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Layered Process Audit-LVSS
Layered Process Audit-LVSS
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Layered Process Audit-LVSS

Process Audit

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Free Layered Process Audit-LVSS Checklist

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Information

  • Magna LVSS

  • Auditor(s)

    • Jason Yarbrough
    • Mike Bundy
    • Garry Martin
    • Scott Link
    • Keri Hall
    • Chris Rotta
    • James Butler
    • Steve Alderson
    • Tony Cain

  • Audit Participant(s)-If not listed on the dropdown options

  • Conducted on

Welcome



  • Welcome to the Magna LVSS Layered Process Audit.

    Ideally the audit should follow a path or loop around the plant. Please read all questions within the category before answering as you may be able to save time by answering them in a different order than presented. Your responses should be limited to the questions asked. If you feel the question is should be worded differently or more questions asked, please add it to the note section at the end of every question. This can be completed by touching the switch. If you determine the question to "fail", you may be required to take immediate action. This is to insure compliance to the criteria so please be courteous. A signature may be required to acknowledge understanding of the corrective action required.
    For your convenience, pictures may be taken of non compliance issues. If you mark the question a "fail", a drop down will appear. Please touch it to open the blue crosshairs. From here, you may use the camera or library to record a picture of the non compliance.

    We appreciate you taking pride in our product.
    Thank you for taking time out of your day to improve our work environment!

Audit-Shipping and Quality

Passenger Line

  • Shipping docks have no items outside of labeled zones

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • Area surrounding Quality Cage has no product or boxes resting on the floor outside of walkways

  • Please take a picture of your concern

  • All walkways and designated areas are clearly labeled and clear

  • Please take a picture of your concern

  • Both doors are closed and locked if no Quality personel are in the area

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 2?

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Shipping/Quality area, please flip the switch to the right.

Audit-End of Front Seat Build Line

Question 1

  • FL1 inspector is present at station

  • Operator can show you how to verify each criteria on the monitor

  • Observe 1-2 sets of incoming seats. Operator does not allow a seat to pass that has any contamination or moisture visible

  • Observe 1-2 seats. Operator does not allow a seat to pass that has any other defects

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • Observe 1-2 pallets loaded for shipping. The straps are positively securing the seats to the pallets.

  • Please take a picture of your concern

  • All velcro is used where applicable and securing the seats through the bottom ring

  • Please take a picture of your concern

  • Straps are located over the shoulders of the seats not over the headrest or down the inboard side and no headrests are up

  • Please take a picture of your concern and do not let the pallet leave in current condition

  • Did all sub-questions PASS in question 2?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • Team leader has a copy of preshift check list

  • Check list is complete and filled out clearly

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 3?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • Look around. All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Comments

  • If you would like to make a comment for the EOL Front Line area, please flip the switch to the right.

Audit-Rework

Question 1

  • Scrap bins have a designated location and clearly labeled

  • Please take a picture of your concern

  • They should be located area of Rework closest to Quality Cage

  • Scrap bins are within labeled location

  • Sample 3-5 items. Red tags are secured to each item

  • Please take a picture of your concern

  • Each tag is completely filled out and defect is identified

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • No seats are resting on the ground

  • Please take a picture of your concern

  • No other production components are resting on the ground

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 2?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No barcodes are attached to poles, monitors, etc. or any location not designated for them

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • Shadow board is present with indicator card turned to green

  • Please take a picture of your concern

  • No items are hanging on board that do not have a shadow or are out of place

  • Please take a picture of your concern

  • Tools missing(only showing a shadow) have a matching tag hanging from an operator station

  • Did all sub-questions PASS in question 4?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 5

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 6

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Rework area, please flip the switch to the right.

