November 2025 Volume 7

OPERATIONS & MANAGEMENT

In forging, those might target billet handling, die alignment, lubrication, press control interlocks, or post-forge dimensional checks. Safety-related questions should also be woven in, covering items such as lockout/tagout procedures, guarding, or housekeeping around high-traffic areas. The ideal checklist fits on one page. The goal is not to catch people doing things wrong but to ensure that the most important steps are consistently performed. Auditors at every level should be trained to approach the audit as a conversation, not an interrogation. If a deviation is found, the immediate correction is important, but equally important is feeding the issue into the organization’s broader corrective action system so that it does not recur. LPAs without follow-through quickly lose credibility. Common Pitfalls Of course, LPAs are not without pitfalls. The most frequent misstep is creating checklists that are too long or too complicated. An audit that drags on for half an hour is no longer an LPA; it is a misused tool. Another danger is treating LPAs as a paperwork exercise. If auditors are simply checking boxes without observing the process, the program becomes meaningless. Just as damaging is a failure to act on findings. Nothing erodes trust faster than repeatedly flagging issues that are never addressed. Finally, top leadership involvement is essential. Without visible participation from plant managers and executives, LPAs will fade into the background as just another quality fad. The Value LPAs Add One of the most common concerns managers raise about LPAs is whether they actually save money. The reality is that their financial impact shows up as cost avoidance. Every defect prevented is a cost not incurred, whether in scrap, rework, warranty claims, or customer dissatisfaction. The same is true for safety. Preventing an injury avoids direct medical costs as well as indirect costs like lost productivity, investigations, and potential fines. While it is sometimes difficult to put exact numbers on avoided costs, the business case is strong when you track reductions in repeat problems or safety incidents over time. When done right, the value of LPAs extends well beyond compliance. They strengthen customer confidence by demonstrating that the organization is serious about process discipline. They reinforce accountability by putting leaders on the shop floor, shoulder-to-shoulder with operators. They prevent variation from undermining part quality and prevent safety lapses from endangering people. Most importantly, they help build a culture where following standards is not optional but expected. The forging industry faces increasing demands: new materials, tighter tolerances, more sophisticated customers, and relentless pressure to reduce costs. In this environment, LPAs offer a competitive advantage. They do not require new technology or large investments, but they deliver measurable improvements in quality, reliability, and safety. They help organizations sustain the discipline that is necessary to compete at the highest level. And while LPAs have deep roots in industries like automotive, their logic is universal. Any manufacturing operation that values consistency and safety can benefit from them.

For modern manufacturers, Layered Process Auditing provides a proven framework to control variation, reinforce safety, and create a culture of accountability. It offers a simple yet powerful way to ensure that the basics are never overlooked. The organizations that embrace LPAs and make them part of daily life are the ones that will earn the trust of customers, protect their employees, and stand out as world-class suppliers.

Ray Harkins is the General Manager of Lexington Technologies in Lexington, North Carolina. He earned his Master of Science from Rochester Institute of Technology and his Master of Business Administration from Youngstown State University. He teaches manufacturing and quality-related courses such as “Layered Process Auditing” through the online learning platform, Udemy. He can be reached via LinkedIn at linkedin.com/in/ ray-harkins or by email at the.mfg.acad@ gmail.com.

Reference: AIAG. CQI-8: Layered Process Audit Guideline. Automotive Industry Action Group.

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