e-Learning: APQP Auditing & Layered Process Auditing

Programme overview

The considerable and worthwhile supplier effort put into the AS9145 APQP process and PPAP submission should guarantee ‘perfect product and OTIF performance’ for customers.

Auditing APQP and PPAP processes will verify that the system is in place and is working effectively. However, the nagging fear remains – mission drift on the shop floor! Specifically, manufacturing methods aligned with the Control Plan may not continue to be adhered to, resulting in quality issues and loss of productivity. Clearly, a stringent ‘policing method’ must be deployed.

Layered Process Audits (LPA) are a system of audits performed by multiple levels of supervision and management to check whether the outputs (deliverables) of APQP are being properly followed, correct materials are being used, specified tools and equipment are employed and competent & qualified personnel are involved. LPA also monitor key process characteristics (e.g. Cpk & ppm) and verify process performance on an ongoing basis.

This e-Learning (on-line training) course provides and tests the knowledge required to plan, undertake and report on both APQP Audits and Layered Process Audits.

Programme details

The course is delivered as an online e-Learning module via TEC's learning management system (LMS) platform. Within this e-Learning course, the following sections are covered:


  • APQP & PPAP provide up-front planning
  • LPAs assure ongoing success
  • Overview of this e-Learning course
  • Acronyms associated with APQP, PPAP and LPA

Overview of APQP and PPAP

  • The APQP phases
  • The sequence and purpose of the APQP phases
  • The APQP & PPAP requirements
  • The ‘deliverables’ of the APQP phases
  • The PPAP 'Folder'

The role of auditing

  • Understanding different audit types
  • Phasing of audit types

Session #1 – APQP & PPAP System Audit

  • Identifying the phases of the APQP process

Conducting an APQP System Audit

  • Stages of the APQP System Audit
  • APQP System Audit criteria
  • APQP System Audit scope
  • Competency of auditors
  • Developing APQP System Audit questions
  • AS9145 standard sources
  • SCMH checklists sources
  • Customizing your APQP System Audit questions
  • Customer-specific requirements and the AESQ
  • Competency in the APQP methodologies and tools
  • APQP System Audit question format
  • APQP System Audit sample size
  • Reporting APQP System nonconformities

Session #2 – Layered Process Auditing (LPA)

  • Understanding a Layered Process Audit (LPA)

Prerequisites for LPA – processes and planning team

  • Identifying processes and key steps for LPA
  • Identifying the LPA planning team
  • Need for an LPA process owner
  • LPA audit personnel and top management responsibilities

Prioritizing and developing LPA check-sheet questions

  • Prioritizing and developing LPA check-sheet questions
  • The 'Golden Rules' for prioritizing processes for LPAs
  • Identifying sources of process variation
  • Sources of LPA questions – controlled conditions
  • Documentation types – ensuring controlled conditions
  • Identifying LPA questions – the check-sheet
  • Example: LPA check-sheet questions from work instructions
  • Creating an LPA check-sheet
  • Example: LPA check-sheet with questions – Layer 1
  • Example: LPA check-sheet format – Layer 2
  • Example: LPA check-sheet format – Layer 3

Scheduling, conducting and reporting LPAs

  • Scheduling the LPAs
  • LPAs location, personnel, duration and focus
  • Sequencing the LPA activities
  • Recording the LPA results and actions taken
  • Dealing with 'difficult' situations

Staffing LPAs

  • LPA process owner – responsibilities
  • Reminder – responsibilities for LPAs
  • Top management actions

Drivers and benefits of LPAs

  • Drivers of LPAs
  • Benefits of LPAs

Programme benefits

The benefits of e-learning are numerous; not only are they extremely cost-effective but they provide students with convenience and flexibility as they embark on their learning journey. You can complete your training whenever and wherever you want, and at your own pace.

Companies do not have to tie-up entire teams at the same time as is the case with conventional classroom-based training.


"How to undertake layered process audits" QULAITY WORLD | Summer 2021| by Dr David Scrimshire

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Buy e-Learning: APQP Auditing & Layered Process Auditing

The course is delivered as an online e-Learning module via the TEC Transnational Ltd learning platform - personalised for learners. Set the number of learners and provide their email addresses at the checkout.

e-Learning: APQP Auditing & Layered Process Auditing


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