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ESD audit checklist
An ESD audit checklist is the form used to check that an electrostatic discharge (ESD) protected area, or EPA, and the program behind it are working. It confirms that people are grounded, work surfaces and tools are bonded to ground, sensitive parts move in the right packaging, and the records prove it. This one follows the structure of ANSI/ESD S20.20, the ESD Association standard for an ESD control program, which has an administrative part (the program plan, training, product qualification and compliance verification) and a technical part (grounding, personnel grounding, the EPA, packaging and marking). It has 29 checks in five groups, and it keeps the daily checks operators make at the start of each shift apart from the periodic verification an auditor or ESD coordinator makes with a meter. The standard's limits and test methods are not repeated here: enter the ones your own program plan sets. The Excel file adds a daily test log, a verification log that flags readings over the limit, and a worked example.
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Header fields for the EPA, auditor and date above a table of checks, first the daily start of shift checks and then program and records, each with Pass, Fail and N/A circles and a finding column.29 checks in five groupsDaily checks kept apartProgram and recordsGrounding and workstationsEPA, flooring and garmentsPackaging and markingVerification logPass rateWorked example
When to use it
When to use an ESD audit checklist
- Monthly or quarterly in each EPA, as an internal audit of the ESD control program.
- Before a customer or registrar audit that will look at ESD control on the line.
- After a move, a new line or a new bench layout, when ground cords and mats get disturbed.
- When test failures or field returns point at ESD damage and you need to know where the program has gaps.
- Every shift, using only the first group, as the operators' start of shift check.
How to fill it in
- 1
Agree the scope and the limits
Name the EPA and the workstations in it. Copy the limits and test methods for each item from your ESD control program plan into the verification log, so every reading is judged against your own numbers.
- 2
Check the daily records first
Open the wrist strap and footwear test logs for the period. Count the tests that should be there, the tests logged and the fails, and check that each fail has an action and a retest.
- 3
Walk the EPA
Go station by station and watch people work: is the strap on bare skin, is the cord plugged in, are insulators kept away, do parts leave in shielding bags?
- 4
Measure what the plan says to measure
Use calibrated meters to check work surfaces, ground points, ionizers and tools on the schedule in your compliance verification plan. Record every reading, not only the fails.
- 5
Mark each check Pass, Fail or N/A
Write what you saw for every fail and give it an action, an owner and a date. Use N/A only for items the area does not have, such as ionizers where the plan does not call for them.
- 6
Report and follow up
Pass rate = Pass ÷ (Pass + Fail). Share it with the area, close the actions and check them again at the next audit.
On the floor
The daily test, and what happens on a fail
The daily group stays apart from the periodic audit: each operator tests before work, every shift, and the audit checks that the log is complete.
- 1Operator, start of shift
Test strap and footwear
At the tester, before handling parts, and log the result. - 2Decision
Pass?
- Yes:
- log it and start work
- No:
- fix it and retest before handling parts
- 3Same shift
New strap, retest
In the example, 3 failed tests each had a new strap and a passing retest. - 4Monthly audit
Check the log
Tests due against tests logged: 106 of 110 in the example week.
Two kinds of check
Daily ESD checks vs periodic verification
The checklist keeps them apart because different people make them, with different tools, and a fail means something different.
