Layered Process Audits (LPAs) are a quality improvement strategy that has gained relevance in the recent past. Where it has been well implemented, it has been able to reduce waste, improve First Quality, curb costs, and improve throughput. It can also transform a company’s culture to embrace continuous process improvement. This strategy helps move the company from a reactionary stance to actually monitoring its operations and preventing problems in critical processes.
What is Layered Process Auditing?
LPA is a quality management system in the manufacturing sector designed to add protection layers against critical risks in the process. Among these risks are customer complaints, rework, product recalls, or reputational damage. Unlike other quality assurance systems that look at the final product, this one is used in the private sector during the manufacturing process.
The word “layered” means that there are different classes of auditors in the manufacturing process, all provided with the same set of audits to ensure that that production process does not deviate from the specifications.
How to Create a Layered Process Audit
A successful process audit combines several components and a coordinated effort from different departments involved in the supply chain and production. Here are three of the most critical layers on the component list:
Auditor’s Layer
This layer consists of auditors who double-check processes to ensure that all standards are followed and that any non-conformance is dealt with as soon as it is noted. These auditors conduct identical investigations and inspections using a standard audit template to address various inefficiencies. In most cases, shift supervisors do the daily internal audit activity while top and middle management do weekly or monthly checks.
An Audit Layer
For auditors to do their work perfectly, they need to have a template that shows the process. The company creates a few templates based on the number of processes it looks at with the help of auditors. These templates should be short and easy to answer so that auditors can answer them fast and accurately. In addition, they should have an effective layered process audit questions.
Reporting Audits, Follow-up, and Problem Containment
Once the process audits are completed, the reports should be distributed to the appropriate personnel as soon as possible. This is so that appropriate actions can be implemented as soon as the next production takes place. Sometimes, the processes may have to be stopped if the issues at hand lead to significant errors in the final products.
Once the corrective measures are instituted, there should be a way to check if the issues reported were resolved. This is where follow-up becomes important. The auditors will check for non-conformance and the success of the corrective measures in their next audit. This helps prevent similar issues from happening again.
Both reporting and processes can be done well with the right software to help the relevant personnel track all processes and determine if the corrections were successful. In addition, the records serve as a store of data should the same problem recur in the future. In addition, several audit reports are analyzed and put together to help the organization identify trends affecting production.
For example, the report can show issues with the timely delivery of raw materials or substandard materials. If such cases recur regularly, it shows that the quality or supply chain process is affecting production. This can help the company take the required steps to plug the gaps causing problems with delivery or sourcing better raw materials.
Areas in Production That Require Regular Audits and Peak Response Interventions
Several areas may require real-time analysis to ensure peak response and prevent poor quality output, higher costs, or downtime. Here are some of the areas:
• The security and integrity of the data system
• The quality and timely delivery of raw materials
• Quality checks at each level of the manufacturing process
• Timely delivery of the final product
• Actual processes used in manufacturing individual parts or components
According to the area the company is looking at, the preventive measures taken will vary. For example, there can be security awareness training for teams working on data and IT systems to ensure compliance. A related equipment audit can be done to check for critical hardware in the production process.
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