How to conduct a Layered Process Audit?
March 20, 2025
Just as a beautifully layered salad combines greens, boiled eggs, bacon, tomatoes, peas, cheese, onions, and creamy dressing into a big bowl, each layer contributes its unique flavour and nutrition. Forgetting to include a base of greens could derail your healthy eating plans by tipping the calorie balance. This simple analogy from everyday life highlights the importance of focusing on seemingly minor details, which are vital components of each layer. However, as humans, we can overlook these details, making it crucial to check—or better yet, audit—each layer. And with that, we’ve served up the concept of a layered process audit in the most lighthearted way. Curious to know how to conduct one?
Layered Process Audit: Knowing your process is like peeling an onion
Every project comprises briefs, milestones, action plans, deliverables, challenges, and more. Without a robust layered process audit interwoven into the project’s development, it’s easy to lose track or miss updates. Think of a project as a cup of tea brewed by a process—while a process audit serves as the strainer to remove inefficiencies and clutter. At LTS, we’ve taken this concept to heart, creating a digital layered process tool for seamless process confirmation. With TCards, conducting a layered process audit becomes as straightforward and visible as a salad dressing! We have covered the best parts of the tools and techniques for layered process audit optimisation comprehensively. Read along.
How to conduct a Layered Process Audit (LPA): Step-by-step guide to conducting a layered process audit
A Layered Process Audit (LPA) is a continuous improvement tool designed to ensure compliance with standardised processes on the shop floor. By auditing processes across multiple organisational levels, LPAs help identify errors, eliminate inefficiencies, and promote continuous improvement. Importance of layered process audits in quality assurance is non-negotiable. Wondering how to improve efficiency with layered process audits?
Step-by-step guide to conducting an LPA for shop floor audit
Conducting an LPA without a structured plan can be futile. To ensure success, you need detailed audit checklists and follow-up routines. The right tools, such as TCards for Process Confirmation, are also crucial. Below are expert tips and actionable steps from our team of lean experts:
1. Define objectives
1. Define objectives
- Purpose : Identify specific goals for the LPA, such as improving product quality, ensuring process standardisation, or reducing defects.
- Expert Tip : Align LPA objectives with broader organisational goals, such as achieving ISO certifications or improving customer satisfaction.
- Tasks :
- Define the scope, including areas, processes, and timelines.
- Establish frequency (daily, weekly, monthly).
- Assign responsibilities to multiple layers (e.g., operators, supervisors, managers). - Expert Tip : Use digital tools like TCards for Process Confirmation, to schedule and track audits, ensuring no process is overlooked.
- Tasks :
- Develop concise, process-specific checklists focusing on critical-to-quality (CTQ) aspects.
- Include questions on compliance, safety, equipment maintenance, and procedural adherence. - Expert Tip : Regularly update checklists to reflect process changes or customer feedback.
- Tasks :
- Provide training on audit objectives, tools, and techniques.
- Emphasise consistency in audit execution across all layers. - Expert Tip : Conduct mock audits during training to build confidence and ensure clarity in roles.
- Tasks :
- Perform audits at scheduled intervals, ensuring each layer follows its specific checklist.
- Observe processes in real-time to identify discrepancies between actual practices and documented standards. - Expert Tip : Encourage open communication with shop floor operators to uncover hidden issues.
- Tasks :
- Record observations, deviations, and compliance data.
- Use standard templates or software for consistent reporting. - Expert Tip : Categorise findings by severity to prioritise corrective actions effectively.
- Tasks :
- Address non-compliance issues promptly.
- Develop a root cause analysis for recurring issues.
- Assign accountability for corrective actions. - Expert Tip : Integrate findings into a continuous improvement framework, such as Kaizen.
- Tasks :
- Analyse audit data to identify trends and improvement opportunities.
- Share findings with relevant stakeholders. - Expert Tip : Use visual dashboards to present key metrics like compliance rates and defect reduction.
- Tasks :
- Update the LPA plan based on audit insights.
