Main Training Program

CQI 8 – LAYERED PROCESS AUDITS (LPA)

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INTRODUCTION FOR CQI 8 – LAYERED PROCESS AUDITS (LPA)

In every organization, ensuring that standard operating procedures are consistently followed is vital for delivering high-quality outcomes. The challenge lies in maintaining accountability across all organizational levels. That’s where Layered Process Audits (LPA) come into play.

LPA is a structured, multi-tiered auditing method that involves personnel from the frontline to top management in the quality assurance process. The CQI 8 standard provides comprehensive guidance on implementing LPAs to promote accountability, identify process gaps early, and drive continuous improvement.

LEARNING OBJECTIVES

  • Understand the LPA Framework: Gain a comprehensive understanding of the purpose, structure, and components of Layered Process Audits (LPA) as defined by the CQI 8 standard.
  • Identify Key LPA Roles and Responsibilities: Learn about the various roles involved in the LPA process, including those of executives, managers, supervisors, and frontline workers, and how they contribute to its success.
  • Master LPA Planning and Execution: Develop the skills to plan, schedule, and execute LPAs effectively, including creating and using audit checklists and evaluating process adherence.
  • Track and Analyze LPA Data: Learn how to collect, track, and analyze LPA data to identify patterns and areas for improvement within your processes.
  • Address Non-Conformances and Drive Corrective Action: Understand how to address non-conformances discovered during the audit, create corrective action plans, and close the loop to prevent recurring issues.
  • Promote Continuous Improvement: Equip yourself with the tools to incorporate LPA findings into broader continuous improvement efforts and management review processes.

 

LEARINING METHODOLOGY

  • Face-to-face interactive lectures
  • Group exercises and case studies
  • Pre- and post-assessments
  • MCQs and quizzes
  • Real-world LPA simulations

 

WHO SHOULD ATTEND

This course is suitable for participants across various departments and levels, including:

  • Executives
  • Managers
  • Engineers
  • Supervisors
  • Quality and production staff
  • Team leaders involved in process oversight and improvement

COURSE CONTENTS

Time Details
09.00 am – 09.30 am Opening and introduction (Trainer & Participants)
09.30 am – 09.45 am Introduction to LPA
09.45 am – 10.30 am Introduction to Layered Process Audits (LPA)

    • What is a Layered Process Audit (LPA)?
    • Historical context and purpose of LPA.
    • Benefits of implementing LPAs in a manufacturing environment.
    • The relationship between LPA and other quality management tools (e.g., ISO, IATF 16949, Six Sigma).
    • Key principles behind LPA (e.g., accountability, ownership, sustainability).
10.30 am – 10.45 am Morning Tea Break
10.45 am – 12.00 pm Session 2: LPA Framework and Best Practices

    • LPA levels: What are the different levels (e.g., executive, managerial, and operator audits)?
    • Audit frequency and scheduling – how often should LPAs be performed and by whom?
    • Audit checklist development – how to create an effective checklist and use it efficiently.
    • Standard work for audits and ensuring consistency.
    • Escalation process for addressing non-conformances.
12.00 pm – 01.00 pm Lunch
01.00 pm – 01.30 pm Assignment/Class Exercise 1
01.30 pm – 03.00 pm Session 3: Conducting an Effective Layered Process Audit

    • Roles and responsibilities during an audit (auditors, process owners, and management).
    • How to prepare for an LPA: Pre-audit preparations and defining the scope.
    • Performing audits effectively: observation techniques, questioning methods, and documenting findings.
    • Managing findings: Root cause analysis for non-conformances.
    • Closing the loop: Creating action plans, follow-up, and ensuring closure of identified issues.
03.00 pm – 03.15 pm Afternoon Tea Break
03.15 pm – 04.45 pm Session 4: LPA Reporting and Continuous Improvement

    • How to report audit results effectively (e.g., audit scorecards, dashboards).
    • Using LPA data to drive continuous improvement (identifying trends and areas for action).
    • Integrating LPA results into broader management review processes.
    • Best practices for tracking corrective actions and verifying their effectiveness.

Session 5: Overcoming Common Challenges in LPA Implementation

    • Overcoming resistance from employees and management.
    • Ensuring auditor accountability and consistency across all levels.
    • Maintaining the sustainability of the LPA system over time.
    • Common mistakes to avoid in LPA execution and how to correct them.
04.45 pm – 05.00 pm Session 6: Wrap-up and Q&A

    • Key takeaways from the training.
    • Final Q&A to clarify any doubts.
    • Next steps: How to begin implementing LPA in your own processes.
    • Post Evaluation

 

Ready to Elevate Your Quality Assurance Strategy?

Join this comprehensive, practical training to learn how to implement Layered Process Audits (LPA) effectively in your organization.

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