Process · Reliability & Quality
Layered process audit
Short, frequent audits of a process at the point of work, carried out by people from several levels of management, to check that key controls are followed every day.
- Also known as
- LPA
- Type
- Process
- Domain
- Reliability & Quality, Quality systems
Overview
A layered process audit checks a few important things often, rather than everything rarely. Supervisors, managers and senior leaders each audit the same process at their own frequency, so problems are seen by more than one level and leaders stay in touch with the work.
How it works
Each audit uses a short checklist built from the control plan, the process FMEA and past problems, such as whether work instructions are followed, checks are recorded and reaction plans are used. Lower layers audit more often and higher layers less often, on a planned schedule.
Findings are corrected on the spot where possible, and repeated findings go to structured problem solving. Checklists are refreshed as problems are fixed and new risks appear.
Examples
- A shift supervisor checking that a tester's correlation check was recorded.
- A plant manager auditing one assembly line each week.
- A checklist question added after a complaint about wrong labelling.
- A repeated finding sent to an 8D investigation.
Why it matters
Production supervisors, process owners and quality engineers run layered process audits, and IATF 16949 lists them among the methods for verifying manufacturing processes. In the QMS lifecycle they are part of internal audits and of daily operation and improvement.
It matters most to: Automotive Quality Engineer (IATF 16949), Fab Shift Manager, Quality Systems Manager
Common confusions
- Not the same as Internal audit
- A full internal audit examines a whole process against the standard at planned intervals; a layered process audit checks a few key controls at the point of work, often daily or weekly.
Related standards
- IATF 16949 (automotive quality management system requirements)
Sources
- CQI-8 Layered Process Audit Guideline (opens in a new tab), AIAG (Automotive Industry Action Group), 2026-11-10
- Detail and Examples Promote More Effective Layered Process Audits (opens in a new tab), AIAG (Automotive Industry Action Group), 2026-11-10
Related terms
Part of the Reliability & Quality glossary, with every term in the topic and the lifecycles, tools and standards that use them.
Where it appears on the Hub
Used on 3 pages of the Hub. In each group, the pages that mention it most come first.
Lifecycle stages and gates
Skills
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Last reviewed . Written by The Semiconductor Hub editorial team. The full glossary