Layer of Protection Analysis (LOPA) Checklist
Boost manufacturing safety & reduce risk! Our Layer of Protection Analysis (LOPA) Checklist ensures robust hazard controls. Download now for a systematic approach to process safety, risk mitigation, and compliance. Protect your workforce & operations!
This Template was installed 5 times.
Process Hazard Identification
Identify potential hazards associated with the manufacturing process and the potential consequences if those hazards are realized.
Describe the Manufacturing Process Being Analyzed
Identify potential hazards associated with each step of the process.
Which hazard types are present? (Select all that apply)
For each identified hazard, describe the potential consequences if it occurs.
Estimated Number of Employees Potentially Affected by Each Hazard
Describe any existing documentation related to these hazards (e.g., SDS, process procedures)
Upload Process Flow Diagram (PFD)
Initial Risk Assessment (Without Layers of Protection)
Evaluate the initial severity and likelihood of the identified hazards, forming a baseline risk assessment before considering protective layers.
Describe the manufacturing process being assessed.
Estimated Frequency of Occurrence (per year)
Severity Classification (e.g., Catastrophic, Critical, Moderate, Minor)
Describe the potential consequences of the hazard if it were to occur.
Estimated Number of Personnel Potentially Affected
Environmental Impact Classification (e.g., High, Medium, Low)
Justification for Severity and Frequency Assignments
Existing Layers of Protection (LOLs)
Document and describe the existing controls and safeguards in place to prevent or mitigate the identified hazards. This includes procedural, mechanical, electrical, and administrative controls.
Describe the Standard Operating Procedure (SOP) for the process.
Which of the following mechanical safeguards are in place? (Select all that apply)
What is the frequency of preventative maintenance for critical equipment (e.g., machine, conveyor)? (Days)
What type of personal protective equipment (PPE) is required for this process?
Last review date of the process safety information (PSI).
Upload a copy of the relevant training records for personnel involved in this process.
LOL Effectiveness Assessment
Evaluate the effectiveness of each existing LOL. Consider independent verification, testing, and past performance.
Frequency of LOL Testing/Inspection
LOL Verification Method
Summary of Previous LOL Performance/Failures
Is the LOL Fully Operational?
Last LOL Maintenance Date (YYYY-MM-DD)
Which supporting documentation is available for this LOL?
Describe any known limitations of this LOL.
Potential Failures of LOLs
Identify potential failure modes of each existing LOL. What could cause the LOL to fail to perform its intended function?
Describe potential human error scenarios that could lead to LOL failure.
Which of the following factors could contribute to LOL failure due to inadequate training?
What is the estimated frequency (per year) of scheduled maintenance for this LOL?
When was the last time a complete audit/review of this LOL was conducted?
Describe any historical incidents or near misses where this LOL failed or nearly failed. (Include details of root cause and corrective actions)
What is the primary reason for LOL failure in similar processes or equipment?
Describe how environmental factors (e.g., temperature, humidity, vibration) could degrade the LOL’s effectiveness.
Upload any relevant maintenance logs, inspection reports, or failure analyses for this LOL.
Risk Reduction with Existing LOLs
Assess the risk reduction provided by the existing LOLs. How much has the likelihood and/or consequence been reduced?
Is the LOL regularly inspected and maintained?
Frequency of LOL inspection (e.g., days, weeks, months)
Describe the process for verifying LOL effectiveness (e.g., testing, audits, reviews)
Has the LOL performed as intended in the past?
If 'No' was selected above, describe past failure events and corrective actions taken.
Estimated reduction in consequence severity (as percentage)
Estimated reduction in frequency of occurrence (as percentage)
Is independent verification of the LOL effectiveness available?
Risk Evaluation After Existing LOLs
Re-evaluate the risk level after accounting for the existing LOLs. This provides a current risk level assessment.
Severity Rating (Pre-LOLs)
Likelihood Rating (Pre-LOLs)
Risk Score (Pre-LOLs)
Severity Reduction Factor (Due to LOLs)
Likelihood Reduction Factor (Due to LOLs)
Residual Severity Rating (Post-LOLs)
Residual Likelihood Rating (Post-LOLs)
Residual Risk Score (Post-LOLs)
Risk Level (Post-LOLs)
Justification for Risk Level Assessment
Identification of Additional Layers of Protection (ALOPs)
Determine if additional layers of protection are needed to reduce the risk to an acceptable level. Consider feasibility and cost-effectiveness.
Describe potential failure scenarios that existing LOLs cannot adequately address.
Which of the following ALOP types are being considered?
Estimated Cost of implementing the ALOP (in USD).
Target Implementation Date for the ALOP.
Which department/team will be responsible for ALOP implementation?
Briefly explain the rationale behind selecting this particular ALOP.
Attach supporting documentation (e.g., vendor quotes, design drawings).
Describe any potential limitations or secondary risks associated with the proposed ALOP.
Proposed ALOP Implementation
Detail the proposed implementation of any additional layers of protection. Include timelines, responsibilities, and resource allocation.
Detailed Description of Proposed ALOP
Estimated Cost of Implementation (USD)
Target Implementation Start Date
Target Implementation Completion Date
Responsible Department for Implementation
Required Resources (Select all that apply)
Supporting Documentation (e.g., vendor quotes, design drawings)
Potential Challenges & Mitigation Strategies
ALOP Effectiveness Assessment
Assess the expected effectiveness of the proposed ALOPs. Consider independent verification and potential limitations.
Has the ALOP been subject to independent review?
Estimated Reduction in Likelihood (Percentage)
Estimated Reduction in Consequence (Scale 1-5)
Justification for Estimated Reduction
What verification methods were used to assess ALOP effectiveness?
Specify 'Other' verification method (if selected)
Date of Last Verification/Testing
Upload Verification Documentation (e.g., test reports)
Risk Evaluation with Proposed ALOPs
Re-evaluate the risk level after accounting for both existing and proposed layers of protection.
Estimated Reduction in Likelihood (%), after implementing ALOPs
Estimated Reduction in Consequence Severity (Scale: 1-5, 1=Negligible, 5=Catastrophic)
Overall Risk Level After ALOP Implementation (Compared to 'Risk Evaluation After Existing LOLs')
Justification for the Assigned Risk Level
Does the calculated risk level meet the pre-defined acceptance criteria?
If 'No' to acceptance criteria, describe necessary actions or alternative strategies
Date of Next Review of Risk Level and ALOP Effectiveness
Documentation and Review
Document all findings, assumptions, and decisions made during the LOPA process. Establish a review schedule to ensure ongoing effectiveness.
LOPA Completion Date
LOPA Reviewer Name
Review Frequency (in months)
Summary of Key Findings & Recommendations
Supporting Documentation (e.g., P&IDs, Procedures)
Areas Requiring Follow-Up Actions
Notes from Review Meeting (including action items and assigned responsibility)
Date of Next Scheduled Review
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