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Engineering process instruction (EPI) template
An engineering process instruction (EPI) is the engineering definition of a process: what it covers, the equipment and materials it uses, the parameters it must run within and their limits, how it was validated or qualified, and what counts as an acceptable output. Operators do not work from it directly; the work instructions for each station are written from it. Some companies call it a process specification or engineering specification, and no standard defines the name. Where a company also uses a manufacturing process instruction (MPI), the EPI says what the process is and why, and the MPI says how the operator does it. Page 1 of this template covers the purpose and scope, references, equipment and materials and a table of parameters with nominal, lower and upper limits, how each is set and monitored and what to do if it goes out. Page 2 has the process sequence and the validation or qualification steps with acceptance criteria and results; page 3 the product acceptance criteria, change history and approvals.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for EPI number, revision, title, effective date, owner and what it applies to, boxes for purpose and scope and references, an equipment and materials table and a process parameters table with nominal, lower and upper limits.Purpose and scopeReferencesEquipment and materialsParameters and limitsProcess sequenceValidation or qualificationAcceptance criteriaChange history and approvals
When to use it
When to use an engineering process instruction
- For special processes such as heat treatment, welding, plating, bonding or molding, where the result depends on the process window.
- When a process is introduced, moved to a new line or site, or given new equipment.
- When process limits need to be agreed and documented before work instructions are written.
- When a customer or your quality system asks for the process to be defined and validated.
How to fill it in
- 1
Define the scope
What the process does, which parts, lines and sites it covers, and what it does not cover.
- 2
List the references
Drawings, material and process specifications, customer requirements, the FMEA and the control plan.
- 3
Set the parameters and limits
For each parameter: the unit, nominal, lower and upper limit, how it is set and monitored, how often, and what to do if it goes out.
- 4
Write the sequence
The main stages of the process in order. The detail for operators goes in the work instructions.
- 5
Validate the process
Record how the equipment, the parameter window and the output were proven before production, with the method, acceptance criterion and result.
- 6
Approve and control changes
Engineering, quality, production and EHS sign. For every change, record whether it needs revalidation and update the work instructions.
A filled-in example
Illustrative, not a benchmarkAn example: an EPI for induction hardening a shaft (illustrative values).
The example's validated process window
- Powertarget 85, 80 to 90 kW
- Scan speedtarget 6, 5.5 to 6.5 mm/s
- Quench concentrationtarget 8, 7 to 9 %
- Scope: induction hardening of the bearing journals on shafts in one part family, on one hardening machine.
- Parameters: power 85 kW, 80 to 90; scan speed 6 mm/s, 5.5 to 6.5; quench flow 40 l/min minimum; quench concentration 8%, 7 to 9%.
- Validation: parts hardened at the low and high ends of the power and speed window, cut and checked for case depth and hardness; all within the drawing requirement.
- Acceptance criteria: surface hardness and case depth to the drawing, checked on the first and last part of each shift.
The station work instruction was written from the EPI, with the same limits, and a later change of quench fluid was recorded as needing revalidation before use.
Common mistakes
Limits with no reason
Limits copied from an old document and never tested give false confidence. Base them on validation data.
Mixing it with the work instruction
Operators need steps, engineers need the process definition. Keep the EPI for the definition and write the instructions from it.
No reaction plan
Say what happens when a parameter goes out of its limits, including the parts made while it was out.
Changes without revalidation
A new material, equipment or limit is a change to the process. Decide whether it needs revalidation before it is used.
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 an SOP can be drafted by AI from a video or a paper procedure, routed to engineering, EHS and quality for e-signature with an audit trail and version history, and kept in Document Management with an owner, a review date and read-and-sign.
See it in a 45-minute demoIn the lean glossary
FAQ
Engineering process instruction (EPI) template: common questions
The engineering definition of a process: its scope, equipment and materials, the parameters and their limits, how it was validated and what counts as an acceptable output. Work instructions for operators are written from it.
An EPI defines the process for engineers. An MPI, or work instruction, tells the operator how to do the job at the station. The MPI should use the same limits as the EPI. Companies use the names differently, and no standard defines them.
Each parameter that affects the result, with its unit, nominal value, lower and upper limits, how it is set and monitored, how often it is checked, and what to do if it goes out of limits.
When something that affects the result changes: the equipment, a material, a parameter limit, the site or line. Decide it for each change and record the decision in the change history.
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- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
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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.