Free template
Updated
8D report template
An 8D report is the record of an eight disciplines problem solve: a team describes a serious or repeat problem, contains it to protect the customer, verifies the root causes, proves permanent actions work and stops the problem coming back elsewhere. Ford documented the method in Team Oriented Problem Solving in 1987 and later added D0 in its Global 8D. This template gives you D0 to D8 as a 3-page printable form, plus an Excel tracker that dates every discipline, flags what is overdue and refuses to call a discipline done until its gate is met: containment counts reconciled, a verified occurrence and escape cause, every action proven in a trial before rollout, and weeks of clean production before you remove containment. A filled-in example of a customer complaint runs through both files. For one problem that does not need a team, use the corrective action request form; to list every corrective action, the CAPA log; for a problem in a supplier's process, the SCAR.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Header fields for 8D number, customer, part, champion and team leader, and sections for D0 emergency response, D1 team and D2 problem description with an is/is not table.D0 to D8 with due datesOverdue and gate checks5W2H is/is not tableContainment countsOccurrence, escape and systemic causesVerified permanent actionsEffectiveness checkD7 updatesWorked example
When to use it
When to use an 8D report
- A customer complaint or returned part, especially when the customer asks for a formal 8D response with deadlines.
- A problem that has come back after an earlier fix, which usually means the real root cause was missed.
- A problem whose causes cross several departments, such as production, maintenance, quality and a supplier.
- A safety-related or costly failure where the investigation must be documented and signed off.
- Not for everyday problems with one obvious cause: a 5 Whys with a small team is faster.
How to fill it in
- 1
Open it and set the targets (D0)
Enter the 8D number, part, customer and the date it was opened. Type your customer's deadline for each discipline in days; the sheet works out the due dates and flags anything overdue. Record the emergency response already taken.
- 2
Form the team (D1)
A champion who can free up time and money, a team leader who runs the 8D, and someone from each function that touches the process, including the supplier if a bought part is involved.
- 3
Describe the problem (D2)
Write a problem statement with a number in it, then fill the 5W2H and is / is not table on the form. Where the problem is not seen matters as much as where it is.
- 4
Contain it (D3)
List every place a suspect part can be: in process, finished goods, in transit, at the customer and at the supplier. Record suspect, checked and bad for each, and the clean point, the first lot known to be good. The sheet flags a sort that ended with parts unchecked.
- 5
Verify the root causes (D4)
Find the occurrence cause (why it happened), the escape cause (why your controls missed it) and the systemic cause (why the management system allowed it). Verify each with data or a test, and keep the causes you ruled out as a record.
- 6
Prove the permanent actions (D5 and D6)
Link each action to a verified cause, try it before rollout and record the result (D5 verification). Record the date it went in, then count weeks of normal production with no defects (D6 validation). Remove containment only when the target is met.
- 7
Prevent recurrence and close (D7 and D8)
Update the process FMEA, control plan, instructions and training, check similar parts, lines and sites, thank the team and close when the customer agrees. The sheet will not pass D8 while an earlier discipline or gate is open.
A filled-in example
Illustrative, not a benchmarkAn example: 3 of 1,200 hose assemblies in one delivery leaked at the crimped fitting on the customer's pressure test (illustrative numbers).
The example 8D at day 45, discipline by discipline
- D2 Problem
3 of 1,200 leaked at the customer; all built on line 2 after a crimp die change
- D3 Containment
3,150 suspect assemblies sorted, 12 bad (0.38%); every line 2 assembly leak tested
- D4 Root causes
Occurrence: no crimp diameter on the setup sheet. Escape: 1 leak test per 50. Systemic: no first-piece check for a new die
- D5 and D6 Permanent actions
Three actions, each passed a trial before rollout; last one in on day 20; 3 of 6 clean weeks so far
- D7 Prevent recurrence
4 of 6 updates done: FMEA, control plan, instructions and training. Line 1 and the other crimp stations still to check
The example 8D at day 45 as five steps: the problem, 3 of 1,200 hose assemblies leaking after a crimp die change on line 2; containment, 3,150 sorted with 12 bad; three verified root causes; three permanent actions, the last in on day 20, with 3 of 6 clean weeks so far; and 4 of 6 prevention updates done.
