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Downtime reason codes template
Downtime reason codes are the short list of reasons an operator picks from when a machine stops, so every lost minute lands in a category someone can act on. A list that works is short enough to pick from in seconds, has one code for each kind of stop, and rolls up to the six big losses, so the minutes feed availability, performance and quality the way OEE does. This template starts you with 26 codes for a filling or packaging line: 3 for time that is not planned and 23 under breakdowns and unplanned stops, setup and adjustments, small stops, reduced speed, process defects and startup rejects. Each code has a description, an example, planned or unplanned, an owner and a rule for when to record it. The Excel log takes codes from a drop-down, turns scrap into minutes, works out availability and a Pareto by code and by big loss, and flags when the catch-all code passes its limit or a code goes unused. The PDF has the code card to post at the line, a paper shift log, the rules for designing your own list and a worked example.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
A code card for the line with large codes grouped as breakdowns, waiting, small stops, setup and adjustments, slow running, scrap and rework, unlisted and not planned time, with the rules for small stops, breakdown time and changeovers.When to use it
When to use a downtime reason code list
- Setting up downtime tracking on a line for the first time, before the first log sheet goes out.
- When the top reason on your downtime Pareto is Other, Misc or blank.
- When operators pick different codes for the same stop, or the list has grown past what anyone can scan in a few seconds.
- Before you track OEE or the six big losses, so each lost minute lands in the right factor.
- At the 30-day review of a list already in use, to drop unused codes and split the catch-all.
How to fill it in
- 1
Start from the starter list
Rename the codes for your equipment on the Code list sheet. Keep the first letter for the group (B breakdown, W waiting, S setup, M small stop, R speed, Q quality, X not planned, Z unlisted) and stay at or under 25 loss codes for a machine.
- 2
Write the rules down
Set your small-stop limit (5 minutes is the starting value), the ideal cycle time, the Unlisted limit and whether planned stops count in availability. Write the small-stop limit on the code card.
- 3
Test it on last week's stops
Give the same five stops to two people and ask each to code them. Where they disagree, rewrite the Record when rule, not the people.
- 4
Post the card and log every stop
One row for each stop at or over the limit, with its minutes. Tally shorter stops on M1 or M2 each shift. Scrap and rework go in as parts; the Excel turns them into minutes.
- 5
Read the Pareto every week
Take the top code to its owner. If Unlisted is over its limit, read the notes and split it into new codes.
- 6
Review after 30 days
Drop or merge codes nobody used, keep rare costly ones such as a utility failure, reprint the card, then review with the Pareto every month.
The starter list
26 downtime reason codes, grouped by loss
An example list for a filling or packaging line, made for this template, not a standard. Each code rolls up to one of the six big losses or to time that is not planned. Rename the codes to fit your machines and keep the rules.
| Code | Reason | Big loss | Planned or unplanned | Owner | Record when |
|---|---|---|---|---|---|
| X1 | Break or meal | Not planned time | Planned | Production | The whole scheduled break. If the line runs through the break, log nothing. |
| X2 | No orders or not scheduled | Not planned time | Planned | Planning | The whole period with no work planned. |
| X3 | Planned meeting or training | Not planned time | Planned | Production | Only when it is on the plan and the line stops for it. |
| S1 | Changeover | Setup and adjustments | Planned | Production | From the last good part of one product to the first good part of the next. |
| S2 | Planned cleaning | Setup and adjustments | Planned | Production | From the stop for the clean to the first good part. |
| S3 | Planned maintenance | Setup and adjustments | Planned | Maintenance | Only scheduled work. A repair is a B code. |
| S4 | Start-up or warm-up | Setup and adjustments | Planned | Production | From start to the first good part after a planned start. After a changeover, use S1. |
| S5 | Reel or consumable change | Setup and adjustments | Planned | Production | Each change, or a tally per shift with the total minutes. |
| S6 | Unplanned adjustment | Setup and adjustments | Unplanned | Production | Adjustments outside a changeover. Inside a changeover they stay in S1. |
| B1 | Mechanical failure | Breakdowns and unplanned stops | Unplanned | Maintenance | From the stop to running again, including waiting for the technician and parts. |
| B2 | Electrical or controls failure | Breakdowns and unplanned stops | Unplanned | Maintenance | As B1. An operator reset with no repair is M2. |
| B3 | Hydraulic or pneumatic failure | Breakdowns and unplanned stops | Unplanned | Maintenance | As B1. |
| B4 | Tooling or change part failure | Breakdowns and unplanned stops | Unplanned | Maintenance | As B1. A planned tool change is S1. |
| B5 | Utility failure | Breakdowns and unplanned stops | Unplanned | Maintenance | From the stop to running again. Keep this code even when it is rarely used. |
