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Level 2 and 3 Layered Process Audit Checklist

by Ricky Shanes, from the Community

This Level 2 and 3 Layered Process Audit checklist supports quality assurance in manufacturing, especially automotive. It covers management reviews and logs, training and operator qualification, Level 1 and Level 2 audits, PPAP and engineering change tracking, and workstation checks for 5S, PPE, materials, BOM and control plan conformance. It includes verification of dynamic control plans, first piece approvals, quality alerts, andon response, and nonconforming material control with NCMR. Sections guide error proof verification, packaging and labeling, deviation or bypass controls, daily and final inspections including GP12, gage calibration and instructions, SPC review and reaction plans, and performance charts. Maintenance PMs, safety equipment, chemical handling per SDS, used oil and universal waste areas, storage and receiving inspection, FIFO and shipping are included, plus new employee safety and process knowledge checks with auditor sign off.

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Digitize any process, procedure or policy

Eliminate mistakes made by paper-based processes

Create and share professional reports instantly

Confirm accountability and compliance with a digital log

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Community

This community page makes available free workplace checklists and templates created by other users within the SafetyCulture community. SafetyCulture has re-published this content and where possible, has credited the original author. SafetyCulture has not verified the accuracy, reliability or suitability of any community content. You agree that your use of any of this content is in accordance with SafetyCulture’s Terms and Conditions.

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Level 2 LPA Workstation Specific Audit Checklist
This Level 2 Layered Process Audit workstation checklist helps manufacturers verify critical production controls at the press or cell. It guides auditors to review 5S and housekeeping, PPE use, correct materials and components per bill of materials and control plans, first piece approvals, adherence to operator instructions, quality alerts and certifications, date codes and labeling, tooling and gauge ownership, process setup and verification, and andon operation and escalation. It also covers handling of nonconforming or suspect material and accurate NCMR documentation. Use it to strengthen process discipline, product quality, and compliance on the factory floor.
by Ricky Shanes, from the Community
Downloads: 10+
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Template
Level 2 LPA Bypass and Shipping Audit Checklist
This Level 2 Layered Process Audit checklist helps manufacturing teams verify key management and shop-floor controls. It covers QPR and fast response board updates, monthly and operational management reviews, training compliance, and completion of Level 1 and Level 2 audits with closure of nonconformances. It includes checks for PPAP status, engineering change notices, and read-across actions. Bypass deviation requirements are detailed with approvals, standardized work, and operator training. Shipping controls include proper storage, FIFO, and container certification.
by Ricky Shanes, from the Community
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Template
Level 2 LPA: Error Proofing, Labeling, Receiving
Apply this Level 2 Layered Process Audit checklist to verify error-proofing devices and reaction plans, confirm packaging and labeling match instructions, and review storage and receiving controls. The form guides auditors through documentation checks, fixture and process verification, FIFO and material certification review, and supplier issue status. It also includes new-employee audit questions on PPE, first-piece use, following operator instructions, and emergency and defect handling, ensuring consistent manufacturing quality and safety.
by Ricky Shanes, from the Community
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Template
Level 1 LPA Audit Checklist
This Level 1 Layered Process Audit checklist supports manufacturing quality on the shop floor. It covers housekeeping and organization, correct materials per BOM, cell layout and labeling, protection from contamination, returnable container condition, process setup and verification, fixture and error proofing checks, scrap control and deviations, WIP location, operator PPE and training, work instruction adherence, production and scrap recording, first piece verification, daily inspection logs and reaction plans, inspection status marking, gage presence and calibration, Andon lights, and current quality alerts for automotive programs such as Honda and GM.
by Matthew Zolton, from the Community
Downloads: 10+
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Level 2 and 3 Layered Process Audit Checklist

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