What you’Il learn in 7 minutes
Layered Process Audits (LPAs) are a structured approach to quality control that involves multiple levels of an organization. By regularly auditing processes and identifying issues early on, LPAs help to improve quality, reduce risks, and ensure compliance with regulations.
  • Multiple Layers of Auditing: LPAs involve frontline employees, supervisors, managers, and executives, each with a specific focus and scope of assessment.
  • Benefits of LPAs: LPAs can help to reduce risks, improve quality, ensure compliance, and foster a culture of continuous improvement.
  • Efficiency and Insights: LPAs provide actionable insights through structured audits, helping organizations identify non-conformities early and implement preventive measures effectively.

Auditing processes in the manufacturing, distribution, and healthcare sectors is not merely a luxury; it’s the cornerstone of any organization striving for excellence in its products and services. Maintaining high-quality, safe, and efficient procedures cannot be overstated since the repercussions of subpar standards can be damaging, leading to lost customers, rework, product recalls, and reputational damage.

What are Layered Process Audits (LPAs)?

Layered Process Audits (LPA) are structured audits conducted across multiple organizational layers or levels to ensure process compliance. LPAs involve frontline employees, middle management, and upper management. Auditors follow an audit checklist and verify different workplace areas, processes, or assessment criteria depending on their level of authority.

 

LPAs are a robust quality, safety, and efficiency technique that shifts the focus from inspecting finished products and services to validating the processes that produce them. At their core, LPAs are a proactive approach to management. The primary objective is consistently following operational procedures, maintaining quality standards, rectifying deviations at the earliest possible stage, and driving continuous improvement.

At the heart of Layered Process Audits are multiple layers within an organization. These layers involve individuals from various management tiers, each with a distinct focus and scope of assessment:

Layer 1 – Frontline Employees and Operators:

Frontline employees conduct audits within their workstations or areas. Their audits concentrate on adhering to safety standards and standard operating procedures (SOPs). These employees are well-positioned to identify issues as they are directly engaged in day-to-day operations.

Layer 2 – Team Leaders and Supervisors:

Team leaders or supervisors play a pivotal role in conducting audits. These audits mainly verify that team members follow established procedures and safety protocols.

Layer 3 – Managers and Directors:

Middle managers (production managers or department heads) participate in LPAs to assess overall performance. They review processes, resource allocation, and efficiency, often identifying training needs, resource requirements, or improvement opportunities.

Layer 4 – C-Level Executives:

Senior management (top executives) engage in LPAs to gain a high-level view of the organization’s processes. Their audits focus on strategic aspects, such as alignment with organizational goals and regulatory compliance. Senior management’s involvement underscores its commitment to quality and continuous improvement.

Cross-functional Teams:

LPAs may also involve cross-functional teams collaborating to address non-conformity identified during audits. These teams guarantee a comprehensive strategy for overseeing quality, safety, and efficiency control.

Quality Assurance and Continuous Improvement Teams:

Quality assurance and continuous improvement teams are the driving force behind LPA programs. They coordinate the audit schedule, provide training, and promptly take corrective actions. These groups play a crucial role in fostering a culture of accountability.

The overarching principle in conducting LPAs is collaboration among all management levels, relentlessly focusing on transparency, accountability, and continuous improvement.

LPAs involve multiple layers of auditors across the organization, each with a different scope.

The frequency of Layered Process Audits varies depending on the level conducting the audit: the closer an auditor is to the audited area, the more frequently they will complete the audit. For instance, a line supervisor may perform daily audits, while a plant manager might conduct monthly audits.

Moreover, LPA schedules are an essential tool when implementing Leader Standard Work. Set the LPA schedule for regular assessments and choose from daily, weekly, monthly, or custom recurrence to ensure auditors stay on top of their deadlines.

Schedule Layered Process Audits in your auditors' calendars to ensure timely assessments.

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How to conduct Layered Process Audits

Layered Process Audits are structured processes involving several vital steps. Here’s a roadmap for conducting effective LPAs:

  1. Define Critical Processes:

    Begin by clearly outlining the processes that require auditing. These could include safety protocols, quality control procedures, and more.

  2. Create Audit Checklists:

    Develop detailed checklists or assessment criteria to comprehensively cover each step of the audited processes. These checklists serve as a guide for auditors to evaluate compliance.

