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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.

Layered Process Audit Metrics: 4 Enterprise-Level Numbers to Track

Aug 28, 2019  |  Chris Shoe

According to a recent LNS Research survey, 37% of quality leaders cite an inability to measure quality metrics as their number one barrier to achieving quality goals. Even worse, the survey showed a full 4 in 5 companies have poor visibility into real-time metrics.

These figures highlight a central problem in quality management: in an era of increasingly large data sets, how can manufacturers leverage this data for meaningful improvement?

It’s a question that’s especially relevant for manufacturers engaged in layered process audits (LPAs), a high-frequency verification strategy where teams conduct short audits every shift. With hundreds or even thousands of audits taking place over the course of a year, making sense of a large volume of data is a core challenge of LPA programs.

While plant managers often track metrics at a granular level, director and VP-level leaders need to look at the data a little differently at a higher level. Let’s look at four of the most important enterprise-level layered process audit metrics to track. 

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How to Use Gamification Principles to Boost Audit Participation

Aug 15, 2019  |  Paul Foster

When Deloitte wanted to get people excited about employee training, the company decided to adopt a gamification strategy for its online training portal. Using elements like achievement badges, missions and leaderboards, they achieved a 37% increase in participation.

And when Ford Canada gamified its sales and service training, platform usage jumped a massive 417%, with big gains in engagement among younger employees.

Saying gamification makes work a game is an oversimplification. In reality, it’s all about leveraging proven psychological principles around our motivation to compete, encouraging habits and behavior that improve business performance.

These principles can also be used in manufacturing to increase engagement in audits, which are critical to quality but often suffer from low participation. Key gamification tools and techniques to consider include mobile apps, competitions and recognition programs.

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The Future of Layered Process Audits

Jul 23, 2019  |  Ease Inc

With growth of digitalization in manufacturing, what does the future hold for Layered Process Audits (LPA)?  LPAs today generally verify human conformance to key processes with and outside set of eyes. But with automation, what will humans be doing?... and eyeballs won’t be as accurate as sensors.

Based on a presentation given by Murray Sittsamer and Richard Nave of The Luminous Group at our 2019 Beacon User Summit, this post will discuss the what layered process audit programs might look like in the future with advancement in technology. 

Industry 4.0 will be a $155 billion market by 2024, part of a rapid growth in technologies like machine learning and Internet of Things (IoT) revolutionizing the manufacturing industry. 

As Industry 4.0 picks up steam in automotive and aerospace manufacturing, we are witnessing an evolution towards more sensors, more data communication and more analytics. And while layered process audits (LPAs) could drive even more powerful quality insights and actions, companies also need to be aware of—and hopefully avoid—the potential downsides. 

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6 Dashboard Metrics for Your LPA Program

Jun 24, 2019  |  Chris Shoe

Implementing layered process audits (LPAs) in your facility can mean conducting hundreds of audits every single month, a process that generates a large volume of quality data.

As manufacturers lean into Industry 4.0 initiatives, that volume of data is only growing. But according to Forrester, up to 73% of data within businesses never gets analyzed.

How can automotive and aerospace manufacturers leverage more of their LPA data to maintain steady progress towards their quality goals?

The answer lies in dashboarding, which allows teams to keep their most important metrics front and center for more effective communication and goal-setting. This post looks at some of the most critical numbers to focus on in order to ensure your LPA program is effective at driving down defects, complaints and costs.

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How Layered Process Audits Drive a Culture of Quality

Jun 03, 2019  |  Murray Sittsamer

Quality is actually quite simple—it’s the human element that makes it difficult. We all know it can be challenging to get employees to follow a standardized set of steps, as people often have their own reasons for taking shortcuts or deviating from the established standard.

The problem is that when people deviate from standards, you’re less likely to achieve the desired outcome. That’s where layered process audits (LPAs) can make a big difference, providing frequent process verifications that address the human element of process adherence.

 In this post, we’ll look at how LPAs help create a culture of quality in manufacturing plants, promoting process conformance and employee engagement. The payback is in improved quality metrics and lower cost of poor quality.

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Comparing GM and FCA Layered Process Audit Requirements in IATF 16949

Apr 23, 2019  |  Paul Foster

In 2017 and 2018, respectively, General Motors (GM) and Fiat Chrysler (FCA) both released new customer-specific requirements that suppliers must meet for IATF 16949:2016 certification. Among other topics, the automakers outline layered process audit (LPA) requirements, each putting their own spin on these high-frequency checks aimed at process standardization.

If you’re a supplier for both original equipment manufacturers (OEMs), it’s important to understand what the two sets of requirements have in common—and where they’re different.

Understanding the details is the only way to create an LPA program that’s streamlined and ensures customer satisfaction. Here we compare the two sets of requirements and summarize best practices for an LPA program that satisfies both of them.

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Risk Management for Automotive Suppliers: 4 Critical Places to Focus

Apr 09, 2019  |  Paul Foster

When you look at standards like IATF 16949 or ISO 9001, the requirements boil down to two essential elements: improving customer satisfaction and reducing risk.

They go hand in hand, because effective risk management means safer products and happier customers—and fewer problems for their suppliers.

To help automotive suppliers proactively avoid quality and safety issues, we’re looking at 4 important places to focus for improving risk management and reducing costs.

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7 LPA Mistakes to Fix Before Your Next Customer Audit Checklist [Plus Download!]

Mar 15, 2019  |  Richard Ruiz

New call-to-actionWhen a customer asks to see your layered process audit (LPA) documentation, will you be ready?

For many manufacturers, the answer is no. Instead of having proof of an effective LPA process, they’re left scrambling for data that show low audit compliance and few actual results. Unfortunately, poor LPA processes are enough to fail a customer audit, which could put your key contracts at risk. 

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5 Lessons from Our 2018 Champions for Quality Winners

Feb 05, 2019  |  Eric Stoop

One of the highlights from last year’s Beacon User Summit was our first annual Champions for Quality Awards. Before jumping into what we learned from our champions, we’d like to introduce the 2018 award winners:

Catalyst Award: Tom Sholty, Girtz Industries

Sholty is a quality manager who led Girtz’s ISO 9001:2015 certification, also helping lead the company to the Quality Magazine 2018 Quality Leadership 100. His efforts helped reduce Girtz’s warranty rate to 0.26% of sales dollars and nonconformance rate to 0.89% of sales dollars, both record lows for the company.

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