26, 2016  |  Mark Whitworth

Automotive and Aerospace manufacturing suppliers practice layered process audits to maintain quality control in increasingly demanding and challenging production environments. Learn the immediate ROI associated with LPA in this Linkedin Slideshare presentation.

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How Software Can Close the Loop on Manufacturing Quality Control

Feb 04, 2016  |  Mark Whitworth

A recent Wall Street Journal article detailing how Boeing is facing up to 24 million dollars in FAA penalties over quality control going back several years across a number of locations shows how even the biggest manufacturers need to close the loop on quality control (QC). Closing the QC loop requires a two-way flow of information across functions that enable end-to-end visibility into quality across the value chain.

This can only be done when quality functions such as document control, compliance management, nonconformance/corrective and preventive actions (NC/CAPA), audit management, and others are integrated across critical business processes. It may be clear on the surface to manufacturers that moving beyond the concept of a bi-directional connection of people, processes, and data across the value chain is paramount to success in the manufacturing sector. That being said, the hard work of achieving that goal starts with understanding the benefits and the challenges of a closed loop approach to quality control.

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4 Practical Ways to Maximize Your Layered Process Audits

May 05, 2015  |  Mark Whitworth

Understanding and applying key components of an LPA program are critical to success, but to maximize the short- and long-term effectiveness of an LPA, Ease has found that manufacturers should also integrate the following four key practices.

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Defining a True Layered Process Audit

Apr 21, 2015  |  Mark Whitworth

While nearly every manufacturer has employed audits to identify issues with staff output and process compliance, an LPA is distinctive in that it focuses on driving cultural change throughout an organization to improve quality and reduce failure rates. LPAs are part of a formalized system for providing constant attention to an organization’s core, high-risk processes and controls to ensure minimal variation.

Created by the Automotive Industry Action Group (AIAG) nearly a decade ago, LPAs were first applied in Daimler Chrysler and Toyota plants, and since have become required practice for most auto manufacturers. Over time the practice has spread to other manufacturing industries, but with only varying degrees of success.

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