QM Bench

Layered Process Audit (LPA) Checklist Online with PDF

Tick OK, NOK or N/A at the station, note the reaction and get the score and a PDF report. Audits are saved in your browser.How to use ↓
  1. 1Enter your data
  2. 2Read the verdict
  3. 3Download the PDF report
Saved in this browser

Click OK, NOK or N/A for each item. A NOK opens fields for the finding and the immediate reaction.

Safety and workplace

  • L1

    Operator wears the required protective equipment for this station.

  • L2

    Workplace is clean and organised, only the parts and tools for the current job are at the station.

  • L3

    Emergency stops, guards and light curtains are in place and work.

Standard work

  • L4

    Current work instruction is available at the station and matches the part being produced.

  • L5

    Operator follows the work instruction (observe one cycle).

  • L6

    Operator is trained and released for this station (training matrix).

Quality checks

  • L7

    First-off / start-up check was done and recorded for this shift.

  • L8

    In-process checks are done at the frequency in the control plan and recorded.

  • L9

    Gauges in use are calibrated, identified and within the calibration date.

  • L10

    Control chart or check sheet is up to date and out-of-control points have a reaction recorded.

Process and material

  • L11

    Process parameters (temperature, pressure, speed, torque) are within the specified window.

  • L12

    Error-proofing devices were verified at start of shift and work.

  • L13

    Material is identified and traceable, no unlabelled containers.

  • L14

    Nonconforming parts are segregated in a marked red box or area.

Follow-up

  • L15

    Findings from the previous audit at this station are closed or have an action in progress.

  • L16

    Operator knows the reaction plan when a part is out of tolerance (ask).

Photos (evidence)

How to run a layered process audit

  1. Pick the station from the audit schedule. Each layer audits on its own frequency.
  2. Observe, do not interview. Watch one cycle, look at the records and the gauges, ask the operator only what you cannot see.
  3. Rate each item OK, NOK or N/A. A NOK opens fields for the finding and the immediate reaction.
  4. React on the spot: correct the label, segregate the part, retrain the operator. Record what was done.
  5. Follow up open actions at the next audit. The last question in the checklist checks exactly that.

Typical layers and frequency

LayerWhoFrequency
1Team leaderEvery shift
2Supervisor, quality engineerWeekly
3Department or production managerMonthly
4Plant managerQuarterly

What to include in the checklist

Take the items from the control plan and the process FMEA: high-risk failure modes, special characteristics, error-proofing checks and reaction plans. Add items from recent customer complaints and 8D reports so the fixes stay in place.

Frequently asked questions

›What is a layered process audit?

A short, frequent check of the critical process controls at a station, done by several levels of the organisation: team leaders every shift, supervisors weekly, managers monthly and the plant manager quarterly. It confirms that the standard work and the controls in the control plan are really followed.

›How long should an LPA take?

About 10 to 15 minutes. Keep the checklist to 10 to 20 items that matter most for quality and safety at that station, and rotate stations so every area is covered.

›What happens when an item is not OK?

Fix it on the spot if possible (immediate reaction), record what was done and, if the issue cannot be fixed at once or repeats, open an action with an owner and a due date. Repeated findings on the same item point to a systemic problem that needs a root cause analysis.

›Is LPA required by IATF 16949?

IATF 16949 requires manufacturing process audits, and several automotive customers (for example GM, Ford and Stellantis in their customer-specific requirements) require layered process audits explicitly. Check your customer-specific requirements.

›Can I change the questions?

Yes. Click “Edit checklist” to rewrite, add or remove questions. The changed checklist is saved with the audit in your browser.