Ultimate Layered Process Audit (LPA) Guide for Quality Assurance

In the world of quality assurance, the layered process audit is a powerful tool to improve product quality and reduce the risk of costly recalls. 

LPAs transform quality culture and boost compliance. By involving managers, team leaders, and frontline employees in regular process checks, LPAs catch issues early and drive continuous improvement.

Our guide covers everything you need to know about implementing an effective LPA program, including:

• The basics of layered process audits

• Their importance for quality control

• How to set up an LPA system

• Conducting audits efficiently

• Using technology to streamline the process

• Creating effective audit checklists

• Analyzing data

• Standardizing processes to mitigate risks

By the end, you'll have a roadmap to strengthen your quality management system and build a culture of excellence.

The regular and recursive nature of LPAs provides immediate feedback and correction, leading to:

• Reduced defect rates

• Improved compliance

• Enhanced operational efficiency

Integration with ISO Standards LPAs aligns with several ISO standards:

• ISO 9001: Quality management

• ISO 14001: Environmental management

• ISO 45001: Occupational health and safety

These standards emphasize systematic process management, supported by LPAs to ensure consistent and reliable process audits.

Key LPA Components

The key components of LPAs include the use of standardized checklists tailored to specific processes, frequent and regular audits, and immediate feedback mechanisms. These audits aim to identify deviations, non-conformities, and potential areas for improvement promptly.

Integration with IATF 16949 and CQI-8: For automotive industry standards, LPAs can be particularly effective when integrated with IATF 16949, which focuses on quality management systems, and CQI-8, the layered process audit guideline specific to the automotive sector.

Layered Process Audits engage every level of the organization, each with specific responsibilities:

• Operators: Perform daily audits, focusing on immediate operational concerns and ensuring basic checklist adherence.

• Supervisors: Conduct detailed weekly audits to verify corrective actions and monitor ongoing compliance with operational standards.

• Managers: Carry out monthly audits to assess the effectiveness of quality systems, ensure alignment with strategic objectives, and review audit reports to identify trends and systemic issues.

• Top Executives: Participate in quarterly reviews of LPA outcomes to ensure audit findings align with strategic goals and allocate resources for continuous improvement.

Layered Audit Quality Assurance Benefits

Layered Process Audits (LPAs) are essential for identifying inefficiencies, risks, and improvement opportunities in manufacturing and operations. 

By proactively addressing these issues, organizations can consistently improve performance and deliver higher-quality products.

Key Benefits:

• Process Integrity: Ensures proper establishment and adherence to processes at every manufacturing layer.

• Corrective Actions: Prompts correction of non-conformities, preventing recurrence, and maintaining operational flow.

• Comprehensive Records: Emphasizes thorough documentation, tracking changes, corrective actions, and updates for transparency and progress monitoring.

• Evaluation: Involves interviews, process observation, and record verification to ensure compliance and assess communication and training effectiveness.

Layered audits are a proactive management approach, focusing on validating processes rather than inspecting finished products.

Implementing an Effective LPA Program

Implementing a successful Layered Process Audit program requires a structured approach. Here’s how you can do it:

1. Understand LPA Best Practices:

• Familiarize yourself with industry standards and effective practices to ensure your program is robust and efficient.

2. Assemble a Dedicated Team:

• Form a team that includes members from various levels of the organization to bring diverse perspectives and expertise.

3. Identify Critical Processes:

• Determine which processes are crucial for your operations and need regular auditing.

4. Build Custom Checklists:

• Develop checklists tailored to your specific processes, keeping them concise and focused:

• 3-10 questions per checklist

• Less than 15 minutes to complete

• Objective, specific, and concise questions

5. Schedule Audits:

• Plan audits at appropriate intervals to ensure comprehensive coverage:

• Layer 1: Supervisors and team lead conduct daily audits.

• Layer 2: Middle management conducts audits weekly.

• Layer 3: Plant managers conduct monthly audits.

• Layer 4: Executives conduct quarterly or annual audits.

6. Assign Auditors:

• Clearly define roles and responsibilities for each layer of auditors to maintain accountability and thoroughness.

7. Train Auditors:

• Provide comprehensive training for auditors at all levels to ensure they understand their roles and can effectively conduct LPAs:

• Tailored training resources for each level

• Focus on the necessary skills and knowledge

By following these steps, you can implement an effective LPA program that drives continuous improvement and enhances overall quality assurance efforts.

How to Conduct a Layered Process Audit?

Conducting Layered Process Audits (LPAs) involves a structured approach that covers scheduling, execution, and reporting. They should cover all critical aspects of manufacturing operations, from incoming raw materials to final product testing. The scope may also include health and safety protocols and environmental compliance.

Integration with ISO 45001: Incorporating ISO 45001 standards into your LPA program ensures that occupational health and safety considerations are embedded into the audit process, leading to a safer work environment.

Scheduling and Audit Frequency

The audit frequency of each layer is based on the complexity and risk associated with the specific process. 

Higher-risk areas like assembly lines may require daily audits, while less critical processes like inventory management might be audited weekly or monthly.

Determine the audit frequency at each organizational level based on the role and the importance of the processes being audited. For instance:

• Line Workers: Conduct daily audits to identify issues in real-time.

• Supervisors: Perform weekly reviews to oversee and ensure corrective actions are implemented.

• Higher Management: Conduct quarterly audits to assess overall compliance and the effectiveness of the LPA system.

Tip: To minimize disruption to regular operations, schedule audits at times that naturally fit into each department's existing workflow.

Audit Execution Process

Once the schedule and checklists are set and your team is trained, you can begin performing the audits. Initially, closely monitor the execution to ensure audits are conducted as planned, on schedule, and following established protocols.