- Enhance training, checklists, or audit frequency as necessary. - Expert Tip : Conduct periodic reviews to ensure the LPA remains aligned with organisational goals.
Layered process audit checklist for compliance and quality control
Use this checklist to ensure a structured and efficient approach to conducting LPAs. Each step includes key points to focus on during the audit. Are you in search of digital tools to streamline compliance audits with layered process audits?
1. Pre-Audit preparation
3. Post-audit documentation
1. Pre-Audit preparation
- Define the objectives and scope of the LPA.
- Develop process-specific checklists focusing on critical-to-quality (CTQ) elements.
- Determine audit frequency (daily, weekly, monthly).
- Assign responsibilities across layers (operator, supervisor, manager).
- Ensure all auditors are trained and understand their roles.
- Schedule audits and notify relevant personnel.
- Verify Standard Operating Procedures (SOPs):
- Are the SOPs accessible and updated?
- Are operators following documented processes?
- Evaluate Equipment Conditions:
- Are machines calibrated and functioning correctly?
- Is preventive maintenance documented and up-to-date?
- Assess Process Compliance:
- Are CTQ parameters met (e.g., temperature, torque, dimensions)?
- Are deviations or variances recorded?
- Check Safety Protocols:
- Is personal protective equipment (PPE) in use and in good condition?
- Are safety guards and emergency stops functioning?
- Inspect Work Environment:
- Is the workspace clean and organised (5S compliance)?
- Are materials stored and labelled correctly?
- Engage Operators:
- Do operators understand their tasks and quality expectations?
- Are there suggestions or concerns from the shop floor team?
3. Post-audit documentation
- Record all findings systematically using an LPA template.
- Classify findings as compliant, non-compliant, or improvement opportunities.
- Capture photographic evidence of critical issues (if applicable).
- Highlight areas requiring immediate corrective actions.
- Assign responsibility for corrective actions with deadlines.
- Ensure root cause analysis is performed for recurring issues.
- Monitor the implementation and effectiveness of corrective actions.
- Update processes and training materials as needed.
- Analyse trends from multiple LPA results to identify systemic issues.
- Share audit findings and improvement plans with stakeholders.
- Update the LPA checklist periodically to reflect process or regulatory changes.
- Schedule re-audits to verify sustained improvements.
Additional Tips
- Be Consistent: Use the same audit checklist for each layer to ensure comparability.
- Stay Objective: Focus on facts and data, avoiding assumptions or biases.
- Promote Engagement: Encourage operators to participate and provide insights.
- Utilise Tools: Leverage TCards or digital apps to track and streamline the audit process.
How TCards for Process Confirmation help in Layered Process Audits (LPA) (More than just a visual treat!)
Are you enroute to conducting lean layered process audits for manufacturing processes? TCard systems are simple, visual tools used to organise and track tasks, including process confirmation activities. In the context of Layered Process Audits (LPA), TCards enable streamlined tracking of audit schedules, responsibilities, and findings. They promote transparency and real-time updates, making LPAs more efficient and effective. Want to know why Digital TCard systems are key to effective Layered Process Audits?