- D2: all 3 were built on line 2 after a crimp die change; line 1 builds the same part with no leaks.
- D3: 3,150 suspect assemblies sorted at the customer, in transit, in finished goods and in WIP, 12 found leaking (0.38%). An ongoing 100% leak test on line 2 has checked 14,600 and caught 9, all before the fix.
- D4: occurrence, the new die was set to the wrong crimp diameter because the setup sheet had no value for it (6 of 20 trial crimps out of limit with the old sheet). Escape, the leak test checked 1 assembly per batch of 50. Systemic, the die change procedure asked for no first-piece check. A supplier hose lot was ruled out.
- D5: three actions, each tried before rollout: the diameter on the setup sheet with a first-piece check (200 trial assemblies, 0 leaks), 100% in-line leak test, and a first-piece sign-off for new dies.
- D6 and D7: the last action went in on day 20. On day 45 there are 3 full weeks of production with no leaks against the 6 required, so containment stays. 4 of 6 D7 updates are done.
At day 45: D0 to D5 are done (D5 3 days late, 18 against a 15-day target), D6 is at 3 of 6 clean weeks, 21 bad parts have been caught out of 17,750 checked, and no verified cause is without a proven action.
Common mistakes
Closing the 8D at containment
Once sorting stops the complaints, the pressure drops and the root cause is never found. The 8D stays open until D6 data proves the fix.
Only asking why it happened
Without the escape cause, the next defect gets out the same way. D4 needs both occurrence and escape, and the systemic cause stops the same gap appearing on the next part.
A root cause nobody verified
A plausible cause agreed in a meeting is not a root cause. Put it back and the problem should return; take it away and it should stop.
Treating a trial as proof
A 200-piece trial shows the action can work (D5). Only weeks of normal production show it does work (D6). Remove containment after the second, not the first.
Skipping D7
The same setup sheet gap usually exists on similar parts, lines or sites. Check them before they fail the same way.
In LeanSuite
Use this as a Lean Studio board
The same method is one of the 30 ready-made board templates in Lean Studio, LeanSuite's whiteboard: 8D Report, work a structured 8D problem-solving report from team formation through closure.
- Start from the 8D Report template: eight boxes in order, D1 to D8.
- Fill each box with stickies as the discipline completes, and link a fishbone or 5 Whys board for D4.
- Keep the board open until D8 so the team can see the disciplines still empty.
Worked example · sample data
The sample 8D handles a customer return of 14 units with a loose connector. D1 formed a team from quality, assembly and supplier QA. D2 described the problem by count and defect. D3 put a 100% pull test at final assembly from 3 June, so no further loose connectors could reach the customer while the cause was found. D4 traced it to a crimp tool worn past its limit. D5 chose a tool-life counter with replacement at 40,000 crimps, and D6 fitted counters on all three tools by 10 June. D7 added tool life to the PM plan, so the check no longer depends on anyone remembering. D8 closed after eight weeks with zero returns, and the team was recognised. The containment pull test was then withdrawn.
Open this board in LeanSuite
8D Report is one of the 30 ready-made boards in Lean Studio, LeanSuite's whiteboard. Try LeanSuite in your browser, or run it on your own lines for 90 days.
What Lean Studio isHow to run an 8D Report session
- 1D1 to D3 in the first 24 to 48 hours: name the team, describe the problem with what, where, when and how many, and put containment in place so the customer sees no more defects while the cause is found.
- 2D4: prove the root cause with data and an is/is-not comparison; a fishbone or 5 Whys board feeds this box. Ask why the defect was made and why it was not detected.
- 3D5 and D6: choose the corrective action that removes the cause, verify it works before rolling it out, then implement it and remove the containment.
- 4D7: change the system that allowed it: the FMEA, the control plan, the PM plan, the work instruction. This is the box most 8Ds leave thin.
- 5D8: close with the customer, record what was learned and recognise the team. Keep the board until the customer accepts the closure.
Common mistakes
- Leaving containment in place for months as if it were the fix.
- Jumping to D5 with a corrective action before D4 is proven.
- A D4 that says 'operator error'. Ask why the process let the error happen and why it was not caught.
