Key Takeaways

Layered Process Audits (LPAs) are essential for maintaining quality assurance in manufacturing processes by focusing on process validation rather than just product inspection.
LPAs involve multiple layers of the organization, from frontline workers to senior management, promoting cross-functional collaboration and comprehensive problem-solving.
Conducting LPAs helps identify deviations, ensuring adherence to quality standards and driving continuous improvement initiatives.
Digital tools, such as Poka, enhance the efficiency of LPAs by streamlining data collection, analysis, and corrective actions through features like digital forms, analytics dashboards, and video work instructions.
Regularly scheduled audits, tailored to the risk level of processes, ensure timely identification and resolution of issues, contributing to improved operational efficiency and compliance.

In pursuing perfection, challenges can arise—deviations, inefficiencies and lapses in compliance that threaten to undermine the essence of quality production. Enter Layered Process Audits (LPAs), a transformative approach designed to enhance quality by bringing a new dimension to quality assurance in manufacturing.

What are Layered Process Audits?

Layered Process Audits are a quality enhancement technique utilized in manufacturing to ensure the integrity of the production process. Unlike traditional inspection methods focusing primarily on the final product, LPAs observe and validate manufacturing processes on the shop floor. Multiple layers of the organization perform audits on a scheduled cadence with the goal of identifying deviations in the process that could lead to defects in the product.

Questions should examine the most sensitive process variables with simple Yes/No responses, with answers expanded to include observable evidence in the event of a non-conformance. Depending on an individual’s area of authority, audits will occur at different frequencies and cover a part of the production process or an area of the facility. This structured approach helps teams conduct layered process audits effectively.

This approach promotes cross-functional involvement, allowing employees, from frontline factory workers to top-level management to participate. Involving cross-functional teams in LPAs ensures comprehensive problem-solving and the identification of root causes. This diverse participation encourages objectivity, impartiality and a fresh perspective on how processes function and how they can be improved.

Why are Layered Process Audits Important?

Layered Process Audits play a crucial role in the manufacturing industry by ensuring manufacturing processes’ effectiveness, consistency and compliance. These audits are vital for maintaining product quality, reducing defects and enhancing overall operational efficiency. Additionally, adhering to safety standards is essential in maintaining product quality and ensuring the well-being of all stakeholders involved.

By conducting audits at various organizational levels, from the shop floor to senior management, companies can identify potential areas of waste, inconsistencies and improvement opportunities within their manufacturing processes. This proactive approach enables organizations to detect and rectify issues before they escalate into larger problems that could negatively impact product quality and customer satisfaction.

One of the key reasons Layered Process Audits are so important is their ability to drive continuous improvement initiatives. By systematically examining processes and identifying non-conformances or discrepancies, companies can implement corrective actions to streamline operations, reduce costs associated with defects and rework and ensure that products consistently meet quality standards. Moreover, LPAs provide a tangible means of enforcing regulatory compliance, helping organizations adhere to quality standards such as ISO 9001, IATF 16949, ISO 45001, and ISO 14001. Enhancing compliance with both internal and external standards is critical for the success of these audits, ensuring that all processes align with established protocols.

Furthermore, Layered Process Audits foster a culture of accountability, engagement and collaboration across different departments within an organization. These audits encourage open communication between operators on the shop floor and top-level management, giving employees the opportunity to voice their concerns, suggestions and insights.

How to Conduct a Layered Process Audit

Conducting a layered process audit (LPA) is a crucial step in ensuring the quality and efficiency of manufacturing processes. An LPA is a structured approach to process improvement that involves multiple levels of review and analysis. The key elements of a successful LPA include clear objectives, defined scope and a well-structured methodology.

A well-executed LPA begins with setting clear objectives that align with the organization’s quality and operational goals. Defining the scope ensures that the audit covers all critical aspects of the manufacturing process, from initial production stages to final quality checks. A structured methodology, including detailed checklists and standardized procedures, ensures consistency and thoroughness in the audit process.

Audit Process and Procedure

The audit process and procedure for an LPA typically involve the following steps:

Define the Objectives and Scope: Establish what the audit aims to achieve and the specific areas it will cover.
Identify Critical Processes: Determine which processes are vital to the manufacturing operation and require close scrutiny.
Develop a Detailed Audit Checklist: Create comprehensive checklists that cover all aspects of the critical processes.
Assign Auditors: Select auditors from different levels of the organization to ensure a diverse and unbiased review.
Conduct the Audit: Observe processes, verify adherence to standards, and document findings.
Document Findings: Record observations and any deviations from the standard procedures.
Analyze Audit Data: Review the collected data to identify trends and recurring issues.
Develop and Implement Corrective Actions: Create action plans to address identified issues and prevent recurrence.

