What is a Layered Process Audit (LPA)?

A Layered Process Audit, or LPA, is a quality management system in manufacturing. LPA’s are designed to create layers of protection against rework, quality defects, product recalls, dissatisfied customers, and more. Rather than focus on just the final production result, layered process audits focus on observing and verifying how the products are created and manufactured.

Layered process audits set up different “layers” of auditors – who can be comprised of staff, employees, or frontline personnel – that are assigned the exact same set of audits to ensure that high-risk steps in production do not deviate from set standards and specifications. This is a structured, standardized, and systematic audit that ensures optimal functioning of a process/system.

Read our guide below to learn what an LPA in manufacturing entails, how to create a layered process audit checklist, the benefits of layered process audit software, and more.

Why are LPAs Important?
Key Aspects of Layered Process Audits
How to Create a Layered Process Audit Checklist
Benefits of Digitizing LPAs In Manufacturing

Why are LPAs Important?

Layered process audits (LPAs) are an important part of a smart quality approach in manufacturing. According to a survey by Deloitte, 94% of respondents agreed that quality management is a key driver of customer satisfaction. LPAs are conducted at different organizational levels, from shop floor to senior management, and they help ensure that manufacturing processes are effective and efficient.

LPAs help manufacturing companies identify and correct issues BEFORE they cause any actual damage. If processes are followed correctly, LPAs prevent issues like rework, customer complaints, costly product recalls, and reputational damage. This system ensures that quality standards are met and that products and services remain efficient.

Key Aspects of Layered Process Audits

Layered Process Audit’s main defining feature is its multi-level involvement. LPAs engage employees from different organizational levels, from frontline workers to senior management. This broad participation promotes better communication and alignment across the organization. Other key aspects of LPAs are:

Frequency: Lower-level audits occur more frequently (e.g., daily or weekly), while higher-level audits happen less often but cover a broader scope.
Simplicity: Audit questions are designed to be simple, allowing anyone in the organization to conduct them without specialized knowledge.

Common LPA structures typically involve three or four distinct audit layers, though this may change depending on industry and organizational needs:

Layer 1: Operators and frontline workers conduct daily audits of their own processes.
Layer 2: Supervisors perform weekly audits within their departments.
Layer 3: Operations managers conduct monthly audits on quality and review LPA reports.
Layer 4: Senior managers and executives conduct quarterly audits across multiple areas

How to Create a Layered Process Audit Checklist

Layered process audits are used in a variety of industries, including manufacturing, healthcare, and construction. They involve a standardized set of criteria and evaluation processes that personnel must follow to ensure optimal results. One widely used method of standardization used by organizations to achieve this is the creation of a layered process audit checklist.

Here are some things to keep in mind when designing an LPA checklist:

Clearly define scope and objective
Develop focused questions and keep them concise; usually, 10-15 specific questions covering key areas like safety, materials, workstation setup, follow-up actions, etc.
Consider digital formats, like layered process audit software or digital checklists – we will dive into the benefits of this further in the next section.
Organize the questions into relevant categories for ease of completion
Allow for documentation; include space for comments or the ability to attach photos if you are using a digital version
Make it user-friendly; ensure the checklist is easy to understand and use for auditors at all levels of the organization.
Allow for feedback and updates; design the checklist so it can be easily updated to reflect current risks and process changes.

Keep in mind that the goal is to create an easy-to-use and implementable tool that verifies processes are being followed correctly, not just to check boxes. The checklist should drive meaningful quality improvements and foster a culture of continuous improvement.

Benefits of Digitizing LPAs In Manufacturing

As manufacturing and other industries evolve, digitizing quality management processes like layered process audits has become inherent to continued success. Digital processes and checklists allow organizations to streamline the audit process, making it significantly faster and more efficient compared to paper-based methods. AI-driven connected worker platforms take this a step further enabling AI-based insights and analysis to improve, optimize, and augment the audits and auditors for demonstrably better results.

Digital checklists and layered process audit software enabled by an AI-powered connected worker platform offers incredible benefits to both users and organizations alike, such as:

Improved Data Management and Real-Time Reporting
Enhanced Accuracy
Simplified Corrective and Preventive Action (CAPA) Management
Improved Standardization
Increased Mobility, Accessibility, and Adaptability
Cost Reduction

With AI-powered connected worker solutions enhancing the layered audit process, manufacturers and other organizations facilitate more effective quality control and continuous improvement initiatives, leading to improved compliance and overall operational excellence.

Interested in learning more?

If you’d like to learn more about how Augmentir streamlines and optimizes quality management processes like layered process audits and more, schedule a demo with one of our produce experts.

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