• A set of sudits focused on high-risk processes
• Layers of auditors from all areas of management who perform audits
• A system of reporting and follow-up to ensure containment as needed and drive improvement

Why use it: Layered Process Audits provide an excellent tool for minimizing variation in processes and error-proofing systems and making significant progress toward single-digit ppm and even meeting the goal of zero defects to your customers. Key benfits are:

• Reduces variation in production
• improve quality
• Improves & maintains discipline
• Reduces scrap and eliminates waste
• Reduce customer rejections
• Improves discipline & communication
• Increase Employee participation
• Improves overall quality & cuts costs
• Stops production problems from becoming rejections

Where to use it: Layered Process Audits are used to insure high risk processes and error proofing devices do not exhibit a lot of variation and are working properly.

• Assembly Area
• Manufacturing Operations
• Shipping/Receiving
• Repair/Rework Area
• All Operations and other support functions

When to use it: Layered Process Audits shall  be conducted for manufacturing and assembly of high risk items at a minimum of once per shift. Frequency of Layered Audits based on production volume or level of risk associated with process.

How to use it: There are three elements of a layered process auditing system:

• A Collection of Audits - Audits are simply an organized group of questions designed to examine a device or process. Audits in an LPA system should focus only on areas in the manufacturing process where deviation represents a high-risk for producing defective products.
• Layers of Auditors - In an LPA system, your collection of audits is performed on a regular basis, at a predetermined frequency, by multiple layers of management from across the manufacturing organization.
• Containment, Reporting & Follow-up - For a Layered Process Audit system to be truly effective, it must integrate action, analysis and improvements. If an auditor finds a non-conformance while performing an audit, that auditor should not only record their finding, but also take immediate initial corrective action to ensure defective products do not get out the door. Information about the finding should be recorded and readily available to management for later analysis. With a good system for recording and reporting audit information, an LPA system provides an excellent tool for troubleshooting problem areas and identifying places which are ripe for improvement.

Important Notes:

• Management must own the process
• Identify and ask the right questions
• Participation spans all management layers
• Nonconformances lead to immediate containment
• Include a process for continuous improvement
• Schedule and perform audits regularly

Name Format Preview (Click to enlarge)   Layered Process Audit Instructions Adobe PDF Format   Layered Process Control Audit Template Microsoft Excel Format   Layered Errorproofing Verification Audit Template Microsoft Excel Format   Layered Process Audit Checksheet Template Microsoft Excel Format   Layered Process Audit Comprehensive Checksheet Template Microsoft Excel Format   Supplier Audit Template Microsoft Excel Format   Internal Process Audit Report Part A Template Microsoft Excel Format   Internal Process Audit Report Part B Template Microsoft Excel Format   Internal Process Audit Report Checklist Template Microsoft Excel Format   Monitor and Adjust Layered Process Audit Template Microsoft Excel Format   LPA Frequency and Structure Template 1 Microsoft Excel Format   LPA Frequency and Structure Template 2 Microsoft Excel Format

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