Lean toolkit / 08
Layered Process Audit
Ten short checks of the steps that matter most, run by every layer of leadership. The point is frequency, not depth.
Ten questions, ten minutes, at the process, by the layer named. A Fail is not a failure of the operator — it is a finding against the standard, and it needs an action before the next audit.
Escalation: any repeat Fail on the same question in two consecutive audits goes to the next layer up, same day.
Pass rate—of the questions answered
Findings0need an action today
Answered0of 10
Actions assigned0finding has an owner
The audit
P pass · F fail · – not applicable| # | Audit question | Layer | Result | Finding | Corrective action | Owner | Due |
|---|---|---|---|---|---|---|---|
| 1 | Is current standard work posted at the station and legible? | Team lead · Daily | |||||
| 2 | Is the operator working to the posted sequence and cycle? | Team lead · Daily | |||||
| 3 | Are the correct gauges present, in calibration and in use? | Team lead · Daily | |||||
| 4 | Is the first-piece check recorded for this run? | Team lead · Daily | |||||
| 5 | Are error-proofing devices present, functional and verified today? | Supervisor · Weekly | |||||
| 6 | Is nonconforming material segregated, labeled and controlled? | Supervisor · Weekly | |||||
| 7 | Are the last three abnormalities logged with a response? | Supervisor · Weekly | |||||
| 8 | Is the changeover run to the documented setup sheet? | Supervisor · Weekly | |||||
| 9 | Are open actions from the last audit closed on time? | Manager · Monthly | |||||
| 10 | Does the team know the top defect in this area and its countermeasure? | Manager · Monthly |
Layered Process Audit · DF Consulting · df-consulting.net · david@df-consulting.net