- A thin D7. If the FMEA, control plan or PM plan did not change, the problem will return on a different part.
- Closing D8 without the customer's agreement.
Where it goes next in LeanSuite
- Run an 8D as a Kaizen project with your own defined method: eight phases with owners, due dates and the fields that must be filled in before a project can move on; a CAPA runs as a quality project with its own approval steps and root cause sections. Kaizen & Projects
- The D7 check can become a scheduled audit in Audit Management, so it is done and recorded rather than remembered. Audit Management
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite, operators flag a non-conformance from the line with photos, containment is assigned and tracked before root cause analysis starts, and systemic issues run through an 8D template with a time-stamped sign-off at each D-step.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- 8D Problem Solving: The Eight Disciplines Method for Manufacturing
- Is/Is Not Analysis: Problem Definition for Root Cause Analysis
- CAPA Systems in Manufacturing: Corrective and Preventive Action Explained
- Non-Conformance Reports: Managing Quality Deviations in Manufacturing
- Best root cause analysis software: 4 tools compared
- Best CAPA software: 6 tools compared
Put it on the wall
FAQ
8D report template: common questions
Eight disciplines: the steps of the method from forming the team (D1) to recognizing it (D8). Ford documented them in Team Oriented Problem Solving in 1987, and its later Global 8D added D0 for preparation and the emergency response.
Containment (D3) protects the customer while the cause is unknown, for example sorting stock and testing every part. A permanent corrective action (D5 and D6) removes the verified root cause. Keep containment until production data shows the permanent action works.
Occurrence is why the defect was made. Escape is why the controls did not catch it, at the earliest point that should have. Systemic is why the management system allowed both, such as a procedure with no first-piece check. Each needs its own action.
When D6 validation shows the problem is gone in normal production for the period you or the customer set, the containment has been removed, the D7 updates are done and the customer agrees. A trial run before rollout is D5 verification, not proof that the fix holds.
Use an 8D for customer complaints, repeat problems and problems with causes in several departments. The corrective action form records one internal nonconformity, the CAPA log lists them all, a SCAR asks a supplier for their 8D, and a 5 Whys is enough for an everyday problem with one cause chain.
More free templates
All templates- A3 problem solving templateThe standard seven-box A3 from background to follow-up, with a filled-in worked example. PDF and Excel.
- PDCA templateOne improvement cycle on one page: plan, do, check against the goal, then standardize or adjust. PDF and Excel.
- 5 Whys templateA problem statement, a why chain that can branch, evidence for every answer, root causes and countermeasures that are checked.
- 5W1H templateWho, what, when, where, why and how: a problem statement built from checked facts, and an action plan with nothing left open.
- Poka-yoke worksheetEach step's errors and what they cost, the device (approach, function, method), payback, and a log that proves each device works.
- Layered process audit (LPA) checklist20 yes, no or N/A checks at the station, a fixed-on-the-spot box, scores by group and a findings table.
- PFMEA template (process FMEA)Failure modes, effects and causes rated for severity, occurrence and detection, with RPN before and after action.
- Pareto chart templateA tally sheet, the Pareto by count and by cost with the cumulative line and the 80% cut, and a before and after comparison. Excel sorts and draws it.
- Control plan templateWhat is checked at each step, against which limits, how, how often, and what to do when a result is out.
- Corrective action request (CAPA) formOne problem from containment to proof the fix worked, with occurrence and escape causes and a closure check that tells you when it can close.
- Non-conformance report (NCR) formA two-page NCR from the requirement against what was found to disposition and closure, and an Excel NCR log.
- CAPA log templateAn Excel CAPA tracker with status, days open, late flags and counts by source, plus a printable log and monthly review.
- Supplier corrective action request (SCAR) formA SCAR from the problem and containment asked for to the supplier's 8D-style response, verification and closure.
- First article inspection (FAI) report templatePart information, a ballooned characteristic table with tolerances and results, material and process certificates, and sign-off.
- Design FMEA (DFMEA) templateA design FMEA worksheet with S, O, D and RPN before and after action, a class column and a design rating guide.
- PPAP checklistThe 18 PPAP elements with owner, due date and status, the five submission levels and a readiness count.
