Layered Process Audits

Layered Process Auditing, also known as LPA, are a proactive quality tool developed for manufacturing management to ensure control over manual and automated processes. LPAs improve quality, reduce scrap and rework, and increase customer satisfaction.

Layered Process Audits are performed by multiple levels of manufacturing management at different times ensuring process steps are properly followed.

Normally Layered Process Audits are performed on high risk processes. The risk can be identified using the Failure Mode and Effects Analysis. But, increasingly, OEMs expect suppliers to use the process as a means of continual improvement for all processes.

The audits are performed by multiple levels of manufacturing management including:

  • Manufacturing Engineers
  • Quality Engineers
  • Quality Managers
  • Team Leaders
  • Manufacturing Supervisors
  • Plant Managers

To ensure consistency, the same audit criteria is followed by each auditor. And, to rive improvement, an audit report and audit follow up are utilized.

Plantech offers a two day performance packed workshop has you walk away with an action plan designed to reduce Scrap, reduce Warranty Returns generated by manufacturing errors, and improve First Time Through Capability.

Seminar Content

You will learn the DCX and General Motors QSB Layered Process Audit requirements and you will create the necessary audit checklists to support your Layered Process Audit Program. This workshop supports selected TS 16949:2002 and Customer Specific Requirements. This workshop is designed to enhance your current Layered Process Audit Program by conducting Manufacturing Process Reviews with your hourly work groups.

Who Should Attend

Quality Managers, Quality Supervisors, Quality Engineers, Manufacturing Engineers, Production Supervisors, Production Leaders, Quality Technicians, Maintenance Technicians, anyone responsible for making quality improvements.


Basic understanding of process documentation (process flow diagram, PFMEA, control plan).

Seminar Materials

Each participant will receive a seminar manual.

Seminar Goals

  • You will conduct a Manufacturing Process Review of your process documentation including your Process Flow Diagram, PFMEA, Control Plan and Work Instructions of your lowest performing manufacturing cell(s).
  • You will learn how to utilize the Error-Proofing Worksheet to provide a business case to sell your recommended improvement actions.
  • You will gain the understanding of DCX and General Motors QSB Layered Process Audit requirements.
  • You will create process and error-proofing checklists tied to your Layered Process Audit Program.
  • You will create a Walk-away Action Plan that sends you back to your plant with keys-in-hand to drive your plant's quality improvements.

Seminar Outline

Day One

  • What is a Layered Process Audit
  • LPA Requirements and Recommendations
  • Developing the LPA Plan
  • Introduction to Process Review
  • Process Review Team Dynamics
  • Step 1: Process Flow Diagram
  • What is Zero Quality Control?
  • Step 2: Potential Failure Mode & Effects Analysis
  • Error-Proofing Worksheet Overview
  • Step 3: Reviewing & Revising the Control Plan
  • Last Step: Work Instruction Overview

Day Two

  • Review and Update Process Control Documentation
  • Reporting and Managing the LPA Process
  • Reviewing and Approving the LPA Plan
  • Implementing the LPA Plan
  • Maintaining the LPA
  • LPA Best Practices
  • Creating your Walk-away Action Plan

Course Sequence: MPR&LPA

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