Features of TCards for Process Confirmation in LPAs
| Feature | How It Supports LPAs | Real-Life Example on Shop Floor |
|---|---|---|
| Visual Tracking | Displays tasks, schedules, and status in a clear, visual format, ensuring everyone is informed. | A TCard board shows daily LPA tasks, with cards colour-coded (e.g., Green = Completed, Red = Pending). |
| Customisation | Allows creation of process-specific templates for audits. | A TCard includes critical-to-quality (CTQ) checkpoints for auditing a CNC machining process. |
| Compliance Indicators | Colour-coded cards (e.g., red/green cards for compliance). | Digital status indicators, such as colour-coded flags with detailed notes. |
| Accountability | Assigns tasks to specific layers (operators, supervisors, managers) using labelled cards. | Cards labelled with "Operator Audit" or "Manager Review" track who needs to perform each LPA step. |
| Real-Time Updates | Provides an up-to-date view of audit progress and findings. | A supervisor moves a card from "In Progress" to "Completed" after verifying the assembly line process. |
| Integration with Digital Tools | Can integrate with digital systems for automated tracking and reporting. | TCards linked to a tablet notify managers of overdue audits on robotic welding processes. |
| Continuous Improvement | Facilitates recording findings and follow-ups for corrective actions. | Cards for "Non-Conformance" are flagged, prompting a root cause analysis for recurring welding defects. |
Real-life example: Using TCards on a shop floor
| Scenario | Process | Role of TCards |
|---|---|---|
| Audit Scheduling | A daily LPA plan includes checking machine calibration, safety protocols, and operator compliance. | TCards display tasks for each day, showing audit layers and ensuring coverage of all processes. |
| Compliance Tracking | Supervisors check operators’ adherence to documented SOPs on an assembly line. | TCards list specific checkpoints, such as torque settings or component placements, and mark compliance status. |
| Corrective Actions | An operator notices a temperature deviation during an LPA for heat treatment. | A TCard is moved to "Action Required," triggering a supervisor to initiate process adjustments. |
| Managerial Oversight | Managers perform a weekly review of the LPA effectiveness and compliance trends. | TCards summarise audit results and highlight recurring non-conformances, supporting data-driven discussions. |
| Safety Protocol Checks | Auditors verify the availability and condition of PPE on the shop floor. | TCards track inspection points for each PPE category, marking defects for replacement or repair. |
Benefits of using digital tools for layered process audits
- Simplifies task management : Clear visual representation ensures no step is missed.
- Enhances communication : Promotes transparency among operators, supervisors, and managers.
- Improves accountability : Tracks responsibilities and deadlines at all levels.
- Supports real-time monitoring : Provides immediate updates on audit progress.
- Facilitates continuous improvement : Identifies trends and ensures timely corrective actions.
Streamline your Layered Process Audits with TCards—Your key to shop floor audit excellence!
Mastering the art of conducting a Layered Process Audit (LPA) is essential for ensuring compliance, improving process quality, and driving operational efficiency. With its simple yet powerful visual management capabilities, TCard systems revolutionise LPAs by providing real-time tracking, accountability, and seamless organisation across all layers—from operators to managers. Whether it’s scheduling audits, monitoring compliance, or implementing corrective actions, TCards ensure nothing slips through the cracks. Ready to elevate your shop floor operations? Make TCards your ultimate tool for effective LPAs and achieve consistent, measurable improvements today!
FAQs
1. What is a Layered Process Audit (LPA)?
A Layered Process Audit (LPA) is a systematic approach where multiple levels of management review processes to ensure compliance and identify areas for improvement.
2. Why are Layered Process Audits important?
LPAs help maintain process consistency, enhance product quality, reduce defects, and ensure adherence to standard operating procedures (SOPs).
3. Who conducts a Layered Process Audit?
LPAs are conducted by employees from different levels of management, including supervisors, team leads, and higher-level executives.
4. What tools are needed for a Layered Process Audit?
Common tools include checklists, audit templates, and software solutions for tracking and reporting audit results.
5. How often should Layered Process Audits be performed?
The frequency of LPAs depends on the organisation’s needs, but they are typically performed daily, weekly, or monthly.
A Layered Process Audit (LPA) is a systematic approach where multiple levels of management review processes to ensure compliance and identify areas for improvement.
2. Why are Layered Process Audits important?
LPAs help maintain process consistency, enhance product quality, reduce defects, and ensure adherence to standard operating procedures (SOPs).
3. Who conducts a Layered Process Audit?
LPAs are conducted by employees from different levels of management, including supervisors, team leads, and higher-level executives.
4. What tools are needed for a Layered Process Audit?
Common tools include checklists, audit templates, and software solutions for tracking and reporting audit results.
5. How often should Layered Process Audits be performed?
The frequency of LPAs depends on the organisation’s needs, but they are typically performed daily, weekly, or monthly.