By following these steps, organizations can ensure a thorough and effective audit process that identifies areas for improvement and enhances overall operational efficiency.

What is Audited During an LPA Audit?

During an LPA audit, the following aspects of the manufacturing process are typically audited:

Work Instructions and Standard Operating Procedures (SOPs): Ensure that all procedures are clearly documented and followed.
Process Controls and Monitoring Systems: Verify that controls are in place to monitor and maintain process parameters.
Quality Control Measures and Inspection Procedures: Check that quality control measures are effective and inspections are thorough.
Safety Protocols and Emergency Response Plans: Ensure that safety protocols are followed and emergency plans are in place.
Inventory Management and Material Handling Procedures: Review how materials are managed and handled to prevent issues.
Production Personnel Training and Competence: Assess the training and competence of production personnel.
Equipment Maintenance and Calibration Procedures: Verify that equipment is properly maintained and calibrated.

By auditing these critical aspects, organizations can ensure that their manufacturing processes are robust, compliant and capable of producing high-quality products.

Audit Frequency and Scheduling

The frequency and scheduling of LPAs depend on the criticality of the process, the level of risk associated with the process, and the organization’s quality objectives. Typically, LPAs are conducted:

Daily or Weekly for High-Risk Processes: Frequent audits ensure that any issues are quickly identified and addressed.
Monthly or Quarterly for Medium-Risk Processes: Regular audits help maintain process stability and compliance.
Annually or Bi-Annually for Low-Risk Processes: Periodic audits ensure that even low-risk processes remain compliant and efficient.

By tailoring the frequency of audits to the risk level of the processes, organizations can allocate resources effectively and maintain high standards of quality and compliance.

Building an Effective Audit Team

Building an effective audit team is crucial for the success of an LPA. The audit team should consist of individuals from different levels of the organization, including:

Process Owners and Subject Matter Experts: Provide input on process design and operation.
Auditors with Technical Expertise: Conduct the audit, observe processes, and verify adherence to standards.
Quality Assurance Representatives: Ensure that the audit is conducted in accordance with quality standards and procedures.
Safety Inspectors: Ensure that safety protocols and emergency response plans are in place and effective.

A diverse audit team brings a range of perspectives and expertise, ensuring a comprehensive and unbiased review of the manufacturing processes.

Roles and Responsibilities in the Audit Process

The roles and responsibilities of the audit team members include:

Process Owners: Provide input on process design and operation, ensuring that the audit covers all critical aspects.
Auditors: Conduct the audit, observe processes, and verify adherence to standards, documenting any findings.
Quality Assurance Representatives: Ensure that the audit is conducted in accordance with quality standards and procedures, and that findings are addressed.
Safety Inspectors: Ensure that safety protocols and emergency response plans are in place and effective and that any safety issues are promptly addressed.

By following these guidelines, organizations can conduct effective LPAs that drive continuous improvement, enhance compliance, and improve operational efficiency.

How Digital Forms Can Help With Digital Layered Process Audits

To streamline their LPA, organizations are increasingly using a digital tool like digital forms and checklists found in Poka. Going digital offers significant advantages over traditional pen-and-paper methods and helps optimize the audit process by facilitating streamlined completion at all organizational levels, improving audit evaluations through a scoring system, centralizing data for easy real-time analysis, as well as providing efficient digital recordkeeping. The use of digital tools in LPAs enhances scheduling, data collection and analysis, and facilitates quicker corrective actions - thereby improving the overall auditing process.

Given the specific scope and objectives of digital layered process audits, it’s essential that the operations management in the areas where these audits are carried out takes full ownership of the process. Through Poka, managers can ensure:

Timeliness: Layered Process Audits can be scheduled and notifications can be sent to auditors.
Proper Designation: Audits can be assigned to dedicated locations or areas.
Results Tracking: Dashboards and reports make it easy to ensure audits are occurring on time and to identify trends in non-conformities.
Issue Resolution: Follow-up actions can be assigned and tracked.

With that being said, let’s dive into Poka’s different product features that can help you take your LPAs to the next level.

1. Digital Forms

Digital Forms play a crucial role in LPAs by providing a structured framework for auditors to document their observations and findings. Automated form scoring is beneficial during LPAs because it allows auditors to assign quantitative targets to individual checks. For example, audits scoring below 85% can be flagged for immediate review or even specific high-risk questions when they are submitted with a potential problem. Answers are given numerical values, and the digital form automatically calculates the final audit score to quickly and easily determine pass/fail rates. This scoring system allows organizations to identify areas that require improvement more precisely by highlighting consistently low-scoring items.

