If you’re new to quality management, the concept of Layered Process Audits (LPAs) may seem like yet another acronym amongst all the other manufacturing jargon. But don’t be fooled—LPAs, especially when guided by the AIAG’s CQI-8 guideline, are transformative tools that do more than check boxes. They drive real accountability, consistency, and culture change from the ground up.   

At their core, Layered Process Audits are routine checks performed at various levels of an organization by team leads, supervisors, managers, and even executive leadership. These audits verify that critical processes are being followed exactly as designed, every single time. But what makes LPAs unique isn’t just the layered responsibility; it’s the frequency, the focus on high-risk areas, and the cross-functional ownership that embeds quality into the daily rhythm of operations.   

This is where CQI-8 comes in. Developed by the Automotive Industry Action Group (AIAG), the CQI-8 Layered Process Audit Guideline is the industry standard for structuring and optimizing LPAs. It provides the “why,” “what,” and “how” of LPAs, helping to guarantee that organizations generate actionable insights that improve performance and reduce risk, rather than simply go through the motions.  

Why is this important? Because even the best-designed processes can slip under pressure. People get busy, priorities shift, and variability sneaks in. Without a structured approach like CQI-8, it can be too easy for early warning signs to go undetected. In high-stakes industries like automotive and aerospace, missed signals can lead to costly recalls, compliance failures, or even potentially dangerous circumstances.   

Implementing LPAs with CQI-8 isn’t only about compliance, though; it’s also about empowerment. Operators see that leadership cares about their work. Middle managers develop deeper process ownership. Senior executives stay connected to shop floor realities. And most importantly, systemic issues get resolved before they turn into systemic failures.   

For instance, General Motors incorporated LPAs across its manufacturing operations and saw a significant drop in both defective products and warranty claims, thanks to early discovery of process deviations. A real-world example like this highlights the objective value of LPAs in creating consistency, ownership, and risk reduction across complex manufacturing environments.  

Let’s be honest, though: rolling out LPAs the right way isn’t effortless. It isn’t as simple as just downloading a checklist; it takes a cultural commitment and an understanding of how LPAs should be integrated into your organization’s existing quality strategy. That’s why structured education, grounded in real-world application, is critical.   

At Plexus International, we understand these challenges firsthand. For over 20 years, we’ve helped organizations worldwide not only understand standards like CQI-8 but apply them meaningfully to improve performance and outcomes. 

Ready to take the next step by learning more?  

Plexus is pleased to announce the launch of our new course, “Understanding and Applying CQI-8”, designed specifically for industry professionals who are looking to enhance their layered process audits from just a task to a transformational tool. Whether you’re new to quality or looking to refine your existing approach, this course will give you the clarity, tools, and confidence to make CQI-8 work for you.