LIM Sales and Consulting Layered Audit Format 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 123451234512345123451234512345 Item Number Wk Ending Date: Day: Audit Layer Number 1: Operators are to verify each implemented PCA at the beginning of each shift and indicate effectiveness by placing a check mark in the appropriate block. Audit Layer Number 2: At random times during each shift, the area Supervisor verifies each implemented PCA and indicates effectiveness by placing a check mark in the appropriate box. Audit Layer Number 3: During the week the Plant Manager randomly does a verification and indicates effectiveness (this should not be done on just one shift but randomly over all shifts) Audit Layer Number 4: During the month a Quality Representative randomly does a verification and indicates effectiveness (this should not be done on just one shift but randomly over all shifts) If the layered audit has been in place for a full quarter, the Quality Representative pulls all completed forms and turns them over to the Director. Audit Layer Number 5: Director reviews completed forms with the team during Managment Review meeting, indicates effectiveness in the appropriate box, and rewards/recognizes implemented suggestions for improvement. If the audit is determined to be effective, the audit is closed. If there is still a possibility for the PCA's to fail, the audit process is repeated. All information is recorded in the Managment Review meeting minutes. Quarterly Verification by Director Effective (Yes/No) Monthly Verification by Quality Mgr. Effective (Yes/No) Date: Weekly Verification by Plant Mgr. Effective (Yes/No) Supervisor Operator Supervisor Sun Mon Operator Tues Wed Operator Supervisor Operator Supervisor Sat Operator Supervisor Operator Supervisor Operator Supervisor Thur Fri Date: Date: Shift No.: Shift No.: Verification(s) Required (from implemented PCA's) Customer (Internal or External) Complaint Number Any verifications found that are not in compliance with PCA must be noted on back of form Additional concerns, comments, or opportunities for improvement should be noted on back of form LIM Sales and Consulting, Inc. Copyright 2007 -All rights reserved -May not be reproduced without permission www.lueken.comLIM Sales and Consulting Layered Audit Format Date Name Non-Compliance /Concern /Comment /Opportunity for Improvement /Safety Note LIM Sales and Consulting, Inc. Copyright 2007 -All rights reserved -May not be reproduced without permission www.lueken.com1 Layered audit is initiated in an effort to ensure full management support for PCA's implemented internally or externally and to ensure communication of results across all levels. 2 Layered audit results may be used to document short and long term verifications for internal and external issues. 3 Initial information is filled out and the layered audit forms are placed in a binder once an internal or external customer complaint is received. 4 Binder is kept in a centrally located place within the plant. This location is noted and communicated to all personell and is included on all documentation placed at individual work cells (Quality Alerts). 5 Operators should already have a separate verification checklist at each cell where a PCA has been implemented. 6 Once the operator has verified the PCA and completed work cell documentation, the operator goes to the centrally located binder, finds the noted customer complaint, and records necessary information. 7 It is very important that the operator understands that comments are required if a non-compliance is found and the process is stopped immediately and Supervisor is advised. 8 It is equally important that the operator note any additional information or opportunities (the operator with the best suggestion should be recognized in Management Review) 9 The remaining audit layers are completed by management as noted on the audit form. Note: There is no need to maintain this document electronically. The format is designed to be completed and maintained as a hand written record. Instructions