Audit-Rear Seat Build Line

Question 1

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • The Inspectors are understanding of the Customer Top 5 issues posted in the OPS area and can verify them

  • Please greet the Operator and introduce yourself
    1. Creases/Wrinkles (top panel)
    2. Poor gap and flushness to 40% and 60% rear seats.
    3. Crease near recliner Inboard and Outboard back rest on backside both 1st row seats.
    4. at rear seat center console (hinge point)
    5. Front seat left creases on backrest upper

  • Observe 1-2 seats incoming wet seats. Operator does not allow a seat to pass that has any contamination or moisture visible

  • Observe 1-2 seats. Operator does not allow a seat to pass that has any other defects

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • No seats or production components are resting on the ground

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No barcodes are attached to poles, monitors, etc. or any location not designated for them

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • Shadow board is present with indicator card turned to green

  • Please take a picture of your concern

  • No items are hanging on board that do not have a shadow or are out of place

  • Please take a picture of your concern

  • Tools missing(only showing a shadow) have a matching tag hanging from an operator station

  • Did all sub-questions PASS in question 4?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 5

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 6

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Rear Line area, please flip the switch to the right.

Audit-Sub Assembly 1 "Supermarket"

Question 1

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • Inspect several parts boxes. Labels on the boxes match labels on the racks

  • If no label visible, FAIL

  • Please take a picture of your concern

  • All parts in box belong to that box

  • Check box for mixed parts. Use color, part number, Driver/Passenger, etc to compare

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • No production parts or boxes are resting on the floor

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No barcodes are attached to poles, monitors, etc. or any location not designated for them

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 5

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

  • If you would like to make a comment for the Supermarket area, please flip the switch to the right.


  • *************************************************************************************************
    The next section you are going to is SA2(station 3050). Please answer the following questions as you walk down the aisle.
    You are requested to check for FIFO tags on raw materials and verify the supplies to SA1 fall between the min and max amount of boxes needed.
    *************************************************************************************************

Comments

  • If you would like to make a comment for the Storage/Supply area, please flip the switch to the right.

Aisle(s) between Sub Assembly 1 and 2,3


  • *************************************************************************************************
    Please answer the following questions as you walk down the aisle.
    You are requested to check for FIFO tags on raw materials and verify the supplies to SA1 and/or SA3 fall between the min and max amount of boxes needed.
    *************************************************************************************************

Question 1

  • FIFO tags are fixed to the raw material in the area with unopened plastic surrounding the materials

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • No labeled supply racks have zero boxes(empty) supplying the operators

  • Check the boxes behind the available one being used by Operator in SA1 and/or SA3. The rack label shows the min amount needed

  • Please take a picture of your concern

  • The amount of boxes does not exceed the maximum and there are no boxes on the floor or in the aisle(outside of the yellow line)

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 2?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Audit-Sub Assembly 2 "40/60% Prep"

Question 1

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • Inspect several boxes. Labels on the boxes match labels on the racks

  • If no label visible, FAIL

  • Please take a picture of your concern

  • Head Rest Guides are not mixed or overflowing from bins

  • Check both stations' boxes for mixed parts. Use color, part number, Driver/Passenger, etc to compare

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

  • Please take a picture of your concern

Question 2

  • No production parts, frames, or boxes are resting on the floor

  • Please take a picture of your concern

  • No excess frames are resting on the cart

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 2?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No barcodes are attached to poles, monitors, etc. or any location not designated for them

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 5

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the 60/40 Prep area, please flip the switch to the right.

Audit-Receiving

Question 1

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Receiving area, please flip the switch to the right.

Audit-Sub Assembly 3 "FSB Prep"

Question 1

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • No production parts or boxes are resting on the floor

  • Please pay special attention to foam blocks and frames in this area

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • No barcodes are attached to poles, monitors, etc. or any location not designated for them

  • Please pay special attention to heat mats wrapped around poles in this area

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • FIFO tags are fixed to raw material in the area

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 5

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the FSB Prep area, please flip the switch to the right.

