Layered Process Audit Template – Free PDF

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Layered process audit template

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Use this template with Lumiform

Customize this template or build your own
Fill out templates via mobile app
Get reports and analyse your data

Prices start from ░░░ per month

Book a demo

Learn more

Our layered process audit template makes it easier for you to verify that critical processes are consistently followed across all levels of your organization. Unlike standard quality checks, this template focuses on process adherence rather than just inspecting end products, addressing the root causes of quality issues.

According to Applied Logistics, 75% of manufacturing defects stem from non-conformance with established processes, which is precisely why LPA programs significantly reduce quality costs. Use this template to engage employees at all organizational levels in regular audits. This creates accountability while identifying process deviations so you can reduce costly defects, rework, and customer complaints.

Related categories

Preview of the template

Inspection

Communication

Are employees aware of any recent quality issues or customer complaints?

Is in-process & outgoing material properly identified?

Is traceability in place where required?

Is FIFO used?

Is nonconforming or suspect product identified and placed in a designated area?

Are proper containers used in production, including outgoing material?

Is workplace clean and orderly?

Set-Up

Are Visual Aids (required by the Control Plan) available?

Are Change Over instructions followed?

Operator Certification/Standardized Work

Are Operators following standardized work?

Are Operators certified on the job?

Control Plan

Are control plan checks made at the proper frequency, with the correct sample size and on the correct form?

Are product/process checks within specification? If not, are reaction plans being followed?

Are significant process events recorded?

First Time Quality

Are alarm limits being used?

Is a reaction plan available and being followed?

Measurement Systems

Are Error Proofing devices, gages and fixtures verified?

Are all gages (required by the Control Plan) available at the workstation? Are the gages numbered, calibrated and match the Control Plan?

Containment/Rework

Is containment information documented when the product is non-conforming?

Is rework/teardown completed per instructions with proper identification?

P.M. Activities

Are Preventive Maintenance activities complete to schedule?

Completion

Comments

Auditor Name and Signature

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Frequently asked questions

How can I customize this layered process audit template for my manufacturing process?

Start by reviewing the existing categories and determine which apply to your operations. Modify questions to reflect your specific process requirements, equipment, and quality standards. Keep questions objective and verifiable. Consider your most critical process points and quality risks when adding custom questions, and ensure the language is clear enough for auditors at all organizational levels.

Who should be involved in conducting audits using this template?

Involve personnel from multiple organizational levels to create the “layered” approach. First-layer auditors should be supervisors or team leads who oversee the area daily. Second-layer auditors might include department managers or quality specialists. Third-layer participants should be executives or directors. Cross-functional auditors also provide fresh perspectives on processes they don’t regularly oversee.

How do I ensure my team doesn’t treat this layered process audit as just another paperwork exercise?

Connect the audit directly to meaningful outcomes by sharing how findings have prevented quality issues. Train auditors to understand why each question matters rather than just checking boxes. Rotate auditors to maintain fresh perspectives. Most importantly, visibly act on findings—when teams see audit results driving real improvements, they’ll understand the value.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.