November 2025 Volume 7

OPERATIONS & MANAGEMENT

LAYERED PROCESS AUDITING A Practical Tool for Forging Operations By Ray Harkins

I n the forging industry, variation is not an occasional nuisance but a daily reality. Temperatures, forces, lubrication, die wear, and material handling all combine to determine the outcome of a forged part. When any of these factors drift out of control, the result can be scrapped parts, costly rework, or worse, defects that reach customers. Process discipline has always been the lifeblood of successful forging, and while sophisticated monitoring systems and inspection equipment have their place, one of the most powerful tools available is surprisingly straightforward: the Layered Process Audit (LPA). What is Layered Process Auditing? An LPA is a short, structured check of critical process steps performed frequently and by multiple levels of the organization. Instead of relying solely on inspectors or engineers, LPAs spread responsibility across supervisors, managers, and even senior leaders. A line supervisor may conduct an audit every day, a department manager once a week, and the plant manager once a month. Each level checks the same handful of vital items, reinforcing the message that these steps are non-negotiable. Unlike traditional audits that can last days and occur only a few times per year, a well-designed LPA takes ten minutes and happens continuously. The strength of this auditing strategy lies in its repetition and visibility. Forging provides fertile ground for LPAs because of the industry’s reliance on consistent execution. Consider billet heating. Improper control may result in excessive flash or incipient melting when the billet temperature is too high; underfills, cracks or premature tools wear when its too low. An LPA question might ask simply, “Is the billet temperature verified and within specification before forging?” By requiring this question to be asked and answered daily by supervisors, weekly by managers, and monthly by executives, the organization underscores the importance of billet heating. The repetition not only catches errors early but also drives home a powerful message: this step is critical to quality and reliability. The same logic applies to die setup and lubrication. In closed-die forging, ensuring that the die is properly seated and secured is

critical for dimensional control and tool life. An LPA can reinforce this by asking, “Is the die secured according to the setup sheet?” or “Is lubrication being applied at the required intervals?” Over time, these small but frequent checks prevent variation from creeping in and help operators internalize the importance of discipline at every stage. LPAs Application to Safety What makes LPAs especially powerful is their ability to expand beyond product quality into the realm of safety. Forging is one of the most hazardous manufacturing environments, with extreme heat, massive equipment, and heavy materials moving overhead. Safety procedures are often written down and trained, but without reinforcement they can be overlooked. An LPA system provides a natural mechanism to keep safety top of mind. Audit questions might include, • Is the operator wearing the required protective gear? • Are the crane rigging straps free from burns, knots and edge cuts? • Is the work area around the forging press and furnace free from oil, scrap, and other trip or slip hazards? By integrating safety into LPAs, forging organizations send a clear signal that protecting people is as important as producing quality parts. Operators see leaders at every level asking questions not only about product requirements but also about personal well being. This consistency builds trust and reinforces a culture where following safety standards is viewed as a shared responsibility. It also helps organizations reduce incidents, minimize downtime, and improve morale -- all of which contribute directly to performance. How to Implement an LPA System Implementing an LPA system is not complicated, but it does require planning, discipline, and intent. Success begins with a cross-functional team representing operations, engineering, maintenance, and quality. This group identifies the highest-risk processes and crafts a list of yes/no or short answer questions.

Forging Quality LPA Sample Questions • Is billet temperature within the specified range before forging? • Are dies free from visible damage or wear before production begins? • Is lubricant being applied at the specified frequency and amount? • Are first-piece inspections being performed and documented according to the process control plan? • Are forged parts being cooled according to specified procedures? • Is material traceability maintained from raw billet through finished forging? • Are in-process gauges, pyrometers, or other measuring devices within their calibration intervals?

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