- Process capability (Cpk) study sheet25 subgroups of readings with Cp, Cpk, Pp and Ppk worked out, control limits to check stability, and a histogram.
- Incoming inspection checklistReceiving inspection checks from paperwork to sample, the sampling plan, the decision, and an Excel log by supplier.
- Supplier audit checklistA supplier process audit of 32 questions scored 0 to 3, with section scores, a rating and the findings.
- Supplier scorecardMonthly PPM, on-time delivery and SCAR measures turned into points, a weighted score and a rating per supplier.
- Pre-shipment inspection checklistThe last check before shipping: part, quantity, labels, packaging, paperwork and photos, then release.
- Defect check sheetTally defects by type and day, with units inspected, defect rates, a location sheet and the week's Pareto.
- DMAIC project charter templateThe Define-phase charter on one page: problem and goal, metrics, scope, team and phase dates, with savings and a tollgate checklist.
- QA matrix templateDefect modes against stations in flow order: where each is made and first caught, a weight × occurrence × detection score, an AA to C class and the escapes flagged.
- Fault tree analysis templateA drawing area with the FTA symbols, an event table with probabilities and minimal cut sets, and the gates worked out bottom-up in Excel.
- Is / is not analysis templateWhat, where, when and extent with is, is not, distinctions and changes, then each possible cause tested against every pair and ranked.
- 5G investigation sheetConfirm the facts before naming a cause: 5W1H, the five G's with 20 prompts, the gap against the principle and the standard, and the countermeasures.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- Histogram templateReadings, bins set by the square root rule, a tally and counts, the spec limits drawn and the share out of spec, with the common shapes explained.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Gauge calibration logA gauge register with next due dates and status, a calibration record with as-found and as-left readings, and the steps when a gauge fails.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- TQM self-assessment templateThe eight TQM principles in 24 statements you can check on the floor, scored 0 to 4 by several people, with the spread, the top 3 gaps and an action plan.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- 5S audit checklist template25 checks, five per S, scored 1 to 5, with a score summary and a chart of the five S's.
- 1-1-90 method worksheetOne page: score areas 1 to 5, write the pain point with a before and target number, check days 30, 60 and 90, and plan the next three areas.
- Gemba walk checklistA walk plan and route, 30 prompts in six groups and a findings table with owners and due dates.
- Leader standard work templateA team leader's daily, weekly and monthly routine with a box per day, follow-ups and a weekly review.
- Supervisor leader standard work templateA supervisor's daily, weekly and monthly routine with a box per day, an escalation log and a weekly review.
- Production manager leader standard work templateA production or value stream manager's routine by day, week and month, with an escalation log and a weekly review.
- Plant manager leader standard work templateA plant manager's short routine by day, week and month, with an escalation log and a weekly review.
- Autonomous maintenance (CILR) checklist20 clean, inspect, lubricate and retighten checks with a box per day, an abnormality log and sign-off.
- Skills matrix templatePeople by tasks on a 0 to 4 scale, coverage and gaps per task and shift, and a training plan that closes them.
- Standard work sheet templateTakt time, each element's manual, machine and walk time on a time chart, key points and standard WIP.
- One point lesson (OPL) templateOne topic on one page: wrong way and right way pictures, checkable key points, the standard it belongs to and a sign-off record.
- SMED changeover worksheetChangeover steps with times, internal or external, what can move, ideas and before/after totals.
- Kaizen event charter templateProblem, goal, scope in and out, boundaries, metrics from baseline to target, team and roles, and sign-off before day one.
- RACI matrix template17 kaizen project tasks by 10 roles, with R, A, C, I drop-downs and a check for one accountable per task.
- 5S red tag log and red tagsA log of every red-tagged item with its decision, and six printable red tags to cut out.
- Shift handover templateSafety, production against plan, holds, downtime events, materials and people, and the open actions the next shift takes over.
- Kanban card templateSix production and six withdrawal kanban cards to print and cut out, with loop sizing and a card register.
- Idea suggestion formA one-page idea form with the supervisor's answer and points, and an idea log that tracks days to answer.
- Just Do It (JDI) card templateSix Just Do It cards per sheet for quick fixes, with the rules for what counts and a log of every card.