| W1 | Waiting for material | Breakdowns and unplanned stops | Unplanned | Materials | From the stop to the material arriving and the line running. |
| W2 | Waiting for operator | Breakdowns and unplanned stops | Unplanned | Production | From the stop to the station staffed and running. |
| W3 | Waiting for quality release | Breakdowns and unplanned stops | Unplanned | Quality | From the request to the release. |
| W4 | Starved or blocked | Breakdowns and unplanned stops | Unplanned | Production | Only on a log kept per machine. On a whole-line log, use the code of the machine that stopped. |
| M1 | Jam or misfeed | Small stops | Unplanned | Production | Under the small-stop limit. Tally the count and the minutes each shift. |
| M2 | Sensor trip or fault reset | Small stops | Unplanned | Production | Under the small-stop limit. Tally as M1. |
| R1 | Slow running: material | Reduced speed | Not a stop | Production | Minutes lost = minutes run slow × (1 − actual rate ÷ rated rate). |
| R2 | Slow running: machine condition | Reduced speed | Not a stop | Maintenance | As R1. |
| Q1 | Scrap in steady running | Process defects | Not a stop | Quality | Enter the parts. The Excel turns parts into minutes. |
| Q2 | Rework in steady running | Process defects | Not a stop | Quality | Enter the parts. A reworked part is not a good part. |
| Q3 | Start-up scrap | Startup rejects | Not a stop | Quality | Enter the parts made before the process was stable. |
| Z1 | Unlisted (write what happened) | Breakdowns and unplanned stops | Unplanned | Production | Always write what happened. Review it every week and split it when it grows. |
X1
- Reason
- Break or meal
- Big loss
- Not planned time
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- The whole scheduled break. If the line runs through the break, log nothing.
X2
- Reason
- No orders or not scheduled
- Big loss
- Not planned time
- Planned or unplanned
- Planned
- Owner
- Planning
- Record when
- The whole period with no work planned.
X3
- Reason
- Planned meeting or training
- Big loss
- Not planned time
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- Only when it is on the plan and the line stops for it.
S1
- Reason
- Changeover
- Big loss
- Setup and adjustments
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- From the last good part of one product to the first good part of the next.
S2
- Reason
- Planned cleaning
- Big loss
- Setup and adjustments
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- From the stop for the clean to the first good part.
S3
- Reason
- Planned maintenance
- Big loss
- Setup and adjustments
- Planned or unplanned
- Planned
- Owner
- Maintenance
- Record when
- Only scheduled work. A repair is a B code.
S4
- Reason
- Start-up or warm-up
- Big loss
- Setup and adjustments
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- From start to the first good part after a planned start. After a changeover, use S1.
S5
- Reason
- Reel or consumable change
- Big loss
- Setup and adjustments
- Planned or unplanned
- Planned
- Owner
- Production
- Record when
- Each change, or a tally per shift with the total minutes.
S6
- Reason
- Unplanned adjustment
- Big loss
- Setup and adjustments
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- Adjustments outside a changeover. Inside a changeover they stay in S1.
B1
- Reason
- Mechanical failure
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Maintenance
- Record when
- From the stop to running again, including waiting for the technician and parts.
B2
- Reason
- Electrical or controls failure
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Maintenance
- Record when
- As B1. An operator reset with no repair is M2.
B3
- Reason
- Hydraulic or pneumatic failure
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Maintenance
- Record when
- As B1.
B4
- Reason
- Tooling or change part failure
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Maintenance
- Record when
- As B1. A planned tool change is S1.
B5
- Reason
- Utility failure
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Maintenance
- Record when
- From the stop to running again. Keep this code even when it is rarely used.
W1
- Reason
- Waiting for material
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Materials
- Record when
- From the stop to the material arriving and the line running.
W2
- Reason
- Waiting for operator
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- From the stop to the station staffed and running.
W3
- Reason
- Waiting for quality release
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Quality
- Record when
- From the request to the release.
W4
- Reason
- Starved or blocked
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- Only on a log kept per machine. On a whole-line log, use the code of the machine that stopped.
M1
- Reason
- Jam or misfeed
- Big loss
- Small stops
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- Under the small-stop limit. Tally the count and the minutes each shift.
M2
- Reason
- Sensor trip or fault reset
- Big loss
- Small stops
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- Under the small-stop limit. Tally as M1.
R1
- Reason
- Slow running: material
- Big loss
- Reduced speed
- Planned or unplanned
- Not a stop
- Owner
- Production
- Record when
- Minutes lost = minutes run slow × (1 − actual rate ÷ rated rate).
