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Done correctly, layered process audits (LPAs) are among the most effective tools manufacturers have for maintaining consistent quality through process conformance. But when attempting to scale these often-manual audits across plants, divisions, and even globally, it becomes difficult to recognize the benefits these audits should be resulting in. Rather, it quickly becomes apparent procedures vary from plant to plant, management doesn’t always buy in the way they should, and more effort is spent trying to administer the program than addressing findings.
Join us for a one-on-one conversation with Paul Flaherty, Global Quality Director for Valmont Industries, to discuss how digital LPAs have helped the global manufacturer of critical infrastructure maintain a world-class quality management system. This 30-minute conversation will cover:
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A global automotive supplier looking to improve visibility into quality decided to replace its manual paper-based audit system with Beacon Quality software. Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions.
Jacobs’ Drive the Future demonstrator truck is traveling throughout North America to show off its latest technologies which lead to improved productivity, engine braking, and emissions.
Industry: Trucking
Company size: 501-1000 employees
Location: Bloomfield, CT
Software used: EASE LPAs, Safety & 5S Audits
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
A global automotive supplier looking to improve visibility into quality decided to replace its manual paper-based audit system with Beacon Quality software. Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions.
The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks. Jacobs Vehicle Systems is a leading manufacturer of advanced engine braking systems and valve activation technologies, with manufacturing locations in North America, Europe and Asia.
The team would choose a card from the first deck to determine the audit location. The card selected from the second deck indicated the process to audit, showing acceptable results on one side (colored green) and non-compliant results on the opposite side (colored red). Auditors would post results on a dry erase board, then log them in spreadsheets.
Jacobs’ Drive the Future demonstrator truck is traveling throughout North America to show off its latest technologies which lead to improved productivity, engine braking, and emissions.
Jacobs’ Drive the Future demonstrator truck is traveling throughout North America to show off its latest technologies which lead to improved productivity, engine braking, and emissions.
A global automotive supplier looking to improve visibility into quality decided to replace its manual paper-based audit system with Beacon Quality software. Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions.
The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks. Jacobs Vehicle Systems is a leading manufacturer of advanced engine braking systems and valve activation technologies, with manufacturing locations in North America, Europe and Asia.
The team would choose a card from the first deck to determine the audit location. The card selected from the second deck indicated the process to audit, showing acceptable results on one side (colored green) and non-compliant results on the opposite side (colored red). Auditors would post results on a dry erase board, then log them in spreadsheets.
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Director of Product Marketing, Ease Inc.
Jason Holte is the Director of Product Marketing for EASE, the innovative mobile platform that helps manufacturers simplify how they administer, conduct and respond to plant floor audits.
Jason began his career at The Behr Paint Company, a leading North American CPG manufacturer. It was at Behr that he developed a passion for enabling quality, safety, and productivity on the shop floor through the use of real-time insights into process and protocol adherence. He considers digital transformation essential to zero error, zero injury manufacturing.
A California native, Jason is a graduate of Concordia University Irvine.
Paul Flaherty is the Global Quality Director for Valmont Industries, a global leader in creating the critical infrastructure essential for economic and agricultural growth. Paul has been in manufacturing for 20 years, with a proven track record of meeting and exceeding challenging targets. He accomplishes this by ensuring his teams know the goals and by empowering them to create creative systems to succeed. He keeps safety first and promotes an employee-driven organization where his team members know they always come first.
Paul holds an MBA from University of South Carolina, and he is currently enjoying the process of developing and installing a world-class quality management system in a global organization.
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"Et harum quidem rerum facilis est et expedita distinctio!"
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.
Six months after implementation, the organization has increased audit completion rates more than 40% and created more accountability around corrective actions. The company had conducted paper-based layered process audits (LPAs) for many years. In 2012, they launched a visual management process called Kamishibai—Japanese for “paper drama”—to structure audits using cards randomly selected from two decks.