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First article inspection report template (AS9102 forms)
A first article inspection (FAI) is a complete, recorded check that the production process makes a part to every requirement on its drawing and purchase order. It is done on a part from the first production run, before the rest of the run is released. In aerospace the record follows AS9102, the IAQG's first article inspection standard (published by SAE), which splits it into three forms. Form 1 is part number accountability: which part, which revision, which process, and for an assembly every part inside it. Form 2 is product accountability: the materials, special processes and functional tests, with their certificates. Form 3 is characteristic accountability: every ballooned characteristic on the drawing, with its requirement and the measured result. This template lays out the three forms with field names of its own that follow the same structure, plus 22 checks to run before anyone signs, the triggers for a full and a partial FAI, and a worked example. The Excel version works out each characteristic's limits from the nominal and tolerances, flags any result outside them and counts the open nonconformances. These are not SAE's forms, and filling them in does not make an FAI conform to AS9102: if your customer requires the SAE forms or its own format, use those.
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Form 1, part number accountability, with fields for part number, name, revision, drawing, process reference, purchase order and FAI number, a full or partial choice and a table of detail parts and subassemblies.Form 1: part number accountabilityForm 2: materials, special processes, testsForm 3: every characteristicFull and partial FAI triggers22 review checksLimits and pass or fail in ExcelNCR number on a failed rowWorked example
When to use it
When a first article inspection is needed
- Full FAI: the first production run of a new part, or whenever the customer asks for one.
- Partial FAI after a change that could affect fit, form or function: a design change, or a new manufacturing source, process, inspection method, location, tooling or material.
- After an NC program is changed or moved to another machine, and after an event such as a fire, a flood or a machine crash that could have changed the process.
- After a lapse in production. AS9102 names two years; many customers set their own rule or ask for a full FAI, so read the purchase order.
- Outside aerospace too, for a new part or a big change: the three forms are a sound way to prove a first part even when no customer asks for them.
How to fill it in
- 1
Balloon the drawing
Number every requirement on a copy of the drawing or model: dimensions, notes, general tolerances, finishes, markings and flag notes. The balloon numbers become the row numbers on Form 3. - 2
Fill in Form 1
Part number, name and revision, drawing number, the router or traveler with its revision, your organization and supplier code, the purchase order, the serial or lot, and whether this is a full or partial FAI. For an assembly, list every detail part and subassembly with its own FAI number. - 3
Fill in Form 2
Each material and special process with its specification, the certificate number and who did the work, whether the source was checked against the customer's approved list, and each functional test with its procedure and report number. - 4
Measure and fill in Form 3
One row per balloon: the requirement with its tolerance, the actual result as a value, the gauge or tool used, and a nonconformance report number for any result outside the requirement. - 5
Review before anyone signs
Run the 22 checks on page 4 of the PDF. The counts must agree, every certificate must be read against the drawing, and someone other than the person who measured reviews the package. - 6
Close the nonconformances
A failed characteristic gets a nonconformance report and a disposition. Fix the cause, then inspect a new part for the characteristics the fix could affect, and file that as a partial FAI.
The three forms
What each AS9102 form accounts for
The record in the order it is filled in. The names describe AS9102's structure in this template's own words.
- Form 1The partNumber, revision, drawing, process reference, full or partial, and every part inside an assembly.
- Form 2The productMaterials, special processes and functional tests, each with its specification and certificate.
- Form 3Every characteristicOne row per balloon: the requirement, the actual value, the gauge, and an NCR number if it is out.
- SignReview, then signThe 22 checks, every NCR closed, then Form 1 is signed as complete.
Full or partial
What calls for a full FAI and what calls for a partial one
The triggers below are paraphrased from AS9102's list, not quoted. Your customer's purchase order and quality clauses come first: some ask for a full FAI where the standard allows a partial one.
| Trigger | What the FAI covers | Notes |
|---|---|---|
| New part, first production run | Full: every characteristic, material, process and test | The baseline every later partial FAI points back to. |
| Customer request | Full, or what the customer names | Read the purchase order and the customer's quality clauses. |
| Design change that affects fit, form or function | Partial: the changed characteristics and anything they affect | Name the baseline FAI and the new drawing revision on Form 1. |
| New source, process, inspection method, location, tooling or material | Partial: the characteristics the change could affect | A move to another site or a new special process source counts. |
| NC program changed, or moved to another machine or media | Partial: the features that program makes | The trigger most often missed on the floor. |
| Fire, flood, crash or other event that could change the process | Partial: what the event could have affected | Write down why the characteristics chosen are enough. |
| Lapse in production | Partial or full, by the rule that applies | AS9102 names two years; customer rules can be stricter. |
New part, first production run
- What the FAI covers
- Full: every characteristic, material, process and test
- Notes
- The baseline every later partial FAI points back to.