| Daily checks | Periodic verification | |
|---|---|---|
| Who makes them | Each operator, or the line leader | The ESD coordinator or a trained auditor |
| When | At the start of each shift and on entering the EPA | On the schedule in the compliance verification plan, often monthly to yearly by item |
| What is checked | The person's own wrist strap and footwear, the station's cords, ionizers running, no insulators on the bench | Work surfaces, floors, seating and ground points, ionizer balance and discharge time, tools, packaging, training and records |
| Equipment | A wrist strap and footwear tester at the EPA entrance | Calibrated meters and the test methods your plan names |
| Record | The daily test log | The verification log and this checklist |
| When it fails | No handling of sensitive parts until the strap or footwear passes a retest | Take the item out of use or fix it, then decide whether parts handled since the last good reading are at risk |
Who makes them
- Daily checks
- Each operator, or the line leader
- Periodic verification
- The ESD coordinator or a trained auditor
When
- Daily checks
- At the start of each shift and on entering the EPA
- Periodic verification
- On the schedule in the compliance verification plan, often monthly to yearly by item
What is checked
- Daily checks
- The person's own wrist strap and footwear, the station's cords, ionizers running, no insulators on the bench
- Periodic verification
- Work surfaces, floors, seating and ground points, ionizer balance and discharge time, tools, packaging, training and records
Equipment
- Daily checks
- A wrist strap and footwear tester at the EPA entrance
- Periodic verification
- Calibrated meters and the test methods your plan names
Record
- Daily checks
- The daily test log
- Periodic verification
- The verification log and this checklist
When it fails
- Daily checks
- No handling of sensitive parts until the strap or footwear passes a retest
- Periodic verification
- Take the item out of use or fix it, then decide whether parts handled since the last good reading are at risk
What's on the checklist
The 29 checks on the ESD audit checklist
The first group is the daily check made at the start of each shift; the other four are the periodic audit. On the sheet each check is Pass, Fail or N/A, with a finding, an action, an owner and a date for every fail.
Daily checks at the start of each shift
Operator or line leader, every shift
- 1Each operator tests the wrist strap on the tester before work and the result is logged
- 2Each person tests footwear or heel grounders on entry and the result is logged
- 3Wrist straps are worn snug on bare skin and the cord is plugged into the workstation ground point
- 4Mat and work surface ground cords are connected and not damaged
- 5Ionizers the workstation needs are switched on and running
- 6No plastic cups, bags, foam or loose paper sit on the ESD work surface
Program and records
The administrative part of the program
- 7A written ESD control program plan covers this area and names the program coordinator
- 8The plan states the sensitivity of the parts it was written to protect
- 9Everyone who handles sensitive parts was trained before starting and is current on refresher training
- 10A compliance verification plan says what is measured, how and how often, and the schedule is being kept
- 11Daily wrist strap and footwear test logs are complete for the period audited
- 12Every failed test and out of limit reading has a recorded action and a retest
Grounding and workstations
Periodic verification against the limits in your plan
- 13Every workstation has a common point ground connected to equipment ground
- 14Work surface resistance to ground was measured on schedule and is within the plan limit
- 15Wrist strap cords and continuous monitors were checked on schedule
- 16Soldering irons and powered hand tools are grounded and were checked on schedule
- 17Ionizers were checked for balance and discharge time on schedule and are within limits
- 18Carts, shelves and racks that hold sensitive parts are grounded or dissipative
- 19Insulators needed for the job are kept at the distance the plan sets, or neutralized with an ionizer
Protected area, flooring and garments
The EPA itself
- 20The EPA boundary is marked and every entrance has a sign
- 21Only trained people, or escorted visitors who are grounded, are inside the EPA
- 22ESD flooring and seating that form part of the grounding system were verified on schedule
- 23ESD garments are worn closed, and grounded where the plan requires it
- 24Seated operators are grounded through a wrist strap, not footwear alone
Packaging, handling and marking
How sensitive parts move
- 25Sensitive parts leave the EPA only in closed shielding packaging
- 26Totes, trays and bins inside the EPA are the types the plan allows
- 27Shielding bags are not torn, punctured or creased past the plan rule for reuse
- 28Packages and storage locations that hold sensitive parts are marked
- 29Incoming sensitive parts are opened only inside an EPA
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a monthly audit of a made-up hand solder and rework cell with 12 workstations and 22 operators, covering one week of daily logs. The same audit is page 4 of the PDF and the Example sheet of the Excel file.
The example audit and the week's daily tests
- Pass: 24 checks
- Fail: 4 checks
- N/A: 1 check
- Wrist strap tests logged (22 operators × 5 days)106 of 110
4 night shift entries missing; 3 tests failed and were retested
- Work surfaces within the plan limit11 of 12
Station 7: mat cord unplugged when the bench moved
29 checks: 24 pass, 4 fail, 1 not applicable, a pass rate of 85.7 percent. Wrist strap tests: 106 of 110 logged. Work surfaces: 11 of 12 within the plan limit.
