Layered process audit poster

A layered process audit (LPA) is a short, frequent check that the process is being run to its standards, done by several layers of leadership, from team leaders every shift to the plant manager on a set rhythm. Each layer asks a few yes or no questions at the station, fixes small things on the spot and records the rest. This poster gives the layers with blank frequencies to fill in, six rules and sample questions.

Download the poster

The PNG is free to download now. The print-ready vector PDFs open after a short form, once.

Download PNG (300 dpi)2550 x 3300 px, prints at 8.5 x 11 in · 396 KB · no form

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Layered process audit poster — 24 x 36 in18 x 24 inA2A3LetterA4PNG 300 dpi

The words on the poster

Layered process audits

Short checks of the process, done at every level of leadership.

Who checks, how often

Team leader Every shift
Supervisor Every ____
Managers Every ____

Rules

At the station, not in the office
A few yes or no questions
Check the process, not the person
Fix small things on the spot
Record and follow up every no
Rotate questions. Trend the answers.

Sample questions

Is the work instruction at the station and current?
Are the gauges in calibration?
Was the first-piece check done and signed?
Are suspect parts tagged and in the hold area?

On the floor

How to use it

Putting the Layered process audit poster to work

1
Write in your own frequencies for each layer before you print.
2
Post it on the LPA or kamishibai board where the audit cards hang.
3
Rotate the sample questions with your own, from your control plan and recent defects.
4
Pair it with the free process audit checklist and standard work audit checklist.

Where the poster goes and how to teach with it, in the order to try them.

Which size to print

24 x 36 in or A2: a main wall or team board, read from a few metres away.
18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
Letter or A4: a clipboard, binder or handout, on any office printer.

Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.