  3. Assign Auditors:

    Assign individuals from each management level to conduct audits. For example, team leaders could audit frontline operators. Managers could audit team leaders, et cetera.

  4. Schedule Auditing Frequency:

    Set daily, weekly, monthly, or custom audit frequencies in auditors’ calendars to increase ownership and adherence to best practices.

  5. Conduct Audits:

    Regularly conduct audits using checklists. Auditors verify the processes and identify any non-compliance.

  6. Document Findings:

    Audit findings, both positive observations and areas requiring improvement, must always be documented and delegated to the appropriate team.

  7. Analyze Data:

    Collect and analyze audit data to discern trends, recurring issues, and potential areas for process enhancement.

  8. Manage Corrective and Preventive Actions:

    When auditors identify discrepancies or issues, they must define actions, escalate or assign them to the right management layers, and involve cross-functional teams.

  9. Feedback Loop:

    Share audit results and improvement actions with relevant stakeholders. Transparency is critical to building awareness and accountability.

In brief, establishing clear roles and responsibilities for each layer is necessary to ensure that findings from LPAs are not just isolated observations but catalysts for meaningful progress.

Importance of Layered Process Audits

Layered Process Audits hold significance in process improvement, quality, and safety control. Here’s why they are indispensable:

Above all, the benefits of LPAs extend beyond tangible improvements to include intangible gains, such as increased floor time for management, reinforced process steps, and the demonstration of the importance of critical processes to the entire organization.

Industry leaders leverage Tervene to perform their audits & inspections

Without Tervene today, I wouldn't be able to perform my job as effectively.
Jacques Aumont
Director of Operations, Groupe Bouhyer

Benefits of digitized Layered Process Audits

The transition from traditional paper-based audits to digital Layered Process Audits offers countless advantages:

Digital LPAs also improve visibility into document modifications, prevent manual errors, and facilitate continuous improvement initiatives. With digital solutions, users can assign audits efficiently, ensuring that the right individuals receive the correct requests at the right time.

Digital Layered Process Audit tools

Digital Layered Process Audit tools are at the forefront of enabling organizations to implement an LPA Program and to conduct audits quickly and efficiently. Digital LPAs offers a wide range of features and benefits, including:

Tervene: Leader of digital LPA tools

Tervene is a leading provider of digital Layered Process Audits. Our tools empower organizations to enhance quality, efficiency, and compliance. With a proven track record across manufacturing and healthcare industries, Tervene helps hundreds of clients reach new heights of operational performance.

Tervene makes LPAs effortless

  • Perform your LPAs on mobile or tablet
  • Build custom LPA checklists
  • Schedule periodic LPAs
  • Report and monitor LPA compliance throughout your team
Discover Tervene’s LPA tools

FAQ: Layered Process Audits (LPAs)

Layered Process Audits are structured audits conducted across different organizational levels. They focus on verifying compliance with processes rather than inspecting finished products, ensuring operational consistency, quality, and safety.

LPAs involve employees at all levels:

  • Frontline workers audit daily processes at their workstations.
  • Supervisors verify compliance with safety standards and team procedures.
  • Managers assess broader performance and resource allocation.
  • Executives evaluate strategic alignment and regulatory adherence.

LPAs help identify and mitigate risks early, improve product quality, reduce rework or recalls, ensure compliance with certifications like ISO 9001 or ISO 45001, and foster a culture of accountability and continuous improvement.

The frequency depends on the auditor’s level. Frontline audits may be daily, supervisors typically audit weekly, and managers and executives conduct audits less frequently, such as monthly or quarterly.

LPAs involve these steps: defining critical processes, creating detailed checklists, assigning auditors from different levels, setting a regular audit schedule, documenting findings, analyzing trends, and managing corrective actions.

Traditional audits focus on end products or periodic evaluations, while LPAs emphasize process validation at every level of the organization and occur more frequently.

Digital tools simplify scheduling, data collection, and analysis. They reduce errors, enhance data security, and provide instant feedback, enabling faster corrective actions.

Yes, LPAs complement systems like Leader Standard Work and continuous improvement initiatives, making them versatile for enhancing overall operational excellence.

Manufacturing, healthcare, and distribution industries benefit significantly by reducing errors, improving compliance, and streamlining operations.

LPAs ensure processes are consistently followed, minimize risks, and reinforce quality standards, helping organizations maintain competitive advantages and meet regulatory demands.