What is Layered Process Audits?

The Layered Process Audit (LPA) is a tool that has been developed for manufacturing management. It is an effective tool that drives cultural change throughout an organization to improve quality, reduce scrap and customer rejections. Acting as a formalized system, it focuses time and energy towards insuring high risk processes and error proofing devices to ensure that they do not exhibit a lot of variation and are working properly. It is a set of audits on high risk processes, used as system of reporting and following up to ensure containment is appropriate and to drive improvement. It is organized into a simple group of questions designed to examine, advise, or process. The process reduces variation in production and improves/maintains discipline. As a result, there is scrap reduction and elimination of wastes while at the same time improving discipline and communication. The audit is performed by multiple levels of supervision and management to monitor key process characteristics and the verification process on an ongoing basis.

Benefits of Layered Process Audits?

  • Reduces variation in production, improves and maintains discipline.
  • Reduces scrap and eliminates waste.
  • Improves discipline and communication
  • Increases employee participation.
  • Improves overall quality and cuts costs.
  • Stops production processes from being rejected.
  • Helps the management of organizations and businesses to own the audit process.
  • Helps in identification and asking of the right questions.
  • Influences participation from all of the management layers.
  • Helps businesses and organizations to deal with non-conformity through immediate containment.
  • Assists organizations and companies in implementing a process of continuous improvement within an organization or business.
  • It places a demand on businesses and organizations to schedule and perform audits regularly.
  • Prevents or corrects the most common mistakes made in developing and implementing layered process audits.
  • Forces organizations and businesses to enhance their competitive advantage.
  • Identification of variation in high risk processes that lead to production of the non conforming products.
  • Identification of error proofing systems that become ineffective over time.
  • Leads to the creation of appropriate containment measures which prevent bad products from shipping and reduces/eliminates customer rejections.
  • Helps the management of organizations and businesses to have an exact location to where they can direct their resources to review systems, identify problems, and find their root causes.

Our approach

QSE adopts a “Ten Step Approach” to Implementation. This approach, designed and perfected by QSE, addresses each facet in an easy to implement manner. Tools merge with each other seamlessly and so effortlessly that the end product is a top-notch quality.