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Layered Process Audit

Our auditor devises and conducts an intensive periodic layered process audit on your supplier’s processes and quality systems, one area/topic at a time, in order to maximize their improvement.

It’s standard practice to conduct factory audits to evaluate a new supplier before working together. Some companies and retailers will even arrange to go in again to re-audit them after a number of months.

In China, in particular, many suppliers take the attitude of “wait until the buyer forgets”. So, having a regular re-audit plan should work well to counter that attitude, as it “maintains pressure,” right? Not always.

We have found that coming back and checking the same points does not stimulate improvement. It actually stimulates better paperwork and better justifications on the manufacturer’s side!

In order to drive continuous improvement in your supplier, it often makes a lot of sense to perform a layered process audit on the quality systems and on the operational & support processes in a systematic monthly re-auditing cycle for a period of time where each audit focuses solely on one theme, in more depth. This is especially important for key suppliers with whom you want a long-term relationship.

How much does it cost?
Pricing is tailored to each project based on its scope and complexity. Typical costs vary depending on product type, supplier location, and required support.

Costs for an LPA program start at 500 USD per visit in South China (in the Shenzhen/Dongguan area). Quotation on request in other areas and countries.

Learn more about our pricing and cost structure

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    Layered Process Audit FAQs

    In a Layered Process Audit program, our auditor re-audits your supplier’s processes and quality systems by focusing on one key aspect per month.

    Rather than trying to examine all kinds of quality systems and processes in one day, the auditor makes a plan to systematically examine each one in-depth per month which maximizes the opportunities to identify and correct any problems or inconsistencies.

    It also makes it easier for the supplier to think systematically because they are only required to focus on fixing one thing at a time.

    The auditor often uses typical documents such as a process & product control plan, a process FMEA, a preventive maintenance plan, etc. as the basis of the audits.

    An LPA program can be customized to your needs, and suppliers will all have their own features and challenges. However, here’s a typical example of how our auditors may approach assessing your key supplier’s factory:

    • Month 1: the measuring & testing instruments (accuracy, precision, users’ training, records…)
    • Month 2: the quality control plan (inspection points, inspectors, records…)
    • Month 3: maintenance of production equipment
    • Month 4: standard work instructions for operators
    • Month 5: staff training
    • Month 6: mistake proofing and other preventive approaches
    • Month 7: labeling and identification
    • Month 8: general housekeeping, cleanliness, storage
    • Month 9: machine setup
    • And so on…

    Following the audit, the supplier has 1 month to make corrective changes ready for the auditor’s next visit where the changes will be examined before she moves on to the next target.

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