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Free checklist · Word + PDF

Layered process audit (LPA) checklist

A two-page LPA form for a short check at one station, done by several layers of leaders, plus a filled week of audits from a fictional press-fit station. Free, no card.

Get the free LPA checklist

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What is in the checklist

  • Audit details: Station, part, date and shift, auditor and layer, and the control plan and work instruction revisions found at the station.
  • 10 station questions: Each answered OK, NOK or N/A, with a box for a NOK fixed on the spot and a note. Replace them with the risks of your station.
  • Findings that need an action: Each NOK not fixed on the spot, with action, owner, due date and closure.
  • Who audits and how often: A table for your plant's layers, people, frequencies and stations.

The questions are a generic starting set. If your customer or your procedure prescribes LPA questions, layers or frequencies, use theirs.

The filled example

Pages 1–2 are the blank form. Page 3 shows one fictional week of LPAs at the bushing press from the control plan template example. The questions come from that control plan: the locating-pin check, the seeded master part at shift start, the force monitor and the push-out record. In the week, 17 audits give 170 answers with 3 NOK; 2 are fixed on the spot and 1 becomes an action with an owner and a due date. All companies, people and data are invented.

LPA vs a process or system audit

A process or system audit looks at a whole process or quality system in depth, at longer intervals. An LPA is a short check at one station, repeated by different layers of leaders, and checks that the controls already decided are still being done. After an 8D, LPA questions are one way to check that the D7 changes to the control plan and work instruction stay in place.

Quick checks for good LPA questions

  • Each question can be answered by looking at the station or a record, without opinion.
  • Questions point at the controls that matter for this station: special characteristics, mistake-proofing, reaction plans.
  • A NOK has a note, and if it is not fixed on the spot it gets an owner and a due date.
  • Questions are updated when the control plan or the work instruction changes.

Related

Advisory template, in English. Not a customer decision.