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Emergency action plan template
An emergency action plan is the written answer to what everyone on a site does in an emergency: how it is reported, where people go, who does what, who stays to make critical equipment safe, and how you know everyone is out. In the United States OSHA's emergency action plan standard (29 CFR 1910.38) applies to many workplaces and expects the plan in writing once an employer has more than ten employees; check the rules that apply where you are. This template has five landscape pages: site facts and emergency numbers, roles with a named backup for each, a warden coverage grid by area and shift, a starting procedure for fire, chemical release, severe weather, medical emergency and power loss, a drill record with a yearly review, and a worked example. The Excel version adds a roster with training dates, coverage that flags any area with people but no warden, a drill log that works out minutes and checks the head count, and a yearly review date. It is a general starting point, not legal advice.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Site, address, plan owner and review date above a table of twelve site facts and a table of emergency numbers.Site facts and emergency numbersRoles with a backupWarden coverage by area and shiftSteps for five scenariosDrill record with head countYearly reviewWorked example
When to use it
When to write or update an emergency action plan
- When a site has no written plan, or the one it has is a page nobody has read since it was filed.
- After a layout change, a new shift pattern, a new hazard such as a chemical store, or a change of coordinator.
- Before an audit, an insurer visit or a customer visit that will ask for the plan and the drill records.
- After a drill or a real event shows that people did not know where to go or who was in charge.
- At least once a year, as a review with the people who carry the plan out.
How to fill it in
- 1
Fill in the site facts and numbers
Write how many people are on site by shift, how the alarm sounds, where the assembly points are, where responders enter and where the shut-offs are. Add the emergency numbers on the same page, so the plan can be used without looking anywhere else.
- 2
Name a person and a backup for every role
A coordinator, a deputy, area wardens, first aiders, a shutdown lead, a head count lead and a person to meet responders. People are on leave and shifts differ, so every role needs a named backup.
- 3
Check warden coverage by area and shift
List each area and the people usually there on each shift, then the warden for each box. An empty box is a gap. The night shift and the weekend are where gaps usually hide.
- 4
Adapt the scenario steps
Start from the steps given for fire, chemical release, severe weather, medical emergency and power loss. Change them to fit your site, add the signal people will hear and where they go, and add any scenario your site has that these do not cover.
- 5
Train, then drill
Walk everyone through the plan when they join and when it changes. Run a drill, time it from the alarm to the last area counted, and compare the people counted with the people expected.
- 6
Fix what the drill shows and review the plan
Write down each problem with an owner and a date, and close it. Review the whole plan at least once a year, and whenever the layout, hazards, people or contacts change.
A filled-in example
Illustrative, not a benchmarkAn example: a made-up plant of 180 people on two shifts, with four assembly points and five areas.
- Shift 1 has 122 people and shift 2 has 58. The coverage grid lists each area with its wardens.
- Laid out by area and shift, the grid shows the warehouse has 9 people on shift 2 and no warden. The plan looked complete until it was drawn this way.
- The first drill took 9 minutes and counted 118 of 118. It found a warehouse door blocked by pallets, so the pallets moved and a keep-clear zone was marked.
- The second drill, on shift 2, took 13 minutes and counted 56 of 58. Two people had been sent home early without signing out, so a sign-out step was added to the shift handover and two wardens were named for the warehouse.
Both fixes came from counting and timing a real drill against a roster, not from rereading the plan. The numbers are invented to show how the form is used.
Common mistakes
No backup for a role
A plan that names one person per role fails the day that person is on leave. Name a backup for each role and put both on the roster.
Plan written for the day shift only
The night shift and the weekend have fewer people and often no one with a role. Check coverage for every shift, not just the busiest one.
Never timing a drill
A drill with no times and no head count shows nothing. Record the alarm time, the time the last area was counted, and the people expected against counted.
Filing it and forgetting it
A plan nobody has read is not a plan. Post it, walk new people through it, review it every year and after every change.
Copying another site's plan unchanged
Another site has other exits, hazards and shifts. Use a template as a starting point and fit it to your own layout and people.
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.
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In LeanSuite safety procedures start from marketplace templates, including risk assessments; anyone reports a hazard as a tag from a QR code, and a serious hazard can become a CAPA project with root cause analysis.
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Emergency action plan template: common questions
An emergency action plan is a written plan for what people on a site do in an emergency: how it is reported, how and where they leave, who does what, who stays to make critical equipment safe, and how everyone is accounted for afterwards.
A way to report emergencies, evacuation routes and assembly points, steps for anyone who must make critical operations safe before leaving, a head count after evacuation, rescue and medical duties, and who to contact for more information. This template also adds roles with backups, scenario steps and a drill record.
In the United States, OSHA's emergency action plan standard (29 CFR 1910.38) lets an employer with ten or fewer employees communicate the plan orally, and expects it in writing above that. Rules differ by country and by state, so check the ones that apply to your site.
There is no single answer. Many sites drill at least once a year and cover every shift; some drill more often for higher risk. Set the interval from your local rules, your insurer and what your drills show, and write it down. The Excel version works out the next drill date from the interval you set.
No. It is a general starting point. Adapt it to the law that applies to your site and to your own procedures, and have the people who carry it out review it.
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- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Energy loss matrix templateSeven types of energy loss by six energy sources with a cost in each cell, an action plan and an idle-period shutdown checklist.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
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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.