A multi-tier process audit checklist aligned to the AIAG CQI-8 Layered Process Audit guideline. Covers the Tier 1/2/3 frequency schedule, a 12-item standard work adherence question set with Pass/Fail/NA and comment columns, a nonconformance log, and escalation rules for repeat findings. Generated instantly in your browser — no login required.
CQI-8 Note: Layered process audits work because different roles catch different failure modes at different frequencies — Tier 1 catches drift daily, Tier 3 catches systemic gaps monthly. Skipping tiers or letting one role audit every layer defeats the method.
Audit Header
Process/station, part number, date, shift, audit tier, and auditor name/role
Tier & Frequency Schedule
Tier 1/2/3 table defining auditor role, frequency, and audit scope for each layer
Standard Work Adherence Questions
12-item question set covering work instructions, PPE, calibration, control plan, poka-yoke, FIFO, and escalation awareness
Nonconformance Log & Escalation Rules
Finding log with immediate action, owner, and target date, plus the escalation rule for repeat or aging findings
What is a Layered Process Audit (LPA)?
An LPA is a structured audit where multiple layers of the organization — operators, supervisors, and plant/quality management — audit the same process at different frequencies (typically daily, weekly, and monthly) to verify that standard work is actually being followed, not just documented.
How is an LPA different from an internal quality audit?
An internal quality audit (e.g. against ISO 9001 clauses) checks whether the management system meets a standard, usually annually or on a scheduled cycle. An LPA checks whether operators are following the defined process at the station, right now, and does so far more frequently and at multiple organizational levels.
Who should conduct Tier 1 audits?
Tier 1 audits are typically conducted daily by the operator or team lead running the process, checking their own station against the standard work requirements before or during the shift.
What happens when an LPA finding isn't closed?
Under the escalation rule, a finding left open past one audit cycle at its tier should escalate to the next tier for review. Findings that recur repeatedly at Tier 1 (e.g. three consecutive audits) should trigger a Tier 3 review of that station to address the root cause.
COPLAIN AI PLATFORM
Describe your process and Coplain AI generates a station-specific LPA question set with your control plan and work instruction requirements built in — plus the tier schedule and escalation tracker.
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