Layered Process Audits (LPA): Digitize With Audit Software and Checklists

Scheduled reviews and audits are not always enough to ensure consistent quality at all levels of the organization. As a result, many manufacturers have introduced Layered Process Audits (LPA) to strengthen their quality management and verify that the standard process is consistently followed on the factory floor.

Many organizations use LPA software for layered process audits to minimize the admin burden for everyone.

Layered Process Audit Software: Streamlining LPAs With a Digital Tool

In many cases, the layered audit process happens with various paper checklists filled in by different personnel, many times per day or week. This means the Cost of Quality and quality appraisal costs can quickly escalate.

With this in mind, many plants have implemented LPA software to digitize their layered process audits to cut the paperwork and administrative tasks. 

The good news? There is no need for major IT projects or process changes: an app like GoAudits is user-friendly, easily available on everyone’s phone or tablet, works offline, and can be swiftly rolled out to all locations and personnel within days.

Here are some of the key advantages of digitizing layered audits on the plant floor with layered audit software:

1. Documentation: The user can take a photo and attach it to document the non-conformance. Additional annotations and comments can be added as required.
2. Visibility: Any issues logged are immediately visible to management or the right team members.
3. Scheduling & Compliance: You can set reminders and notifications to ensure your team doesn’t miss out on daily checks.
4. Analysis: See trends, how often a certain issue re-occurs, how frequently the audits take place, and more.
5. Accountability: Assign corrective actions to the right team (or vendors) and track resolution. Receive alerts and set up escalations in case of delays or recurring non-conformances.
6. Efficiencies: Save paper and your team’s time. All the information can be easily captured on a mobile device – no need to move data from paper to emails or spreadsheets.
7. Standardization: Use standard checklists in all locations, and easily update them anytime, on everyone’s device.

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LPA Meaning: What is a Layered Process Audit?

Layered process audits (LPAs) are a type of audit that focuses on observing and validating how products are made, rather than inspecting the finished products. 

The primary benefit of an LPA check is that it allows process engineers to identify problems as well as pinpoint their root causes. Additionally, it ensures compliance and helps in enhancing performance over time.

Who Conducts LPA Audits?

LPAs involve not only the working level team members (e.g. team leader or shift supervisor) and internal auditors but also department managers and ultimately the executive management. This demonstrates that compliance is everyone’s responsibility. 

Manufacturing audit checklists are an integral part of LPA audits as they are used by different “layers,” or management levels, and production personnel to perform quick and frequent audits.

Why Conduct Layered Audits: Importance & Benefits 

Largely, a layered process audit helps management teams continuously improve and strengthen their quality control plan: identifying recurring issues, correcting them right at the source, and standardizing processes to eliminate non-conformances.

An effective layered process audit will help you:

• increase product uniformity
• reduce wastage, rework, and scrap materials
• promote communication between working-level teams and management
• establish a roadmap for continuous improvement

Layered Process Audit Procedure: How to Conduct Layered Process Audits?

Layered audits help process engineers ensure quality and efficiency in their organization. Here’s a step-by-step guide to conducting LPA process audit:

Step 1: Define Objectives and Scope

Clearly define what you want to achieve with LPAs. Is it improving a specific process, reducing errors, or enhancing compliance? Determine which areas or processes will be audited based on risk and importance.

Step 2: Assemble Cross-Functional Teams

Define workflow and involve employees from different levels – frontline, supervisors, and management to conduct audits at all levels of the operations.

Step 3: Choose the Right LPA Process Auditor App

Look for features like customizable checklists, scheduling audits, efficient reporting, real-time collection, and defining workflow.

Step 4: Develop Layered Audit Checklists in Digital Format

Paper checklists can be cumbersome and prone to errors. Consider using an LPA app like GoAudits to create digital factory audit checklists. 

It offers features like pre-built templates, easy customization, and the ability to attach photos or notes. Also, you can easily update the checklists to ensure they remain relevant.

Step 5: Layered Process Audit Training

Train auditors, floor workers, and management on LPA procedures using checklists and identifying non-conformances. Ensure everyone understands their role and expectations.

Step 6: Conduct Audits

Schedule daily, weekly, and monthly or quarterly audits. Equip auditors with digital checklists and require them to observe processes, verify adherence, and document deviations.

Step 7: Reporting

Analyze audit data to identify trends and recurring issues. Generate reports that include findings, propose corrective actions, and track progress.

What is Audited During an LPA Audit?

The audit commences with an in-depth look at the work instructions for each production layer. After this initial assessment, the audit team evaluates the effectiveness of each layer. Furthermore, LPA audits also encompass:

1. Talking to staff involved in production.
2. Observing actual processes in action.
3. Validating the correctness of records and paperwork.
4. Checking the quality management systems.
5. Scrutinizing inventory management and monitoring methods.
6. Ensuring compliance with applicable regulations or standard manufacturing SOPS.

Layered Process Audit Frequency

The frequency of LPA checks depends on the hierarchical level of personnel conducting the audits. A typical LPA audit plan includes 3 layers that total up to a relatively high number of regularly scheduled audits:

• Layer 1: Daily – supervisors or team leads who conduct audits at every shift.
• Layer 2: Weekly – middle management who performs weekly or bi-weekly audits.
• Layer 3: Monthly or Quarterly – plant managers or upper management/executives.

Layered Process Audit (LPA) Example: Efficient Daily Quality Assurance on the Plant Floor

Many manufacturers have implemented LPA software for their layered audits, including daily production line checks, good manufacturing practice checks, plant walk-throughs, and more.

For example, Miniclipper Logistics relied on Excel sheets, fetching them basic results and no real follow-up or resulting action plans. Also, the team could perform audits only once every few months.

After switching to GoAudits, the audit responsiveness went from 65% to 97% through self-audits. The auditing time was drastically reduced, enabling the team to perform monthly inspections in more areas.

After trialing GoAudits in tandem with our selected audit system, we found rather quickly that GoAudits provided a far better system in terms of ease-of-use, template design options, layout, flow, functionality, actions, reporting, and excellent customer support.

Steve Blaydon, Business Process Manager, Miniclipper

Layered Process Audit Checklists & More

Other audit areas typically include daily, weekly, or monthly checks. We offer a library with 100s of checklist templates for different types of audits.

• ISO 9001 Self-Assessment Checklist
• ISO 13485 Checklist
• Pre-Start Safety Review (PSSR) Checklist
• General Gemba Walk Checklist
• Process Safety Management Audit
• Production Quality Control Checklist for Manufacturing
• Industrial Housekeeping Checklist
• 5S Audit Template
• 6S Audit Checklist
• Hot Work Permit Checklist
• Cold Work Permit Template
• Contract Permit to Work Checklist
• GMP Inspection Checklist
• New Miss Log
• Monthly Manufacturing Risk Assessment Checklist
• Process Audit Template
• Manufacturing Process Audit Checklist
• Manufacturing Audit Checklist
• Safety Walkthrough Checklist
• Manufacturing Safety Audit Checklist – Monthly