What’s the difference between a normal process audit and a layered process audit?

The main difference between a normal and layered process audit is who is involved and how often the audits happen. In a normal process audit, only quality department auditors check processes. In a layered process audit, people from all levels of the organization, including top management, join in. Supervisors conduct audits more often in their areas, while upper managers do them less frequently but cover more areas. This approach ensures quality is valued at every level and it helps catch more errors via multiple checkpoints.

What steps should I take to start an LPA program?

To build an effective LPA program, you should focus on the plan-do-check-act approach:Plan: First steps include learning about LPAs, creating your team, writing questions and determining audit layers. Do: Rolling out your LPA program requires disciplined scheduling, as well as a closed-loop system to manage findings. Check: Data analysis is key to assessing performance and leveraging results for further gains. Act: Continuous improvement means ongoing engagement and updates to questions.

Digitized LPAs

Layered process audit software.

Catch non-conformances at every layer. Fix findings for good.

Create, schedule, and close out Layered Process Audits (LPAs) digitally, so your time goes to improvement instead of admin. Catch the gap between your standards and your floor, layer by layer, shift by shift.

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Built-in efficiency drivers with layered process audits.

Mobile Auditing

Run your audits at the line, on a phone, even offline, with AI translation into 29 languages.

Scheduling

Schedule every layer, shift, and line for the year in a few clicks. Complete visibility and notifications keep it on track.

Reporting & Dashboards

Track the leading indicators of your operational performance, live, on dashboards configured your way.

Question Library

Build and edit your own questions: store, rotate, and randomize from one central library.

Closed Loop Corrective Action System

Own every finding, and when issues run deep, drive root cause and problem solving with Action Plans.

Email Notifications & Escalations

Keep everyone accountable: notifications for scheduled audits, completed work, and anything past due.

ROI Calculator

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Calculate your return and build a business case your whole leadership team can get behind, with data from organizations like yours.

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I highly recommend EASE to any organization using paper and pencil or other manual spreadsheet LPA systems. The savings in administrative tasks and data collection is well worth the investment.

John Rose

Quality Systems Manager at Jacobs Vehicle Systems

What are LPAs?

Layered Process Audits (LPAs) are an essential audit type where multiple layers of management evaluate product and process quality at random intervals. Discover what makes LPAs such a crucial tool for quality assurance in manufacturing.