Quality Management Today
In modern quality management, more and more organizations are moving away from traditional audit approaches to adopt more collaborative and effective models. One of the most relevant is the Layered Process Audit (LPA), a practice designed to more accurately verify whether procedures are being correctly executed at all hierarchical levels.
Unlike conventional audits that focus on the final product, LPAs provide a comprehensive view of operational performance, focusing on how processes are executed rather than just what is delivered. This cross-functional approach promotes continuous improvement, fosters a culture of shared responsibility, and enables early detection of deviations for faster corrective action.
What Are Layered Process Audits (LPAs)?
As the name suggests, Layered Process Audits (LPAs) are based on the concept of different “layers” made up of various hierarchical levels of management and production staff who participate in regular audits using checklists.
In layered process audits, everyone involved at each “layer” or hierarchical level performs audits tailored to their specific roles and responsibilities. This means that not everyone conducts the same audit — each focuses on the control areas relevant to their position.
In addition, specific audit frequencies are established for each level, which are defined by the quality team responsible for carrying out the audit. a14> quality team responsible for carrying out these audits. As a general rule, the workers in production usually carry out more frequent checks than management staff, with the help of a QMS such as Kapture.io.
Layered audits take a comprehensive approach that covers a broad scope within the organisation, but their true value lies in their ability to prioritise and delve deeper into the assessment of critical areas. This means that LPAs should focus on examining fundamental processes related to safety and risk management, quality management systems, evaluating the efficiency and maintenance of facilities and equipment, and thoroughly controlling all phases of product manufacturing.
Finally, LPAs should focus on continuous improvement, which means that it is not only about detecting problems, but also about identifying opportunities to optimise and refine existing processes.
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Implementation of Layered Process Audits
Implementing a layered process audit program is a strategic process that requires meticulous planning to ensure its effectiveness.
First, a scheduled program must be established that defines when and by whom the audits will be carried out, according to the “layer” or hierarchical level within the organization. This involves an equitable distribution of responsibilities.
Next, the audit design must be carried out. To do this, questionnaires or checklists should be created to obtain clear and objective answers. In addition, it is advisable to consider including free-text fields or numerical ratings to gather more detailed information. If it becomes necessary to support any response with graphic documentation, the option to attach images or files should be provided.
When nonconformities are identified during the audits, it is essential to record them accurately and completely. Each nonconformity should be evaluated based on its type to determine its severity and impact on the organization. Then, specific action plans should be developed to address each nonconformity. Every action plan must assign a responsible person and establish an estimated resolution date. This ensures that nonconformities are addressed in a timely and effective manner.
Tracking audit results is a crucial part of the process. The data collected during the audits should be analyzed to assess the progress of all parameters and KPIs that indicate how expected result trends evolve over time. In addition, monitoring the actions derived from nonconformities is essential to ensure they are completed as planned and to prevent the same deviations from recurring in the future.
Finally, the support and leadership of the organization’s management play a fundamental role in the success of layered process audits. Their commitment to continuous improvement and quality sends a clear message to all the employees that the management of non conformities and the constant search of the excelence are a priority.
Benefits of Layered Audits
Regarding the benefits obtained, when LPAs are implemented effectively, they help address all the factors that ensure the proper functioning of the entire organizational structure and, consequently, achieve greater profitability.To this end, Layered Process Audits (LPAs) aim to pursue several objectives:
LPAs go beyond simply conducting audits; their purpose is to drive and promote a cultural shift within the organization. By focusing on continuous improvement and quality at all levels, LPAs encourage all employees to take responsibility for quality and to remain committed to maintaining high standards.
Layered Audits with Kapture.io
The implementation of layered process audits requires efficient and centralized data management systems. These systems are essential for collecting, storing, and analyzing the information generated during audits, including results, nonconformities, and action plans. They must be capable of generating customized reports, enabling the tracking of corrective actions, facilitating communication across different organizational levels, and ensuring data security.
This not only streamlines the process but also ensures that audits are carried out in a timely and consistent manner. In addition, the platform contributes to environmental sustainability by reducing paper dependency, while providing real-time visibility into audit results — enabling data-driven decision-making and a more organized, structured approach to information management.
This is how your audits look with Kapture.io
Frequently asked questions
Content reviewed by:
Xavier Conesa Foix, CGO and Co-Founder of Kapture.io QMS
With more than 30 years dedicated to industrial quality improvement, Xavier combines technical expertise and strategic vision to transform quality control and incident management in the plant.
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