Customer request
- What the FAI covers
- Full, or what the customer names
- Notes
- Read the purchase order and the customer's quality clauses.
Design change that affects fit, form or function
- What the FAI covers
- Partial: the changed characteristics and anything they affect
- Notes
- Name the baseline FAI and the new drawing revision on Form 1.
New source, process, inspection method, location, tooling or material
- What the FAI covers
- Partial: the characteristics the change could affect
- Notes
- A move to another site or a new special process source counts.
NC program changed, or moved to another machine or media
- What the FAI covers
- Partial: the features that program makes
- Notes
- The trigger most often missed on the floor.
Fire, flood, crash or other event that could change the process
- What the FAI covers
- Partial: what the event could have affected
- Notes
- Write down why the characteristics chosen are enough.
Lapse in production
- What the FAI covers
- Partial or full, by the rule that applies
- Notes
- AS9102 names two years; customer rules can be stricter.
Before you sign the FAI
The 22 review checks, form by form
Run these over the finished package before anyone signs: five on Form 1, five on Form 2, seven on Form 3 and five for the review. They are this template's own checks, grouped the way AS9102 groups the record, and they sit on page 4 of the PDF.
Form 1: the part and the reason
Part number accountability
- 1The part number, name and revision on Form 1 match the drawing and the purchase order
- 2The FAI is marked full or partial, and a partial FAI names the earlier FAI it builds on and the change that called for it
- 3The manufacturing process reference (router, traveler or operation sheet) is recorded with its revision
- 4For an assembly, every detail part and subassembly is listed with its own FAI report number, or the reason it has none
- 5The part inspected was made with the production process, tooling, program and materials, not a trial setup
Form 2: materials, special processes and tests
Product accountability
- 6Every material on the drawing is listed with its specification and the certificate of conformance number
- 7Every special process (heat treat, plating, anodize, painting, welding, NDT) is listed with its specification and who did it
- 8Where the customer keeps a list of approved special process sources, the source used was checked against it
- 9Every functional test the drawing or a specification calls for is listed with its procedure and the report number
- 10Each certificate was read against the specification and revision on the drawing, not only filed
Form 3: every characteristic
Characteristic accountability
- 11The drawing is ballooned, and every balloon has a row on Form 3 with the same number
- 12Notes, general tolerances, finishes, markings and flag notes are ballooned as well as dimensions
- 13Key and critical characteristics are marked the way the drawing or the customer flags them
- 14Each row shows the requirement with its tolerance and the actual result as a value, not only a tick
- 15The gauge or method for each row can measure to the tolerance, and its ID is recorded
- 16A characteristic checked with designed or qualified tooling says which tool
- 17Every nonconforming result has a nonconformance report number on its row
Review and sign-off
Before anyone signs
- 18The counts agree: balloons on the drawing, rows on Form 3, and results recorded
- 19Every nonconformance is closed or has an approved disposition before the FAI is called complete
- 20Someone other than the person who measured reviews the whole package
- 21Customer approval is obtained where the purchase order asks for it
- 22The package (ballooned drawing, the three forms, certificates and reports) is filed so it can be found by part number and revision
A filled-in example
Illustrative, not a benchmarkAn example: a full FAI on a new machined aluminum bracket, BRK-4471 rev C, with 6 ballooned characteristics (illustrative, the same as page 5 of the PDF and the Excel example sheet).
The example FAI: one characteristic out holds the whole first article
- Conform: 5 characteristics
- Out: NCR-0412: 1 characteristic
- Balloon 3: bore position (limit 0.10 mm)0.06 mmconforms
- Balloon 4: flatness, key characteristic (limit 0.05 mm)0.08 mmout
- Balloon 4 after the fixture change (partial FAI)0.03 mmconforms
Bracket BRK-4471, six ballooned characteristics on Form 3. Five conform and one does not: balloon 4, flatness of the mounting face, measured 0.08 millimeters against a limit of 0.05. Balloon 3, bore position, measured 0.06 against 0.10.
- Form 1: full FAI, new part, first production run. Router R-4471 rev B, ops 10 to 40, lot 26-0917, part 1.
- Form 2: 6061-T6 plate on certificate MC-22817, and clear anodize by an outside anodizer on certificate AN-5530, a source checked against the customer's approved list. No functional test called for.