R2
- Reason
- Slow running: machine condition
- Big loss
- Reduced speed
- Planned or unplanned
- Not a stop
- Owner
- Maintenance
- Record when
- As R1.
Q1
- Reason
- Scrap in steady running
- Big loss
- Process defects
- Planned or unplanned
- Not a stop
- Owner
- Quality
- Record when
- Enter the parts. The Excel turns parts into minutes.
Q2
- Reason
- Rework in steady running
- Big loss
- Process defects
- Planned or unplanned
- Not a stop
- Owner
- Quality
- Record when
- Enter the parts. A reworked part is not a good part.
Q3
- Reason
- Start-up scrap
- Big loss
- Startup rejects
- Planned or unplanned
- Not a stop
- Owner
- Quality
- Record when
- Enter the parts made before the process was stable.
Z1
- Reason
- Unlisted (write what happened)
- Big loss
- Breakdowns and unplanned stops
- Planned or unplanned
- Unplanned
- Owner
- Production
- Record when
- Always write what happened. Review it every week and split it when it grows.
A filled-in example
Illustrative, not a benchmarkAn example: the filler on line 2, the constraint, logged for 4 weeks of one 480-minute shift a day (illustrative numbers).
The example month's 2,622 lost minutes, by loss
- Setup and adjustments: 1013, 39% of the total, cumulative 39%.
- Breakdowns and unplanned stops: 853, 33% of the total, cumulative 71%.
- Small stops: 599, 23% of the total, cumulative 94%.
- Scrap and rework: 92, 4% of the total, cumulative 98%.
- Slow running: 65, 2% of the total, cumulative 100%.
Availability = (planned production time − availability losses) ÷ planned production time
The rule on the card: planned stops such as changeovers count as availability losses.
- Planned stops counted: (8,820 − 1,866) ÷ 8,820= 78.8%
- The same month with planned stops taken out= 88.5%
Pareto chart of the filler's 2,622 lost minutes: setup and adjustments 1,013, breakdowns and unplanned stops 853, small stops 599, scrap and rework 92, slow running 65. The two availability losses, 1,866 minutes, are the first two bars. Availability is 78.8 percent with planned stops counted as losses, and would read 88.5 percent with them taken out.
- Scheduled time 20 × 480 = 9,600 min. Breaks, no orders and team meetings (the X codes) take out 780 min, leaving 8,820 min of planned production time.
- Setup and adjustments lost 1,013 min and breakdowns and unplanned stops 853 min, so availability is (8,820 − 1,866) ÷ 8,820 = 78.8%.
- Small stops (339, tallied) cost 599 min, slow running 65 min, and 11,040 scrapped or reworked bottles at 0.5 seconds each 92 min: 2,622 lost minutes in all.
- Top codes: changeover 474 min (18.1%), jam or misfeed 460 (17.5%), Unlisted 318 (12.1%). Two codes, utility failure and slow running for machine condition, were not used.
Unlisted is over the 10% limit. Its notes show 255 min of one symptom, a capper torque alarm, so the team adds it as a breakdown code. Taking planned stops out of availability instead would show 88.5% for the same month, which is why the rule goes on the card.
Common mistakes
An Other code with no limit
When Other is the easy pick it becomes the top reason and the Pareto says nothing. Make a note compulsory and split it when it passes the limit.
Root causes as codes
An operator can see a jam. A worn cam follower takes a repair to find. Code the symptom and find the cause in a breakdown analysis.
Too many codes
With 80 codes on the list, people pick the first one that looks close. Vorne's guidance is no more than 25 for a machine.
Waiting for maintenance as its own code
It splits one breakdown into two and hides the real repair time. Breakdown time runs from the stop to running again.
Changing the planned-stop rule mid-year
Availability jumps with no change on the line. Pick the rule, write it on the card and keep it.
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 you upload loss data from a spreadsheet and map its columns once; each record is sorted into a cost bucket and a causal or resultant loss, and a loss tree ranked by cost shows which losses to work on first.
See it in a 45-minute demoIn the lean glossary
FAQ
Downtime reason codes template: common questions
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- 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.
- Forklift inspection checklist23 pre-shift checks for a week on one page, a do-not-operate rule, and a defect and repair log.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Pre-shipment inspection checklistThe last check before shipping: part, quantity, labels, packaging, paperwork and photos, then release.
- 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.
- 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.
- Defect check sheetTally defects by type and day, with units inspected, defect rates, a location sheet and the week's Pareto.
- 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.
- 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.
- 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.
- Cost deployment matrixCost 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.