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FOD walk checklist (foreign object debris)
Foreign object debris (FOD) is any object in or near the product that does not belong there: a rivet, a curl of swarf, a clipping of safety wire, a cap, a rag, a lost tool. Foreign object damage is the harm it does once it gets into an engine, a duct, a bearing or a wiring bundle. A FOD walk is a short, regular walk of a work area to find and remove that debris. It also checks that the habits which keep debris out are in place. In aerospace production the FOD prevention program usually follows AS9146, the SAE and IAQG standard for FOD prevention programs, which some customers now ask for in place of NAS 412, the older Aerospace Industries Association standard. This checklist is written for the production floor, not the flight line. It has 26 checks in six groups (the area and its people, tools, hardware and consumables, protecting and closing out the product, housekeeping, and records), a FOD found log, an area plan that separates FOD critical areas from FOD control areas with a route and frequency for each, and a worked six-week trend. The Excel version keeps the log, counts finds per walk by area and week, and ranks finds by type. It supports your own FOD prevention program; it does not replace one, and using it does not make a site meet AS9146.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Header fields for area, route, date and walker, a choice of FOD critical or control area, and the first three groups of checks with OK, Not OK and N/A columns.26 checks in six groupsOK, Not OK, N/AFOD found logCritical and control areasRoute and frequencyFinds per walk by areaFinds by typeWorked six-week trend
When to use it
When to run a FOD walk
- Every shift in a FOD critical area, where an object could get into the product: at the start of the shift, and again before any space in the product is closed.
- Daily or weekly in a FOD control area, where objects are made or carried toward critical areas: machining, kitting, stores and tool cribs.
- After a lost tool or a find inside the product, as a full walk of the area before work goes on.
- Before a customer visit, a source inspection or an audit, to check that the program works on the floor and not only on paper.
How to fill it in
- 1
Map the areas
Mark each area FOD critical or FOD control on a plan of the floor (page 4 of the PDF), with its boundary, its entrances and how often it is walked. Use the names your FOD program uses.
- 2
Set the route
Walk the same route each time: the product, the stands and the benches first, then the floor, the corners and the doors. The same route makes one week comparable with the next.
- 3
Walk and check
Mark each of the 26 checks OK, Not OK or N/A. Look under stands, inside open bays with a light, in tool drawers and at the doorways.
- 4
Pick up and log every find
Bag everything you find, then log each object: what it was, where, who found it, whether it was in or on the product, and what was done.
- 5
Act on the same shift
Fix a Not OK on the spot where you can. A find in the product becomes a nonconformance, and a missing tool stops work in that area until it is found.
- 6
Trend it every week
Count finds per walk by area and by type. Go after the source of the biggest type, not only the debris it leaves.
On one walk
A FOD walk, from the doorway to the log
The order this template suggests, so one walk can be compared with the next.
- 1At the entranceBoundary, rules posted, pockets, people briefed.
- 2Tools and hardwareShadow boards full, kits counted, broken pieces found.
- 3The productPorts capped, bays covered, close-outs inspected with a light.
- 4Floor and binsStands, benches, corners, doorways and FOD containers.
- 5Log and actEvery find logged; a find in the product becomes an NCR.
Two kinds of area
FOD critical area or FOD control area: what changes
Most FOD programs split the floor into at least these two kinds of area. The names and rules come from your own program and your customer; the walk frequencies here are this template's suggestion.
| FOD critical area | FOD control area | |
|---|---|---|
| What it is | Where an object could get straight into the product: open assemblies, engine and fuel system work, final assembly. | Where objects are made or carried toward a critical area: machining, kitting, stores, tool cribs. |
| Entry | Marked boundary, rules posted, visitors briefed; tools and hardware logged in and out. | Marked, with the general FOD rules posted. |
| Walk frequency | Every shift, and before any close-out. | Daily or weekly, set by risk. |
| Tool control | Shadow boards or kits, counted at the start and end of each task. | Shadow boards and a crib, checked each shift. |
| A find means | Log it; a find in the product is a nonconformance. | Log it and trace where it came from. |
What it is
- FOD critical area
- Where an object could get straight into the product: open assemblies, engine and fuel system work, final assembly.
- FOD control area
- Where objects are made or carried toward a critical area: machining, kitting, stores, tool cribs.
Entry
- FOD critical area
- Marked boundary, rules posted, visitors briefed; tools and hardware logged in and out.
- FOD control area
- Marked, with the general FOD rules posted.
Walk frequency
- FOD critical area
- Every shift, and before any close-out.
- FOD control area
- Daily or weekly, set by risk.
Tool control
- FOD critical area
- Shadow boards or kits, counted at the start and end of each task.
- FOD control area
- Shadow boards and a crib, checked each shift.
A find means
- FOD critical area
- Log it; a find in the product is a nonconformance.
- FOD control area
- Log it and trace where it came from.
What's on the checklist
The 26 checks on the FOD walk, in six groups
Walk the route with the sheet and mark each check OK, Not OK or N/A. Every Not OK and every object found goes on the FOD found log with where it was, who found it and what was done. Add the checks your FOD prevention program and your customer ask for.