- Form 3, balloons 1 to 3: length 120.00 ±0.10 mm measured 120.04, bore 8.00 +0.05/0 mm measured 8.03, bore position 0.10 mm measured 0.06. All within.
- Balloon 4, flatness of the mounting face, a key characteristic: 0.05 mm allowed, 0.08 measured on the CMM. Out, so NCR-0412 was raised and written on the row.
- Balloons 5 and 6: roughness Ra 1.6 µm allowed, 1.1 measured; the anodize note conforms against certificate AN-5530.
5 of 6 conform and 1 does not, so the FAI is not complete. The material review board scrapped the part rather than ask the customer, as design authority, to accept it as it was. The cause was the op 20 fixture clamping the thin web too hard. After the fixture was changed, a new part was inspected for balloons 1, 3 and 4, the features machined in that setup: 120.02, 0.05 and 0.03, all within. That partial FAI closed the first article.
Common mistakes
Ballooning only the dimensions
Notes, finishes, general tolerances and markings are requirements too. An FAI that skips them is incomplete, and it is usually a note that comes back from the customer.
Ticks instead of values
"OK" on Form 3 tells nobody how close the part was. Write the measured value for every variable characteristic.
Filing certificates unread
Read each certificate against the specification and the revision on the drawing. A certificate to an old revision is a common find.
Missing the partial FAI after a change
Moving an NC program to another machine, a new fixture or a new special process source is a change. Check the triggers every time a change is released.
A part from a trial setup
Inspect a part made with the production process, tooling, program and materials, or the FAI proves nothing about production.
Signing with an open nonconformance
An FAI with an open NCR is not complete. Record the NCR on Form 3 and close it before calling the FAI done.
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
Digital instructions and checklists, with number limits, required photos and signatures, build quality into every task. Run the same quality checks at every stage; an out-of-spec answer can raise a tag or start a CAPA automatically.
See it in a 45-minute demoIn the lean glossary
Guides
- Material review board guide: who decides what happens to a failed part
- Non-conformance report guide: when a first article fails
- APQP: the phases a new part goes through before production
- NCR form template
- PPAP checklist: the automotive equivalent of a first article
- AS9100 internal audit checklist
- First article inspection as an app checklist in LeanSuite
- Measurement System Analysis: Validating Gauge Reliability in Manufacturing
- AS9100 in plain language: what it adds to ISO 9001, including first article inspection
FAQ
First article inspection report template (AS9102 forms): common questions
A complete, recorded check, on a part from the first production run, that the process makes the part to every requirement on its drawing and purchase order. It is done before the rest of the run is released, and done again in part after any change that could affect the part.
Form 1 accounts for the part: its number, revision, process reference and, for an assembly, its detail parts. Form 2 accounts for the product: materials, special processes and functional tests, with their certificates. Form 3 accounts for every characteristic on the drawing, ballooned, with its requirement and result.
A full FAI covers every characteristic, material, process and test, and is done for a new part. A partial FAI, often called a delta FAI, covers only what a change could affect, and points back to the full FAI it updates.
Until something changes that could affect the part. AS9102 also treats a lapse in production of two years as a trigger, and many customers set their own rule, so check the purchase order and the customer's quality clauses.
No. It lays out the three forms in its own words so the record follows the structure of AS9102, but conformity depends on what goes in them and on your customer's requirements. If the customer requires the SAE forms or a particular FAI tool, use those.
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- Toolbox talk templateA record of a short safety talk: topic, key points, questions raised, actions and an attendee sign-in sheet.
- Lockout/tagout (LOTO) procedure templateA machine-specific LOTO procedure: energy sources and isolation points, the steps from shutdown to restart, and the annual review.
- Forklift inspection checklist23 pre-shift checks for a week on one page, a do-not-operate rule, and a defect and repair log.
- Preventive maintenance checklist templateA PM checklist per machine with readings and sign-off, and a PM schedule that works out the next due date.
- Equipment downtime log (MTTR and MTBF)A breakdown and downtime log, with MTTR, MTBF and downtime by machine and cause worked out in Excel.
- Environmental aspects and impacts registerAn ISO 14001-style register of aspects and impacts, with significance scoring, legal requirements, controls and owners.
- Manufacturing process instruction (MPI) templateOperation steps with parameters, tools, quality checks, safety and a photo each, plus revision history and approval.
- Engineering process instruction (EPI) templateScope, parameters and limits, equipment and materials, validation steps, acceptance criteria, change history and approvals.
- Training sign-off sheetAn attendance and sign-off record where each person signs they understood, with a competence check and an Excel log.