Audit-Front Seat Build Line

Question 1

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • The Operator is understanding of the purpose of the ODS

  • Please greet the Operator and introduce yourself

  • The Operator knows where to find the ODS

  • The Operator is wearing proper PPE

  • The Operator is following the ODS for side shield install

  • Slide OB sideshield in place. Line up plastic tab in rear of sideshield to hole in rear of cushion structure. Reach under sideshield and close 2 tabs. Get punch and lock plastic rivet. JDP seats - Use hand to cover EPP foam block during the installation process to prevent damage. With opposite hand hold center side shield clip "open" during installation. An impact load is not required to ensure proper installation.

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • Please select a station location from the dropdown list to the right--------------------------------------------HERE-->

  • Please go to this location

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • Quality Alert is posted to the monitor

  • Please greet the Operator and introduce yourself

  • The Quality Alert is current and not expired

  • Please take a picture of your concern

  • The Operator is wearing proper PPE

  • Did all sub-questions PASS in question 2?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No seats are resting on the ground

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • Shadow board is present with indicator card turned to green

  • Please take a picture of your concern

  • No items are hanging on board that do not have a shadow

  • Please take a picture of your concern

  • Tools missing(only showing a shadow) have a matching tag hanging from a operator station

  • Please take a picture of your concern

  • All tools are hanging in matching shadow location

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 4?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 5

  • Team leader has a copy of preshift check list

  • Check list is complete and filled out clearly

  • Please take a picture of your concern

  • Did all sub-questions PASS in question 5?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 6

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 7

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Front Line area, please flip the switch to the right.

Audit-Glue Cell Sub Assembly

Question 1

  • The station location plack(signage) is available and clearly visible

  • Please take a picture of your concern

  • Operator uses full 17 seconds on glue gun

  • Please greet the Operator and introduce yourself

  • Operator applies 8-9 rows of glue

  • Please take a picture of your concern

  • The Operator is wearing proper PPE

  • Did all sub-questions PASS in question 1?

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 2

  • Testing Sheet complete and current. All previous days have 2 signatures, weight ratio, and 2 pull test results

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 3

  • No bins or parts are resting on the ground in work area (out of labeled areas)

  • Please take a picture of your concern

  • Check the box indicating you notified an available supervisor of the non compliance.

  • Please have supervisor initial, sign, or print to acknowledge they will take steps to correct the problem

Question 4

  • All visible operators are wearing proper PPE

  • Please take a picture of your concern

  • Check the box indicating you notified Operator to fix the non compliance.

  • Please have Operator initial, sign, or print to acknowledge they will correct the non compliance

Question 5

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

  • If small action such as sweeping or picking up debris is required please do so now. If it requires further attention, please acknowledge notification of area champion and mark the checkbox

Comments

  • If you would like to make a comment for the Glue Cell area, please flip the switch to the right.

Audit-OPS

Question 1

  • All other areas are clear of debris/dirt, within labeled zones, labels clear, and organized to 5S standards

  • Please take a picture of your concern

Question 2

  • Operations meeting area being utilized

  • White board being used with date and fix clearly posted

  • Please take a picture of your concern

  • No target dates have passed and remain incomplete

  • Please take a picture of your concern

  • Metrics charts (KOI) are up to date. (previous month's data posted before second Friday of current month)

  • Please take a picture of your concern

Question 3

  • Customer Quality Issues is posted and clearly visible

  • The revision date has not passed

Question 4

  • LPA compliance to Performance Schedule

  • Open issues are posted and revision date has not passed

  • Checks and X's represent days of the week. Previous days are checked

  • Please take a picture of your concern

  • Please acknowledge you turned your indicator card to a green check under your name

Comments

  • If you would like to make a comment for the OPS area, please flip the switch to the right.

Complete!



  • You have completed the LPA for today.
    Please review any sections you may have missed or intended to return and answer.
    Thank you again for your time! Please provide any additional feedback below and sign your report.

More

  • Comments

Sign-off

  • Please provide the Auditor(s) signature or initial acknowledging you completed the LPA and answered every question to the best of your ability

Layered Process Audit-LVSS
Anonymous

Layered Process Audit-LVSS

Process Audit

Use this Template
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