Deviations are inevitable in any process, and LPAs can be effectively managed using the Poka platform. When an auditor identifies a deviation from the established process during an audit, the system can automatically flag it accordingly. Depending on the responses provided by auditors, the form can also adapt accordingly. This feature streamlines the audit process by reducing unnecessary data collection, making audits more efficient and focused.
Furthermore, the ability to create an issue directly from a form enhances the problem-solving process. If a significant issue is identified during an audit, it can be escalated to become an actionable issue. Digital forms work in conjunction with Issues Management, which allows departments across the factory to work together to resolve problems. Audit findings are identified, tracked, and managed until they are resolved, all within the same digital platform.

Digital forms can also be assigned to specific shifts, locations, or equipment, ensuring each worker knows precisely which form to complete. Consolidating all forms into a single application with tailored user assignments prevents confusion from handling multiple files and versions. Additionally, the ability to incorporate media such as images and videos provides invaluable context, allowing workers to visually document and communicate issues or observations. This visual component enhances the clarity of information and facilitates better understanding for other stakeholders.

2. Factory News Feed

Poka's Factory Feed significantly enhances the process of Layered Process Audits by acting as a centralized communication hub. It streamlines various critical aspects of the audit process, including breakthrough improvements, KPI mapping, action plans, shift handovers and layered audits. By consolidating these elements within a single platform, the Factory Feed promotes efficient collaboration and information sharing among different stakeholders involved in the audits.

This centralized approach minimizes communication gaps, reduces redundancy and ensures that all pertinent information is readily accessible to everyone. As a result, Layered Process Audits become more effective and comprehensive, leading to improved overall operational efficiency, better alignment with organizational goals and a streamlined process for identifying and addressing issues at multiple levels of the production process.

3. Analytics & Dashboard Builder

The analytics and dashboard builder feature in Poka empowers organizations with advanced data visualization capabilities. Through visual representations of audit data, trends and metrics, organizations gain deeper insights into the effectiveness of their LPAs. Patterns and anomalies become more apparent - facilitating informed decision-making.

Trend analysis becomes significantly more effective with the ability to analyze historical audit data. By identifying recurring issues over time, organizations can delve into root causes and implement proactive solutions. This contributes to a continuous improvement cycle that drives process excellence. Real-time insights provided by the analytics dashboards enable management to stay updated on ongoing LPAs and their outcomes. Immediate access to data allows for swift responses to emerging issues and better allocation of resources to address pressing concerns.

Moreover, the customization offered by the dashboard builder ensures that organizations tailor their dashboards to their specific LPA requirements. This way, the right stakeholders can access the most relevant information, promoting transparency and accountability in the audit process.

With annual IATF audits being a consistent requisite for companies, it becomes imperative to have a digital trail showcasing that the LPAs have been conducted and monitored and completed consistently. The analytics feature allows companies to have an aggregated view of all activities, ensuring that there's proof of diligence in maintaining quality standards. Beyond merely performing these audits, it's of paramount importance to demonstrate that the LPAs are being completed punctually and subjected to review. The dashboard builder, in this context, offers an organized, visual representation of all relevant data- making it straightforward for auditors to verify the company's compliance.

4. Skills - Digital Work Instructions

Poka Skills facilitates the creation of video-based work instructions for LPAs. These video instructions provide step-by-step guidance to the people conducting the audits, ensuring consistent execution of the audit process. Visual instructions reduce the likelihood of errors and deviations, enhancing the overall quality of audits.

Standardized training is a critical aspect of LPAs, and digital work instructions contribute to this by offering a uniform training experience. Regardless of an employee’s location, they can access the same set of instructions, ensuring that all auditors are aligned regarding procedures and criteria.

Conclusion: How Technology-Driven Layered Process Audits (LPAs) Drive Quality and Operational Excellence

Through their systematic and collaborative nature, LPAs equip organizations to identify challenges early, enhance product quality and cultivate a culture of vigilance. LPAs play a crucial role in quality management by ensuring consistent adherence to standards through structured audits. Incorporating technology into LPAs empowers organizations to enhance their entire auditing process, ensuring efficient data management, improved collaboration and compliance and informed decision-making for sustained operational excellence.

If you want to learn more about how Poka can help streamline your layered process audits, talk to one of our dedicated experts today!

This article was updated in May 2025 for accuracy.

How to Navigate and Master Layered Process Audits