- Checks: 29. 24 pass, 4 fail and 1 is N/A (the cell has no ionizers, so there is nothing to verify). Pass rate 24 ÷ 28 = 85.7%.
- Daily test log: 22 operators × 5 days = 110 wrist strap tests due, 106 logged (96.4%). 3 tests failed, 2.8% of those logged, and each has a new strap and a passing retest.
- Work surfaces: 12 measured, 1 over the plan limit. Station 7's mat cord had been unplugged when the bench was moved; it was refitted and passed the same day.
- The other fails: a plain plastic stores tote holding two boards, creased and taped shielding bags reused at rework, and 4 missing night shift log entries.
Two fails were closed on the day and two are open with owners. The finding that matters most is the tote and the bags: parts were leaving protection between stores and the bench, so the stores route goes on the next audit too.
Common mistakes
Only checking wrist straps
Strap logs are the easy part. Many gaps are in packaging, insulators on the bench and benches moved without reconnecting the mat.
Limits nobody checked
Copy the limits from your program plan, not from a supplier leaflet or another site's sheet, and use the test method the plan names.
Recording only the fails
A verification log with only fails cannot show a reading drifting toward the limit. Record every reading.
Ungrounded visitors
Maintenance, engineers and auditors walk into the EPA too. Give them heel grounders or keep them away from sensitive parts.
No action on a failed daily test
A failed strap test should stop the person handling parts until a retest passes. If the log shows fails with no retest, the daily check is only paperwork.
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FAQ
ESD audit checklist: common questions
It is the ESD Association standard for setting up and running an ESD control program to protect electronic parts, assemblies and equipment. It has administrative requirements, such as a written program plan, a training plan and a compliance verification plan, and technical requirements for grounding, personnel grounding, the protected area, packaging and marking. Get the current edition from the ESD Association for its limits and test methods.
It is a marked area where sensitive parts can be handled out of their packaging because people, surfaces and tools are grounded and insulators are controlled. Only trained people, or grounded visitors under escort, should handle parts inside it.
A written program plan with a named coordinator, training for everyone who handles sensitive parts, a compliance verification plan, grounding for people and workstations, a marked protected area, packaging rules and marking. This checklist has a group of checks for each.
Daily checks happen every shift. Periodic verification of each item follows the schedule in your compliance verification plan, and many plants audit each EPA monthly or quarterly. Audit more often after moves, new lines or failures that point at ESD damage.
No. It supports internal audits beside your own ESD control program plan, and it does not make a site compliant with ANSI/ESD S20.20 or certify it. Where a customer asks for certification, an outside registrar audits the site against the current edition of the standard.
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- 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.
- Learning curve and ramp-up workbookBoth learning curve models side by side, a fit from your own observed hours, batch hours, the unit that reaches standard and a weekly ramp plan.
- Operator staffing calculatorTakt, work content, the operators a line needs, a check of your station plan and the roster with absence cover, from your own demand and element times.
- 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.
- 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.
- Standard cost variance workbookEight standard cost variances from your standards and actuals, favorable or unfavorable, proved against actual cost, with the questions to ask on the floor.
- 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.
- 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.
- Work order template for maintenanceA work order template for maintenance: one form per job from request to handback, and a log of 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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 checklist and logThe 8 monthly checks for each portable extinguisher, plus a log with the hydro test interval from OSHA Table L-1, annual and 6-year due dates and open issues.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- 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.
- 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.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- 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.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Chemical inventory and SDS register templateA register of every chemical on site with its hazard class, safety data sheet and label, and a check that incompatible products are kept apart.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- Management of change formA change request and review form for a plant: what changes, the hazard review, approvals, pre-startup review, training and close-out.
- Silica exposure control plan templateA written silica plan for general industry: tasks, controls and housekeeping, plus monitoring, medical surveillance, training and a 31-check plan audit.
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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.