The Importance of Process Confirmation and Layered Process Audits in Lean Manufacturing
Dr. Anthony Kenneson-Adams DBA. FIoL.  Head of Learning and Knowledge Transfer Project7 Consultancy
Posted 2/4/2025
Introduction
Lean manufacturing is a systematic approach to minimizing waste and maximizing efficiency in production processes. It focuses on continuous improvement and streamlining operations to deliver the highest value to customers. To achieve these objectives, companies must ensure that their processes consistently meet established standards and drive long-term success. Two key tools in this effort are Process Confirmation and Layered Process Audits (LPA). Both play crucial roles in maintaining quality, improving reliability, ensuring adherence to procedures, and driving continuous improvement within a Lean framework.
Process Confirmation: The Foundation of Operational Success
Process Confirmation refers to the practice of ensuring that all operational procedures are followed as designed, without deviation. These can be SOPs, PMs, PdMs, legislation, etc. In a Lean manufacturing environment, processes are designed to eliminate inefficiencies and ensure consistent outcomes. Therefore, any deviation from the standard process introduces variability, which can lead to defects, increased costs, and reduced customer satisfaction.
Process Confirmation is critical in your business because:
- Consistency Ensures Quality: When processes are followed as designed, products are manufactured and machines are maintained with a high degree of consistency. This leads to fewer defects, improved reliability, and increased customer satisfaction.
- Waste Reduction: Process deviations often result in rework, scrap, or downtime. By adhering to established processes, organizations minimize these inefficiencies and reduce waste, a key tenet of Lean manufacturing.
- Efficiency: Standardized processes are optimized for efficiency. Any deviations can slow down production, leading to longer cycle times and higher operating costs.
- Continuous Improvement: Process Confirmation helps companies identify opportunities for improvement. By ensuring that processes are followed as designed, organizations can more easily identify bottlenecks or inefficiencies and take corrective action.
Layered Process Audits: A Tool for Sustaining Process Confirmation
While process confirmation is critical, maintaining it over time can be challenging. This is where Layered Process Audits (LPA) come into play. LPAs are a structured auditing method used to verify that standardized work and procedures are being followed at all levels of the organization. These audits are conducted on a schedule by different layers of management, ensuring that compliance is consistently checked and maintained.  I do not advocate LPA for all your processes, but you should consider LPA for processes that ensure safety, are critical to quality or reinforce customer satisfaction for example.
LPAs are not only valuable audits of all levels in the organization, but I also find them valuable as it takes all levels of leadership out of their offices and onto the shop floor.Â
LPA Benefits
LPAs offer several key benefits to organizations:
Accountability: By involving different layers of management, LPAs ensure that everyone in the organization is responsible for maintaining process confirmation. For example the Plant Manager of a Proctor & Gamble packaging plant was responsible for the LPA for the lubrication of a packing machine. This promotes the culture of accountability where leaders at all levels are engaged in the continuous improvement process.
Early Detection of Issues: Layered process audits allow for the early identification of deviations or potential problems before they escalate into larger issues. This proactive approach can help prevent costly defects, rework, or downtime.
Sustaining Continuous Improvement: LPAs provide real-time feedback on process performance. They help teams identify areas for improvement and adjust processes accordingly, which aligns with the Lean principle of continuous improvement (Kaizen).
Cross-Functional Engagement: LPAs encourage collaboration between different departments and functions. This cross-functional involvement ensures that process improvements are not siloed within a single department but are adopted across the entire organization.
Real-World Examples of Success with Process Confirmation and LPAs
Numerous organizations have reaped the benefits of process Confirmation and LPAs in their Lean manufacturing efforts. Below are a few real-world examples demonstrating how these tools have improved business performance:
General Motors (GM), a global automotive leader, has long been a proponent of Lean manufacturing principles. To ensure consistent process confirmation and drive continuous improvement, GM adopted Layered Process Audits across its manufacturing facilities. These audits helped GM to ensure that each step of the production process was followed consistently.
As a result, GM saw a significant reduction in production defects and warranty claims. By catching process deviations early through regular LPAs, the company was able to prevent issues from affecting the final product. This proactive approach not only improved product quality but also reduced costs associated with rework and repairs and improved customer satisfaction.
Ford Motor Company, another global automotive giant, implemented LPAs to ensure adherence to Lean processes on the assembly line. By performing regular audits at different levels of management, Ford was able to maintain high levels of process confirmation.
One example of the success of this approach was in Ford’s stamping department, where LPAs helped identify inconsistencies in machine settings that were leading to defects in stamped parts. By correcting these issues early, Ford improved first-time quality (FTQ) rates, reduced scrap, and enhanced overall production efficiency.
Bosch, a leading global supplier of technology and services, has implemented LPAs as a part of its Lean manufacturing strategy. Bosch’s LPAs involve daily audits conducted by different management levels, from team leaders to plant managers. This approach ensures that every layer of the organization is involved in process confirmation.
Through the use of LPAs, Bosch was able to identify and correct deviations in its production processes, leading to improved product quality and reduced rework. The company also reported higher employee engagement, as the layered audit process fostered a culture of accountability and continuous improvement.
Conclusion
Process Confirmation and Layered Process Audits are essential tools for any organization striving to achieve Lean manufacturing excellence. By ensuring that processes are followed consistently and engaging all levels of management in continuous improvement efforts, companies can reduce waste, improve product quality, and drive operational efficiency. Real-world examples from companies like GM, Ford, Bosch, and our own experience at Project7 Consultancy demonstrates the power of these tools in achieving long-term success. For any company looking to streamline its operations and improve performance, Process Confirmation and Layered Process Auditing should be at the heart of their Lean strategy.
If you need help in setting up Process Confirmation and Layered Process Audit contact us as Project7 Consultancy for a free 30 consultation to find out how we can help you achieve your business targets.  Â
Dr Anthony Kenneson-Adams
Dr. Anthony Kenneson-Adams had a 30-year career in the Royal Air Force, becoming a Senior Engineering Officer, Project Manager and Engineering Authority responsible for multiple fast jets and large-body aircraft in peace and war operations. On retiring from the Royal Air Force, he became a Corporate Operational Excellence Consultant in the Paper Manufacturing and Packaging Industries and is now the Head of Learning and Knowledge Transfer for the international Project 7 Consultancy. You can contact Anthony at www.project7consultancy.com or [email protected]