- Quick kaizen templateOne page for a small improvement: before and after, the cause, the countermeasure, the results and whether the standard changed.
- Time study sheetTime each element over 10 cycles and work out the average, lowest repeatable and standard time. Excel does the sums.
- Spaghetti diagram templateSquared paper to trace every trip, a trip log that turns grid squares into feet, meters and walking time, and a before and after comparison.
- OEE tracking sheetOne row per shift for a week. The Excel version works out availability, performance, quality and OEE and charts the week.
- Near miss report formA two-page near miss report from the first report to closure, and an Excel log with status and days open.
- Safety observation card templateFour behavior-based safety cards per sheet, with safe and at-risk checks, the conversation and a tally sheet.
- Job safety analysis (JSA) templateJob steps, hazards, risk scored before and after the controls, the hierarchy of controls, PPE and sign-off.
- Risk assessment matrix template (5×5)A color-coded 5 × 5 severity and likelihood matrix, a scoring guide and a risk register.
- Incident investigation report templateFacts and a sourced timeline, causes at three levels, actions by the hierarchy of controls, a US recordkeeping screen and a closure check.
- Toolbox talk templateA record of a short safety talk: topic, key points, questions raised, actions and an attendee sign-in sheet.
- Lockout/tagout (LOTO) procedure templateA machine-specific LOTO procedure: energy sources and isolation points, the steps from shutdown to restart, and the annual review.
- Forklift inspection checklist23 pre-shift checks for a week on one page, a do-not-operate rule, and a defect and repair log.
- Preventive maintenance checklist templateA PM checklist per machine with readings and sign-off, and a PM schedule that works out the next due date.
- Equipment downtime log (MTTR and MTBF)A breakdown and downtime log, with MTTR, MTBF and downtime by machine and cause worked out in Excel.
- Environmental aspects and impacts registerAn ISO 14001-style register of aspects and impacts, with significance scoring, legal requirements, controls and owners.
- Manufacturing process instruction (MPI) templateOperation steps with parameters, tools, quality checks, safety and a photo each, plus revision history and approval.
- Engineering process instruction (EPI) templateScope, parameters and limits, equipment and materials, validation steps, acceptance criteria, change history and approvals.
- Training sign-off sheetAn attendance and sign-off record where each person signs they understood, with a competence check and an Excel log.
- On-the-job training (OJT) checklistThe training record for one trainee on one job: the four TWI steps signed, every try judged, qualified when your rule is met, then tapering follow-up checks.
- New hire onboarding checklist (manufacturing)29 onboarding items from before day 1 to the 90-day review, with owners, dates and review notes.
- Competency assessment formThe one-person assessment behind a skills matrix rating: each task rated 0 to 4 from evidence, checked, with a training plan for every gap.
- Cross-training plan templateWho is learning which task, from and to which level, by when, and how many are qualified on each task.
- Absenteeism tracker templateA monthly attendance grid with codes, absence rate by person and team, and an optional Bradford factor.
- Engineering change request (ECR) formAn ECR form with the change, what it touches, risk and approvals, and an Excel log that tracks each change to done.
- Process flow diagram templateA squared sheet to draw the flow with a symbol key, and a step table that counts operations, moves, checks, waits and storage.
- Office 5S audit checklist25 checks written for offices and shared areas, five per S, scored 1 to 5, with a score summary and actions.
- Floor marking color guideA floor marking color standard with swatches, marks and line widths to fill in, and a floor marking check with a layout sketch.
- Shadow board plannerTool inventory with fetch time, a layout planned from each tool's outline size, a month of daily checks with 5S audit evidence, and a missing tool log.
- Lubrication schedule templateEvery lube point with lubricant, method, amount, frequency and who, with next due dates and a monthly sign-off record.
- TPM tag logEvery abnormality tag with type, who fixes it, priority and dates, with days open and counts by type and week.
- Autonomous maintenance step auditCriteria for each of the seven autonomous maintenance steps, scored 0 to 2, with the step result and the decision to move on.
- Inventory cycle count sheetA blind count sheet with variance and tolerance, an ABC count schedule and record accuracy, worked out in Excel.
- Hour-by-hour production boardHourly plan against actual with running totals and the reason for each miss, plus a shift summary by reason.
