A Layered Process Audit (LPA) is a systematic method to ensure that standardised processes are followed correctly in production. It involves an overlapping layered audit in which employees at different levels conduct a review of processes at regular intervals.
The purpose of an LPA is to evaluate the effectiveness of process controls and to ensure that all employees are following standard operating procedures (SOPs). The LPA aims to identify potential quality problems early and correct them before they lead to errors.
The LPA usually includes a checklist of questions and criteria that auditors use in their review. These criteria are adapted to the specific processes and requirements of the company.
Typically, LPAs are conducted at different levels of the company, such as supervisors, process managers, quality controllers or team leaders. Overlapping shift controls ensure that multiple employees can review the same process and work together to identify quality issues.
The results of the LPAs are documented and analysed to identify trends and patterns in process deviations. Based on this data, appropriate actions can then be taken to improve process quality.
Overall, the Layered Process Audit is an effective method to ensure that processes in production are followed correctly and that the quality of the manufactured products is guaranteed.
The best software solution for pragmatic, operating LPA.
Layered Process Audit (LPA) is a very efficient method to improve the results of your processes continuous and sustainable.
The LPA Manager meets the requirements of IATF 16949.
Typical challenges
- Motivate executive managers for the procedure of LPA
- Diversify the LPA-Questions
- Overload of Excel
- Archive the completed LPA checklists
- Great effort to administrate the questions and checklists
- A lot of trouble by formatting the checklists
- Results have to be typed in manually
- LPA is done to satisfy the costumer and the own benefit is not recognized
- Unsatisfying results do not lead to improvements
- LPA is not accepted
- Non-transparent methods
- Overextended staff
- Claim of standards (IATF16969)
How does the LPA Manager work?
- Individual questions, targeted questioning
- Questions concerning condition and activity
- Focus on solutions
- Focus is to work with people and use methods and techniques. Not the other way around!
- We bring people together across hierarchies and work on lasting solutions for daily (quality) problems.
- LPA works in every department of the company. F.e. Production, Administration and Organisation.
* NEW! *
LPA questions can now also be marked as “VDA relevant”. Simply assign a question to a VDA test point and recognize the results via the VDA catalog or the layer structure based on the usual traffic light functions. Certainly a valuable support for your future VDA audits.
There are no additional expenses for audits. You simply let “LPA questions with VDA relevance” flow into your LPA and prove that VDA 6.3 is implemented sustainably for you.
LPA – step by step.
1. LPA checklists
- LPA Manager will dynamise your LPA.
- LPA Manager allows to generate individual lists of questions.
- Questions getting assigned to categories.
- LPA Checklist align to the result you aim to.
- New questions can be generated and used immediately – Response time to complaints and internal errors goes to zero.
2. LPA execution
- LPA manager supports in the operational planning of the audits and provides the infrastructure for the execution.
- The audits can be executed without any mediabreak in the OS you want – PC, Tablet or digital Pen.
- The recorded data is immediately available, worldwide.
- The Audit- evidence and –history is documented effortless and saved by the LPA manager.
3. LPA analysis
- The Audit results can be visualized without any further effort.
- Data is automatically compressed to the top and displayed as suitable for management – individually configurable.
- Analyses are scalable for every user.
- LPA Boards will be shown in the App and automatically updated.
- The success of LPA is proofed and documented by key figures.
4. LPA measures
- The accured measures will be collected to track them – Interfaces to consisting Systems are possible.
- Every measure is retraceable to the LPA Audit question.
- The time between the definition and the realisation of the measure is recorded.
- The effectiveness of the measures is automatically tracked by the LPA Manager.
- Modules of escalation to execute the measures are presentable by the LPA Manager.
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