Area, boundaries and people
At the way in
- 1The FOD critical area boundary is marked, and the entry rules are posted at every way in
- 2Everyone working in the critical area has had FOD awareness training, and visitors are briefed at the entrance
- 3Pockets hold no loose items in the critical area; pens, badges, glasses and phones are secured or left outside
- 4No food, drink or wrappers in the critical area
- 5The findings from the last walk are closed, or each has an owner and a date
Tools and tool control
Every tool in, every tool out
- 6Every shadow board in the area is full, or each gap has a check-out tag with a name
- 7Tools taken into the critical area are on the tool log or kit list and come back out at the end of the task
- 8No personal tools in the critical area, unless your program allows them and they are marked and logged
- 9Broken tools, drill bits and blades are accounted for in full, with every piece found
- 10A missing tool is reported at once, and work in that area stops until it is found or the person your program names closes the search
Hardware and consumables
Small parts are the usual FOD
- 11Loose hardware (rivets, fasteners, washers, nuts) is kitted per job or kept in closed containers, counted where your program asks
- 12Dropped or spare hardware goes into the marked container, not a pocket or onto the floor
- 13Tape, rags, wire ties, sealant nozzles and similar consumables are collected as they are used, not at the end of the shift
- 14Clipped safety wire, cotter pin ends and wire tie tails are caught as they are cut, not left to fall
- 15Parts and material for the task are counted in, and what is left is counted out at the end
Product protection and close-out
Nothing gets in, nothing is left in
- 16Open ports, ducts, tubes, fittings and connectors are capped or covered when nobody is working on them
- 17Caps, plugs and covers taken off are kept together and counted, and none is left inside the product
- 18Assemblies and bays not being worked on are covered
- 19Before any space in the product is closed, someone inspects inside it with a light and a mirror, then signs and records the close-out
- 20Drilling and trimming near the product uses a vacuum or a catch, so chips do not get into it
Housekeeping and FOD containers
The floor, the stands and the bins
- 21Floors, stands, benches and work platforms are clear of debris, chips and dropped parts
- 22FOD containers are in place, marked, not overflowing and emptied on schedule, and the contents are looked at before they are thrown away
- 23Nobody uses shop air to blow chips toward the product or into the next area
- 24Doors, openings and the ground just outside them are swept where vehicles and parts come in
Records
Every find counts
- 25Every find on this walk is entered on the FOD found log: what, where, who found it and what was done
- 26A find in or on the product is raised as a nonconformance, and its source is traced
A filled-in example
Illustrative, not a benchmarkAn example: six weeks of FOD walks at an aerostructures plant with three areas, 25 walks a week and 150 in all (illustrative, the same as page 5 of the PDF and the Excel example sheet).
Finds per walk, all areas, over the six example weeks
- Week 1: 1.12 finds per walk
- Week 2: 1.04 finds per walk
- Week 3: 0.88 finds per walk
- Week 4: 0.60 finds per walk
- Week 5: 0.48 finds per walk
- Week 6: 0.44 finds per walk
Finds per walk across 25 walks a week: 1.12, 1.04, 0.88, 0.60, 0.48 and 0.44 in weeks 1 to 6. Hardware was kitted in week 3 and a drill vacuum fitted in week 4.
- Final assembly bay (critical, 10 walks a week): 14, 12, 9, 6, 5 and 4 finds, from 1.4 to 0.4 per walk.
- Sub-assembly (critical, 10 walks a week): 8, 9, 7, 5, 4 and 4 finds, from 0.8 to 0.4 per walk.
- Machining (control, 5 walks a week): 6, 5, 6, 4, 3 and 3 finds, from 1.2 to 0.6 per walk.
- By type, loose hardware led with 41 of the 114 finds (36%), then consumables with 29 and chips with 22.
- Week 3: hardware kitted per job in closed trays in both critical areas. Week 4: a vacuum on the drill at the sub-assembly fixture and a catch bag for safety wire tails.
Finds per walk fell from 28 ÷ 25 = 1.12 in week 1 to 11 ÷ 25 = 0.44 in week 6, a drop of 61%. Machining now has the highest rate, 0.6 per walk, so its chips are the next source to fix.
Common mistakes
Picking up without logging
Debris thrown in the bin is a find nobody can trend. Log every object, small ones too.
Walking only before an inspection
A walk an hour before the customer arrives shows a clean floor and hides the habits. Walk every shift in critical areas.
Cleaning, not tracing
Every find came from somewhere. Trace the top type to its source, such as a kit, a drill or a bin, and fix that.
Counting tools only at the end of the shift
A tool lost at 9 a.m. and missed until 6 p.m. may be behind a closed panel by then. In critical areas, count at the end of each task.
Treating the walk as the program
The walk checks the program. Training, area rules, tool control, kitted hardware and close-out inspections are what keep FOD out.
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- First article inspection report (AS9102 forms)
- AS9100 internal audit checklist
- 5S Implementation: Step-by-Step Workplace Organization Guide
FAQ
FOD walk checklist (foreign object debris): common questions
Any object in or near the product that does not belong there, such as hardware, chips, safety wire, caps, rags or tools. Foreign object damage is the harm that debris causes, for example inside an engine or a fuel system.
A short walk of a work area, on a set route and schedule, to find and remove debris and to check the habits that keep it out: tool control, kitted hardware, covered ports and close-out inspections. On a flight line or a ship it is often called a FOD walkdown.
Your FOD program sets it. A common pattern is every shift in FOD critical areas, plus before any close-out, and daily or weekly in FOD control areas. Walk the area again after any lost tool or a find inside the product.
The SAE and IAQG standard that sets the requirements for a FOD prevention program in aviation, space and defense organizations, covering areas such as program management, area designation, training, access and product protection. This checklist supports the checks on the floor; it does not make a site meet AS9146.
A named owner, FOD awareness training, marked critical and control areas, tool and hardware accountability, product protection and close-out inspections, regular FOD walks, a log of finds and a review of the trend. The walk is how you check that the rest works.
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- Incident investigation report templateFacts and a sourced timeline, causes at three levels, actions by the hierarchy of controls, a US recordkeeping screen and a closure check.
- Incident report templateThe first report, filled in the same shift: what happened, people, injury or damage, treatment, a US recordkeeping screen, actions and an Excel incident log.
- 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.
- 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.
- 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.