- 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.
- Office 5S audit checklist25 checks written for offices and shared areas, five per S, scored 1 to 5, with a score summary and actions.
- Floor marking color guideA floor marking color standard with swatches, marks and line widths to fill in, and a floor marking check with a layout sketch.
- Shadow board plannerTool inventory with fetch time, a layout planned from each tool's outline size, a month of daily checks with 5S audit evidence, and a missing tool log.
- Lubrication schedule templateEvery lube point with lubricant, method, amount, frequency and who, with next due dates and a monthly sign-off record.
- TPM tag logEvery abnormality tag with type, who fixes it, priority and dates, with days open and counts by type and week.
- Autonomous maintenance step auditCriteria for each of the seven autonomous maintenance steps, scored 0 to 2, with the step result and the decision to move on.
- Inventory cycle count sheetA blind count sheet with variance and tolerance, an ABC count schedule and record accuracy, worked out in Excel.
- Hour-by-hour production boardHourly plan against actual with running totals and the reason for each miss, plus a shift summary by reason.
- Cost savings trackerA savings log with hard and soft savings, payback and Finance's sign-off, plus a glide path against the year's target.
- CapEx request formA capital request with options, costs, benefits, payback and NPV, and the approval levels the amount needs.
- 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.
- 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.
- 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.
- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
- TWI job breakdown sheetThe TWI Job Instruction breakdown of a job into important steps, key points and reasons, with a worked example and the four steps.
- Standard work combination tableOne operator's manual, machine, walk and wait time on a time chart against takt, with machine cycles and a process capacity sheet.
- Lead time worksheetProduction lead time from the inventory waiting at each step, value-added time and process cycle efficiency, plus an order traced from order to delivery.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- Maintenance KPI trackerMTBF, MTTR, availability and PM compliance per asset and month, plant figures from the totals, planned maintenance % and backlog in weeks.
- Daily huddle agendaA 15-minute start-of-shift stand-up in six timed blocks, with yesterday's SQCDP results, today's plan, actions and escalations.
- 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.
- 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.
- 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.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Safety cross calendarA month drawn as the green cross, colored each day by the most serious safety event, with totals and days since the last injury.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- 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.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- 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.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- Vehicle inspection checklist53 checks for a truck, tractor or trailer, each tied to the federal rule it comes from, with a defect log.
- Pre-trip inspection checklistA driver's 42-check walk-round in order, with the driver vehicle inspection report for the end of the day.
- 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.
- OKR template for manufacturingObjectives with three or four key results each, scored 0 to 1.0 from baseline and target every month, cascaded to facility, department and person with an Other bucket for work that serves no objective.
- Goal cascade and alignment templateA one-page cascade tree from company to person with the catchball reply on every card, and an initiatives list that shows how much work serves a goal and how much sits in Other.
- Monthly business review template (operations review agenda)A 90-minute operations review in nine timed blocks: who speaks when, the KPIs each block reviews with red or green, a prep checklist for every presenter and a log of decisions and actions.
- Rolling action item list (RAIL) templateA single running list of actions kept from meeting to meeting, with a weekly review sheet and age counts.
- Lessons learned templateA one-page lessons log, a 45 minute session guide and an Excel register that shows which actions are done, open or overdue.
- Packing list templateA one-page packing list with a pack checklist, and an Excel file that works out volume, shipped to date and back order.
- Meeting minutes templateA one-page minutes form and an Excel log of decisions and actions with owners, due dates and status.
- Sign-in sheet templateA training and meeting sign-in sheet, a visitor sign-in and out sheet, and an Excel register of attendance and visitors on site.
- Purchase order templateA one-page purchase order and an Excel version that adds up the lines, checks the approval limit and tracks what is still to come.
- Action plan templateA one-page action plan and an Excel tracker with percent done, status and a weekly timeline.
- Maintenance request form templateA one-page request form and an Excel log that times each answer against a priority target.
- Maintenance log templateA maintenance log page and an Excel log that totals cost, downtime and planned work and flags repeat breakdowns.
- Preventive maintenance schedule templateA PM schedule with next due dates and status, and an Excel calendar of the jobs and hours in each month.
- Machine setup sheet templateA setup sheet with limits, a first piece check and setup minutes, and an Excel log of setups against a standard.
- Work instruction templateA one-page work instruction with key points and step times, and an Excel training record that flags re-checks.
- Fire drill report templateA report for each fire or mock drill: a timeline from the alarm, the head count, an observer checklist, actions and a yearly log.
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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.