Why Digital TCard Systems are Key to Effective Layered Process Audits in Manufacturing?

December 9, 2024
Layered process audits in manufacturing

Nothing disrupts a productive shop floor more than chaos and dreaded downtime. A faulty process is like an oversalted soup—no one benefits from it until it’s fixed. Process control is the foundation of every successful manufacturing operation. Ensuring that processes are efficient, glitch-free, and reliable is essential for productivity, performance, and quality. Do you have a solid process auditing system in place? Curious about how our digital TCard system can be your best choice of process auditing software for manufacturing compliance without the hassle? Read on!

What Are Layered Process Audits?

In simple terms, Layered Process Audits (LPA) evaluate the methods used to produce items rather than just the final products. Each layer of an LPA checks for management responsibility, compliance, and process effectiveness. In a constantly changing production environment—whether due to new regulations, equipment installations, or shift changes—LPAs help ensure that processes remain stable and can consistently deliver high-quality products. But how do you know if your processes are running smoothly? A reliable auditing system with data insights and regular quality checks for process improvement is your answer.

Once you understand the importance, the next step is finding a flexible, scalable, and easy-to-adopt solution for process auditing and conformance. Want to know the top digital audit tool for layered audit in manufacturing?

Layered Process Auditing for the Shop Floor Management: Choosing between Digital and Physical Boards

To implement layered process audits in your manufacturing company, it’s essential to set up an LPA framework that spans different organisational levels. Here’s a straightforward breakdown of an effective audit process for achieving process compliance:

  1. Define Audit Criteria: Identify key processes, quality standards, and specific criteria for each audit layer, including Safety, Production Quality, Equipment maintenance, and adherence to Standard Operating Procedures (SOPs).

  2. Assign Audit Layers: Establish audit layers for line operators, supervisors, managers, and top management, each performing audits with varying levels of depth.

  3. Schedule Audits: Set regular schedules for each audit layer. Lower-level audits may be daily, while higher-level audits can be weekly or monthly.

  4. Execute Layered Process Checks: Line operators perform the initial checks, followed by supervisors or managers conducting subsequent audits periodically.

  5. Record Findings: Findings are recorded on a physical board for quick transparency and in the digital system for long-term tracking and analysis.

  6. Assign Actions: Any non-conformances noted on physical or digital boards are assigned to responsible individuals, with follow-up dates.

  7. Daily/Weekly Huddles: Teams gather around the physical board for quick updates, while detailed analysis and strategy sessions use digital data.

  8. Management Reviews: Regular reviews enable management to assess trends, adjust standards, and drive continuous improvement, supported by data insights from digital boards.

Why are Physical Boards not a good choice for your Manufacturing Audit?

Physical boards offer a visual snapshot of the current state of process conformance, with features like KPIs, audit schedules, and corrective actions displayed on the shop floor. While they’re accessible, they have limitations: manual updates, no real-time tracking, unarchived issue logs, and delayed information sharing. This is where digital solutions like TCard come in, offering a comprehensive, streamlined approach to LPAs that transforms your audit process. Curious to learn more? Read on to discover why TCard can revolutionise your LPA strategy for manufacturing process improvement and compliance!

Why Digital TCard is the Best Choice for Layered Process Auditing?

Digital TCard provides an ideal solution for LPAs, with features designed to enhance each step of the audit process. They are traditionally referred to as Digital Kamishibai Boards. Here’s how TCard’s key functionalities can make a difference in your manufacturing facility:

Layered process audit implementation with digital TCard

  1. Digital Workflow for Scheduling and Tracking

    1. Scheduling and Notifications: TCard lets you create and automate LPA schedules, assigning audits to different layers (operators, supervisors, managers) with automated reminders. This feature reduces missed audits and ensures consistency.

    2. Real-Life Example: In an automotive plant, TCard notifies supervisors daily and reminds managers of weekly audits, keeping everyone aligned without requiring manual follow-up.

  2. Customisable Digital Checklists

    1. Process-Specific Checklists: TCard allows for tailored checklists for each process, ensuring each audit layer focuses on relevant quality and compliance criteria. Checklists can be completed on any device, capturing real-time issues with notes and multimedia.

    2. Real-Life Example: In an automotive plant, TCard notifies supervisors daily and reminds managers of weekly audits, keeping everyone aligned without requiring manual follow-up.

  3. Real-Time Data Collection and Analysis

    1. Instant Recording and Analytics: TCard enables auditors to record data instantly, which is then available for analysis in real time. Managers can view compliance data, trend reports, and audit completion rates, making it easier to identify recurring issues.

    2. Real-Life Example: In an electronics manufacturing plant, TCard reveals temperature deviations by shift, allowing management to address the issue and ensure process stability.

  4. Issue Escalation and Alerts

    1. Automated Alerts for Non-Conformance: If an auditor records an issue, TCard automatically alerts the relevant team, speeding up response times and ensuring that issues are resolved quickly.

    2. Real-Life Example: In a chemical plant, TCard triggers alerts when safety audits uncover leaks, allowing the maintenance team to act immediately and prevent safety risks.


  5. Enhanced Accountability with Digital Signoffs

    1. Digital Signatures and Action Logging: TCard requires digital sign-offs at each audit layer, promoting accountability. The platform also tracks corrective actions, showing who has taken responsibility for issue resolution.

    2. Real-Life Example: In a machinery plant, supervisors are accountable for ensuring quality standards are met before the next stage, signing off each audit layer in TCard. This accountability helps reduce defects before final inspection.

  6. Integration with Other Systems

    1. Seamless Data Integration: TCard integrates with ERP or MES systems, allowing LPA data to flow into broader manufacturing analytics and process control dashboards.

    2. Real-Life Example: In a large manufacturing unit, TCard’s integration with the ERP system enables streamlined reporting on audit outcomes, allowing management to view LPA data alongside production metrics.

Why TCard is the Best Choice for Shop Floor Management and Manufacturing Audit?

Our TCard platform is a powerful solution for shop floor challenges due to its real-time tracking, automation, and analytics, all of which facilitate quicker issue identification and resolution. For instance, in a consumer goods plant, TCard helped reduce defects by highlighting and addressing recurring non-conformances during packaging audits. By fostering transparency, accountability, and seamless data integration, TCard makes LPAs more effective, driving continuous improvement and enabling proactive process management in manufacturing environments.

FAQs

  1. What is a digital TCard system in manufacturing?

    2. A digital TCard system is an electronic tool that replaces traditional paper TCards to streamline task management, tracking, and auditing processes in manufacturing.

  2. How do digital TCard systems support layered process audits (LPAs)?

    3. They provide real-time tracking, automated scheduling, and instant data recording, ensuring consistency and efficiency in layered process audits.

  3. What are the benefits of using digital TCard systems for LPAs?

    4. Digital TCard systems enhance accuracy, reduce manual errors, improve data accessibility, and enable faster corrective actions in manufacturing audits.

  4. Can a digital TCard system improve compliance in manufacturing?

    5. Yes, it ensures better documentation, transparency, and adherence to regulatory and quality standards, making compliance management more efficient.

  5. Are digital TCard systems cost-effective for manufacturers?

    6. Yes, they save time, reduce paperwork, and optimise resource utilisation, providing long-term cost benefits for manufacturing operations.
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