Free training deck
Updated · About 45 minutes
Layered process audit (LPA) training presentation
A layered process audit (LPA) is a short check, done at the station, that the critical steps and controls of a process are still being followed. Several levels of leadership run it on their own schedules. This free deck teaches the method in about 45 minutes, using the AIAG CQI-8 Layered Process Audit Guideline as the reference. Its 19 editable slides cover what an LPA is, why controls drift, the layers, how an LPA differs from other audits, what CQI-8 adds, where the questions come from, weak versus good questions, the five steps of an audit, handling a no, scheduling, reading the results, an illustrative worked example, the common mistakes, a 20-minute practice audit and four check questions with answers. Every slide has speaker notes.
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The title Layered process audits (LPA), on a navy background with the LeanSuite logo.A look inside
What is in the 19 slides
For team leaders, supervisors, managers, quality engineers and plant leadership who will carry out or receive layered process audits. Widescreen, in plain language, with speaker notes on every slide.
Slide 5: The layers 
Slide 14: Example: a gauge in the wrong cell 
Slide 16: Try it: run a five-question audit
- 1Layered process audits (LPA): checking the controls still holdCover
- 2AgendaWhat an LPA is and why controls drift · The layers and how an LPA differs from other audits · Writing and asking good questions · Handling findings, scheduling and results · Example, common mistakes and a practice audit
- 3What a layered process audit isA short check at the station that the controls protecting the product are still in place.
- 4Why controls driftA control that worked in month one can be gone by month six, with no defect to warn anyone.
- 5The layersTypical layers. Set the frequency by risk and by what your customer requires.
- 6LPA and other auditsAn LPA does not replace a full audit. It runs between them.
- 7What CQI-8 addsThe AIAG guideline (CQI-8, second edition) is the reference most plants use to set up an LPA system.
- 8Where the questions come fromThe process FMEA: high-severity failure modes and the controls listed against them.
- 9A weak question and a good oneTwo auditors at the same station should give the same answer.
- 10Five steps of an auditTen minutes at the station.
- 11When the answer is noA no that gets fixed means the audit is working.
- 12Scheduling the auditsSpread audits across every shift. Night shift is where controls drift first and where leaders rarely go.
- 13Reading the resultsCount what the audits find and what happens to it.
- 14Example: a gauge in the wrong cellAn illustrative example of one audit. Your own process will differ.
- 15Common mistakesToo many questions, so the audit takes an hour and is skipped.
- 16Try it: run a five-question auditA 20-minute team activity
- 17Check your understanding4 check questions
- 18AnswersThe answers, to discuss
- 19Key points and next stepsNext: run one audit with your own five questions this week.
The 45-minute session, slide by slide
- Slides, about: 25 minutes
- Activity (slide 16): 20 minutes
Present · 15 slides
- 1Layered process audits (LPA): checking the controls still hold
- 2Agenda
- 3What a layered process audit is
- 4Why controls drift
- 5The layers
- 6LPA and other audits
- 7What CQI-8 adds
- 8Where the questions come from
- 9A weak question and a good one
- 10Five steps of an audit
- 11When the answer is no
- 12Scheduling the audits
- 13Reading the results
- 14Example: a gauge in the wrong cell
- 15Common mistakes
Do the activity · 1 slide
- 16Try it: run a five-question audit
Check and follow up · 3 slides
- 17Check your understanding
- 18Answers
- 19Key points and next steps
About 25 minutes of slides and 20 minutes of activity. Present: slides 1 to 15 (Layered process audits (LPA): checking the controls still hold; Agenda; What a layered process audit is; Why controls drift; The layers; LPA and other audits; What CQI-8 adds; Where the questions come from; A weak question and a good one; Five steps of an audit; When the answer is no; Scheduling the audits; Reading the results; Example: a gauge in the wrong cell; Common mistakes). Do the activity: slide 16 (Try it: run a five-question audit). Check and follow up: slides 17 to 19 (Check your understanding; Answers; Key points and next steps).
How to run it
Running the session
- 1
Prepare
Read the speaker notes once and swap the illustrative example for one from your own area if you have it. Print the PDF if people like a handout.
- 2
Present
The slides take about 25 minutes. Every slide has notes, so you can talk from them rather than read the slide.
- 3
Do the activity
In pairs, pick one station and write five questions from its process FMEA or control plan. The activity slide takes the team through it step by step; allow 20 minutes.
- 4
Check and follow up
Ask the check questions before showing the answers, then agree one next step with an owner and a date before people leave.
The check questions
- 1. What does a layered process audit check?
- That the controls on the process are in place now: the process, not the product and not the person.
- 2. What makes a good LPA question?
- It covers one thing, names the standard, and two auditors would answer it the same way from looking or asking the operator to show.
- 3. What do you do when the answer is no?
- Fix it on the spot if you can. Otherwise raise an action with an owner and a due date before you leave.
- 4. Why do the higher layers audit areas outside their own?
- Someone from outside brings fresh eyes and asks the questions the area has stopped asking itself.
Templates and guides to go with it
- Layered process audit (LPA) checklist20 yes, no or N/A checks at the station, a layer and frequency matrix, question banks for four processes and a findings table.
- Process audit checklistAudit one process from inputs to results: 32 questions graded conforms, minor or major, a product check, a score by group and a findings list.
- Control plan templateWhat is checked at each step, against which limits, how, how often, and what to do when a result is out.
- PFMEA template (process FMEA)Failure modes, effects and causes rated for severity, occurrence and detection, with RPN before and after action.
- Topic: Quality managementEvery guide we have on the subject, sorted.
Read more
- Layered process audit (LPA): the layers, the questions and a worked schedule
- FMEA: how to run one, with severity, occurrence and detection
- IATF 16949 in plain language
- CAPA: corrective and preventive action, meaning, process and a worked example
- Run layered process audits in LeanSuite: build the checklist, schedule it, complete it on a phone or tablet with photos, and turn findings into a tag, an action or a Kaizen
After the session
Put it on the wall
Free printable poster on the same subject, so the team sees it every day: a PNG to download now, and print-ready PDFs from Letter to 24 x 36 in.
FAQ
Layered process audit (LPA) training presentation: common questions
A short check, done at the station, that the critical steps and controls of a process are being followed. Several levels of leadership run it on their own schedules, so a process that drifts is found within days.
About 45 minutes: roughly 20 minutes of slides, a 20-minute practice audit on the floor and the check questions.
IATF 16949 does not name layered process audits. It does require manufacturing process audits (clause 9.2.2.3), and many customers ask for LPAs in their customer-specific requirements. AIAG's CQI-8 is the guideline for running them, so check your customer's requirements.
No. It is an introduction that follows the topics CQI-8 covers. The guideline is published by AIAG, and a plant setting up an LPA system should buy it and read it.
Yes. The PowerPoint file is fully editable, including the speaker notes. Many teams replace the illustrative example with a finding from their own plant and add their own questions.
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