#USA #Irvine #Ease.io #Adam Wegel #Layered Process Audit

Ease.io's First Layered Process Audit Benchmark Report

Ease.io, a prominent player in AI-driven audit and inspection software tailored for manufacturers, has unveiled its first-ever Layered Process Audit Benchmark Report. This report presents an extensive analysis of over 2.3 million layered process audits conducted at more than 2,200 manufacturing sites worldwide. The report reveals critical insights into the performance levels of manufacturers against established best practice benchmarks, shedding light on alarming gaps in execution and audit engagement.

While many organizations boast an overall audit completion rate of over 80%, a significant issue emerges when evaluating adherence to best practices. Alarmingly, fewer than 30% of manufacturers manage to meet benchmarks for timely audit completions. Moreover, only 28% of organizations address more than 60% of audit findings within the specified timeframe. These deficiencies carry weighty implications for compliance, especially for firms in the automotive and aerospace industries where stringent layered process audits are mandated by major original equipment manufacturers (OEMs).

Despite these shortcomings, the analysis indicates that organizations completed an average of 8,700 audits, closing approximately 1,460 findings. Interestingly, those employing digital audit systems observed enhancements in their overall completion rates within two years, with a notable reduction in the number of companies struggling to perform. Adam Wegel, the CEO of Ease.io, states, "These statistics reinforce what leading manufacturers already recognize: layered process audits are integral to achieving operational excellence." However, Wegel emphasizes that merely having the right tools isn't sufficient; the central concern lies in accountability and execution gaps.

The report highlighted a surprising trend: 84% of Layer 1 (frontline) audits resulted in zero findings, a stark contrast to the findings for upper management, showcasing disengagement at the operational level. Josh Santo, Senior Director of Industry Strategy and Solutions, notes, "This disparity indicates a clear leadership gap in reinforcing the significance of these critical checks mandated by industry standards and customer expectations." He suggests that many personnel across levels do not comprehend the potential impact of layered process audits and, thus, often treat them as mere formalities.

In response to these findings, the report posits that enhanced leadership involvement is crucial for advancing Layered Process Audit (LPA) maturity. It outlines that plants with engaged leaders participating consistently in audits are 20% more likely to complete audits on time. Santo concludes by pointing out, "All of these findings reinforce that the People-Process-Tools framework is critical for success. Engaged leadership distinguishes high-performing plants from their counterparts."

The full Layered Process Audit Benchmark Report is accessible for those seeking to deep-dive into the report’s findings and insights, potentially guiding manufacturers toward improved audit practices and enhanced quality control processes.

About Ease.io

Founded in 1986 and headquartered in Irvine, California, Ease.io offers a cloud-based Software as a Service (SaaS) solution for manufacturers, called EASE. This platform digitally facilitates essential plant floor processes including audits, inspections, data collection, and scheduling. Recognized leaders like Dana, Tenneco, and Eaton across 50+ countries utilize EASE to boost compliance, productivity, safety, and quality in their operations. For further information, visit ease.io.