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What is it: Layered Process Audits (LPA) are a system of audits performed by multiple levels of supervision and management to monitor key process characteristics and verify process conformance on an ongoing basis. A Layered Process Auditing system is comprised of three critical elements:

  • 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
Adobe PDF
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Layered Process Audit Instructions
  Layered Process Control Audit Template
Microsoft Excel Format
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Layered Process Control Audit Template
  Layered Errorproofing Verification Audit Template
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Microsoft Excel
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Layered Errorproofing Verification Audit
  Layered Process Audit Checksheet Template
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Layered Process Audit Checksheet Template
  Layered Process Audit Comprehensive Checksheet Template
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Layered Process Audit Comprehensive Checksheet Template
  Supplier Audit Template
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  Internal Process Audit Report Part A Template
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Microsoft Excel
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Internal Process Audit Report Part A Template
  Internal Process Audit Report Part B Template
Microsoft Excel Format
Microsoft Excel
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Internal Process Audit Report Part B Template
  Internal Process Audit Report Checklist Template
Microsoft Excel Format
Microsoft Excel
Format
Internal Process Audit Report Checklist Template
  Monitor and Adjust Layered Process Audit Template
Microsoft Excel Format
Microsoft Excel
Format
Monitor and Adjust Layered Process Audit Template
  LPA Frequency and Structure Template 1
Microsoft Excel Format
Microsoft Excel
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LPA Frequency and Structure Template 1
  LPA Frequency and Structure Template 2
Microsoft Excel Format
Microsoft Excel
Format
LPA Frequency and Structure Template 2
USD $29.95
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