Course overview
The considerable and worthwhile supplier effort put into the AS9145 APQP process and PPAP submission should guarantee ‘perfect product and OTIF performance’ for customers.
Auditing APQP and PPAP processes will verify that the system is in place and is working effectively. However, the nagging fear remains – mission drift on the shop floor! Specifically, manufacturing methods aligned with the Control Plan may not continue to be adhered to, resulting in quality issues and loss of productivity. Clearly, a stringent ‘policing method’ must be deployed.
Layered Process Audits (LPA) are a system of audits performed by multiple levels of supervision and management to check whether the outputs (deliverables) of APQP are being properly followed, correct materials are being used, specified tools and equipment are employed and competent & qualified personnel are involved. LPA also monitor key process characteristics (e.g. Cpk & ppm) and verify process performance on an ongoing basis.
This e-Learning (on-line training) course provides and tests the knowledge required to plan, undertake and report on both APQP Audits and Layered Process Audits.
a downloadable (pdf) Delegate Workbook is included
Course details
The course is delivered as an online e-Learning module via TEC's learning management system (LMS) platform. Within this e-Learning course, the following sections are covered:
Introduction
APQP & PPAP provide up-front planning
LPAs assure ongoing success
Overview of this e-Learning course
Acronyms associated with APQP, PPAP and LPA
Overview of APQP and PPAP
The APQP phases
The sequence and purpose of the APQP phases
The APQP & PPAP requirements
The ‘deliverables’ of the APQP phases
The PPAP 'Folder'
The role of auditing
Understanding different audit types
Phasing of audit types
Session #1 – APQP & PPAP System Audit
Identifying the phases of the APQP process
Conducting an APQP System Audit
Stages of the APQP System Audit
APQP System Audit criteria
APQP System Audit scope
Competency of auditors
Developing APQP System Audit questions
AS9145 standard sources
SCMH checklists sources
Customizing your APQP System Audit questions
Customer-specific requirements and the AESQ
Competency in the APQP methodologies and tools
APQP System Audit question format
APQP System Audit sample size
Reporting APQP System nonconformities
Session #2 – Layered Process Auditing (LPA)
Understanding a Layered Process Audit (LPA)
Prerequisites for LPA – processes and planning team
Identifying processes and key steps for LPA
Identifying the LPA planning team
Need for an LPA process owner
LPA audit personnel and top management responsibilities
Prioritizing and developing LPA check-sheet questions
Prioritizing and developing LPA check-sheet questions
The 'Golden Rules' for prioritizing processes for LPAs
Identifying sources of process variation
Sources of LPA questions – controlled conditions
Documentation types – ensuring controlled conditions
Identifying LPA questions – the check-sheet
Example: LPA check-sheet questions from work instructions
Creating an LPA check-sheet
Example: LPA check-sheet with questions – Layer 1
Example: LPA check-sheet format – Layer 2
Example: LPA check-sheet format – Layer 3
Scheduling, conducting and reporting LPAs
Scheduling the LPAs
LPAs location, personnel, duration and focus
Sequencing the LPA activities
Recording the LPA results and actions taken
Dealing with 'difficult' situations
Staffing LPAs
LPA process owner – responsibilities
Reminder – responsibilities for LPAs
Top management actions
Drivers and benefits of LPAs
Drivers of LPAs
Benefits of LPAs
Qualifications & benefits
The benefits of e-learning are numerous; not only are they extremely cost-effective but they provide students with convenience and flexibility as they embark on their learning journey. You can complete your training whenever and wherever you want, and at your own pace.
Companies do not have to tie-up entire teams at the same time as is the case with conventional classroom-based training.