- Cost savings trackerA savings log with hard and soft savings, payback and Finance's sign-off, plus a glide path against the year's target.
- CapEx request formA capital request with options, costs, benefits, payback and NPV, and the approval levels the amount needs.
- Cost-benefit analysis templateUp to three options side by side with costs, hard and soft benefits, payback, NPV and the benefit-cost ratio.
- Cost of poor quality (COPQ) worksheetCost of quality by prevention, appraisal, internal and external failure, with COPQ as a share of sales.
- Receiving logA dock receiving log with quantities, damage, QC holds and putaway, plus a discrepancy report and dock-to-stock time.
- Warehouse safety inspection checklistThirty warehouse safety checks from aisles to fire exits, marked OK or Not OK, with an action for every finding.
- Pallet racking inspection checklistRack checks per aisle with a green, amber and red damage rating, and a damage log with repair dates.
- Material shortage logEvery part short with its need date, line impact, ETA and escalation, and counts by reason and supplier.
- Safety audit checklistThirty-four plant-wide safety checks answered Yes, No or N/A, scored by area, with a risk rating and an action for every No.
- Ergonomic risk assessment checklistScreen a task for 21 ergonomic risk factors, score how long each lasts, and rank tasks so the worst get controls first.
- Maintenance work order formOne form per maintenance job from request to handback, and a log that tracks response, completion and backlog by priority.
- Six big losses worksheetWhere a machine's planned time goes: the six big losses in minutes, ranked, with A, P, Q and OEE worked out.
- Andon response logEvery andon call with response and fix times, flags against your targets, and counts by type and station.
- Changeover checklist25 checks for every changeover, a record of planned and actual times, and a log of changeover time against target.
- Kanban sizing calculatorHow many kanban cards each loop needs, per part, with the change from today's cards and what the loop holds in days.
- Kaizen event trackerEvery kaizen event on one sheet: status, roles, the metric against target, open actions and the 30, 60 and 90 day checks.
- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
- TWI job breakdown sheetThe TWI Job Instruction breakdown of a job into important steps, key points and reasons, with a worked example and the four steps.
- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Maintenance KPI trackerMTBF, MTTR, availability and PM compliance per asset and month, plant figures from the totals, planned maintenance % and backlog in weeks.
- Daily huddle agendaA 15-minute start-of-shift stand-up in six timed blocks, with yesterday's SQCDP results, today's plan, actions and escalations.
- Water spider route plan (mizusumashi)A water spider's fixed route: stops with arrival times, what is delivered and collected, route time against the cycle, cart load and a trip log.
- Cost deployment matrixWCM cost deployment on paper and in Excel: loss quantities by process, causal and resultant losses, the cost of each loss, a Pareto and the projects that recover them.
- Equipment criticality analysisAssets scored 1 to 5 on six criteria with your own weights, ranked and sorted into classes A, B and C with a safety override and a suggested maintenance strategy.
- Bottleneck analysis worksheetEffective capacity per station from cycle time, parallel units, availability and yield, the bottleneck, takt and utilization, a queue cross-check and the five focusing steps.
- Yokoten tracker (horizontal deployment)Copy a proven improvement line by line: the source result, each candidate's own before and after, its share of the source's improvement and the standard updated.
- Coaching kata template (improvement kata storyboard)The learner's storyboard (target condition, current condition, obstacles, PDCA cycles) and a fold-over card with the coach's five questions.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Nemawashi template (stakeholder plan)Plan the one-to-one conversations before a decision: who to talk to in what order, their concerns, what changed and where they stand.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- Future state value stream map worksheetThe eight future-state questions worked through in order: takt, pitch, flow, supermarkets, the pacemaker and the mix, with an EPEI check and current against future lead time.
- Value stream plan (VSM action plan)The future-state map cut into loops, each with an objective and a measurable goal, and its kaizen bursts turned into owned, dated projects on a 12-month timeline.
- Kaizen project plan (Gantt chart)One improvement project as a Gantt chart: tasks by phase with owners, predecessors and working days, a 16-week grid, milestones and a status from planned against actual % done.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
Can't find the template you need?
Tell us what you're looking for. We'll make it and send it to your inbox, free.
A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.