Template

Level 2 LPA Inspection Maintenance Checklist

by Ricky Shanes, from the Community

10+

Use this Level 2 Layered Process Audit template to assess maintenance and quality controls on the production floor. The checklist covers inspection criteria and frequency against the control plan, documentation of lots, touch listen and count methods, lighting adequacy, reaction plans, and execution per work instructions. It includes gage cleaning and calibration, availability of variable and attribute gages, tolerance definitions, and SPC history review. Auditors verify scrap and defect charts, red rabbit samples, preventive maintenance for machines, robots, conveyors, and fixtures, chemical and used oil handling, universal waste storage, critical spares, and safety safeguards.

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With SafetyCulture you can

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

About author

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.

Template
Level 2 and 3 Layered Process Audit Checklist
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.
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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Template
Layered Process Audit (LPA) for Assembly Lines
Use this Layered Process Audit (LPA) template to systematically review assembly line operations. Cover 5S housekeeping, FIFO, maintenance schedules, red rabbit checks, correct labeling and traceability, IT and equipment readiness, adherence to work instructions, operator training and cycle times, scrap logging and suspect parts control, and visibility of KPIs and quality alerts. Standardize audits, capture nonconformities, and drive corrective actions to improve quality, safety, and throughput.
by suchitra kollu, from the Community
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Level 2 LPA Inspection Maintenance Checklist

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