1. Review Process Flow:

• Start with a review of the process flow diagram and checklists.

2. Observe and Verify:

• The auditor observes each step in the process, ensuring it is performed correctly and according to specifications.

3. Document Deviations:

• Note any deviations on the checklist.

Documentation and Reporting Audit Results

Effective Layered Process Audits (LPAs) depend on clear, actionable reporting. Here's how to ensure comprehensive documentation and communication:

1. Set Documentation Guidelines:

• Establish a standardized method for documenting audit findings.

• Include clear, concise descriptions of any issues, photographic evidence if applicable, and the context around the finding.

• Proper documentation is critical for tracking the history of compliance and issues, providing a foundation for improvement discussions.

2. Analyze Findings:

• After the audit, the auditor analyzes all findings and determines if any corrective action is needed.

• If so, they collaborate with management to develop a plan to address and correct the issues.

3. Effective Communication:

• Promptly share audit findings with all relevant stakeholders.

• Include both positive observations and areas needing improvement.

• Promote transparency and open dialogue to encourage continuous improvement.

Finding a Layered Process Audit Software Solution

Managing Layered Process Audits manually can be challenging and prone to errors, leading to missed opportunities for improvement. Digital workflows simplify the management and improve expected outcomes.

Digital Layered Process Audit solutions automate tasks, ensuring consistent data collection globally. Uniform data is crucial for leaders to gain insights without sifting through individual reports.

Key Features to Look for in LPA Software:

1. Forms:

• Create unlimited forms, and question banks, and convert paper checklists to digital forms.

2. Inspections Flexibility

• Perform inspections anytime, anywhere, even offline, on any device.

3. Automated Workflows and Reporting:

• Automate workflows and generate detailed inspection reports and insights to solve issues instantly.

4. Insights & Analytics:

• Transform your data into actionable insights.

5. API Integrations:

• Connect your LPA software to other systems like Tableau, SharePoint, ERPs, and more.

6. IoT Capability:

• Integrate with IoT devices to collect real-time data, monitor conditions, and automate alerts for comprehensive audit management.

Try for free Mobile2b's fully customizable Layered Process Audit checklist app with an intuitive interface for desktop and mobile devices. It allows inspectors to perform audits offline, schedule audits proactively, and assign and track corrective actions.

Benefits:

• Continuous Improvement:

• Provides data and details not captured in manual audits.

• Audit Photos & Custom Tags:

• Helps uncover issues on the plant floor by tagging failed questions for inclusion in all checklists.

• Process-Specific Checklists:

• Tailored to specific areas and processes, ensuring thorough and standardized audits.

By using digital LPAs, companies can uncover continuous improvement opportunities, optimize audit processes, and achieve better outcomes. 

Using question libraries with custom labels, manufacturers can tag failed questions for inclusion in all plant checklists. This helps identify issues at multiple workstations, providing a deep understanding of recurring problems and utilizing the Pareto principle to highlight the most common issues for targeted improvements

For example - Consider creating groups of tags by:

• Process-specific

• Safety

• Continuous improvement

• 5S (Sort, Set in Order, Shine, Standardize, Sustain)

• 6Ms (Man, Machine, Material, Method, Measurement, Mother Nature/Environment)

This approach allows for identifying deeper trends. For example, you might see several issues related to materials (Material - 6M) or multiple failures tagged under both man (Man - 6M) and machine (Machine - 6M).

LPAs are essential for capturing plant floor data used for continuous improvement. They provide frequent checks to ensure teams maintain those improvements.

Conclusion

Layered Process Audits are essential for quality assurance and continuous improvement. They systematically review processes at various levels, catching issues early and standardizing best practices. Involving employees throughout the organization, LPAs adopt a culture of accountability, resulting in better products and increased customer satisfaction.

With the right tools, you can maximize the results. Digital solutions optimize audit scheduling, data collection, and reporting, making it easier to identify trends and take action. Digital LPAs improve safety, reduce costs, increase customer satisfaction, drive continuous improvement, ensure compliance, and build a culture of excellence. 

Start your Digital Layered Process Audits journey today—try our App for free or book a free demo with our team of experts.

FAQ Section: Layered Process Audits (LPAs)

What is a Layered Process Audit (LPA)?

A Layered Process Audit is a quality management system involving multiple organizational layers conducting regular audits of critical processes. This systematic approach ensures consistency, adherence to procedures, and early identification of issues.

How does LPA differ from traditional audits?

LPAs are more frequent and process-focused, involving all management levels, and typically shorter in scope. Traditional audits are less frequent, broader in scope, and usually conducted by specialized auditors.

What are the benefits of conducting LPAs?

LPAs enhance quality assurance by:

• Ensuring process integrity

• Implementing corrective actions swiftly

• Maintaining comprehensive records

• Providing holistic evaluations and ongoing improvement

• Boosting safety, reducing costs, increasing customer satisfaction, ensuring compliance, and fostering a culture of excellence

How often should LPAs be conducted?

The audit frequency varies based on the process's criticality:

• Line Workers: Daily audits

• Supervisors: Weekly reviews

• Middle Management: Monthly audits

• Upper Management: Quarterly or annual audits

How do digital solutions enhance LPA effectiveness?

Digital LPA solutions automate scheduling, data collection, and reporting, ensuring consistent data and making it easier to identify trends and take corrective action. Key features include:

• Digital forms

• Workflow automation

• Automated reporting

• Insights and analytics

• API Integrations

• IoT

What is an example of a Layered Process Audit checklist and schedule?

If you'd like a detailed example of a Layered Process Audit checklist and schedule, drop us an email, and we will send you one for free.