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Gemba walk checklist
A gemba walk checklist is the sheet a leader carries on a planned walk to the place where the work is done, to watch the process, ask the people doing it questions and note follow-ups. This one has a walk plan with the purpose and route, 30 observation prompts grouped under safety, quality, flow and waste, standard work, 5S and visual management, and people, and a findings table where each follow-up gets an owner and a due date. The prompts direct attention; a gemba walk is for understanding the process, not for auditing people.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for area, date, walk leader and team, the purpose of the walk, a route table, and the safety and quality prompts with OK and concern tick boxes.Walk plan and route30 prompts in 6 groupsOK / concern tick boxesFindings with owner and due dateWhat people told us
When to use it
When to use a gemba walk checklist
- On a regular leader walk, for example as part of leader standard work, so each walk looks at the process the same way.
- When a leader or engineer is new to an area and needs to learn how the work really runs.
- With a single focus, such as following up a safety finding or watching material flow into one cell: write the purpose and use the matching group of prompts.
- Before a kaizen event or an A3, to see the current condition with your own eyes.
How to fill it in
- 1
Set the purpose and route
Write the one thing this walk is for, then plan the stops: where, what to look at and who to talk to at each. - 2
Go while the work is running
Tell the area the walk is to learn and help, not to catch people out, and walk it during normal production. - 3
Watch before you ask
At each stop, watch a few cycles of the work. Tick OK or concern for the prompts that apply and skip the rest. - 4
Ask open questions
What, why and show me. Ask the people doing the work what gets in their way, and write down what they tell you. - 5
Write facts, not opinions
For every concern, note what you saw and where: three boxes of parts waiting at station 4, not poor flow. - 6
Agree the follow-ups
Copy each concern that needs action into the findings table with an owner and a due date. The Excel version counts open and overdue actions. - 7
Close the loop
Tell the area what happens next, check the actions on the next walk and record when each one is done.
What's on the checklist
What to look for on a gemba walk: the 30 prompts
Five prompts in each of six groups. On the sheet each one has an OK and a concern box and space for what you saw; skip the ones that do not apply to the area.
Safety
- 1Required PPE is worn and in good condition
- 2Walkways, exits and emergency equipment are clear
- 3Machine guards and safety devices are in place and working
- 4No spills, trip hazards, awkward lifts or long reaches
- 5Near misses and safety concerns are reported and followed up
Quality
- 6Operators know the quality checks for their step and do them
- 7Defects, scrap and rework are counted and visible, not hidden
- 8Nonconforming parts are tagged and kept apart
- 9Gauges and inspection tools are at hand and in calibration
- 10When a defect is found, people know who to call and it is escalated
Flow and waste
- 11Work moves without waiting, searching or rework loops
- 12WIP between steps is at its planned level, not piling up
- 13Operators walk and reach no more than the job needs
- 14Material arrives when and where it is needed
- 15Output is on plan, and the reason for any gap is known
Standard work
- 16Standard work or work instructions are at the station and current
- 17Operators follow the posted sequence
- 18Operators can explain the key points and why they matter
- 19Takt time and the planned output are known at the station
- 20Changes to the method have been written into the standard
5S and visual management
- 21Tools and materials are in marked, labeled places
- 22Anyone can tell normal from abnormal at a glance
- 23Production and KPI boards are up to date
- 24The area is clean, and leaks and damage are tagged
- 25Unneeded items are red-tagged or removed
People
- 26People know today's targets and how they are doing against them
- 27Problems and ideas raised earlier have had an answer
- 28Staffing and skills match the plan for the shift
- 29Team leaders are on the floor supporting the team
- 30Ask: what gets in the way of doing a good job today?
A filled-in example
Illustrative, not a benchmarkA weekly walk by a plant manager through a packing area, with the purpose of checking material flow.
The example walk: what was seen, and what was followed up
- Flow and waste · People
Smaller, more frequent carton deliveries
Seen: a packer walking to the end of the line for cartons; operators say cartons come in one delivery a shift. - Standard work
An updated palletizer instruction
Seen: the instruction shows an old pallet pattern. - Flow and waste
Find why WIP builds before the case sealer
Seen: WIP above the marked maximum.
- Flow and waste: WIP above the marked maximum before the case sealer, and a packer walking to the end of the line to fetch cartons.
- Standard work: the work instruction at the palletizer shows an old pallet pattern.
- People: operators say cartons arrive in one large delivery at the start of the shift.
- Findings: three follow-ups with owners and dates: smaller, more frequent carton deliveries, an updated palletizer instruction, and a look at why WIP builds up before the case sealer.
Four observations and three follow-ups, all facts someone can act on. The next walk starts by checking them.
Common mistakes
Turning the walk into an audit
Scoring people or handing out blame teaches the area to hide problems. Watch the process and ask about it.
Walking without a purpose
A walk with no focus becomes a tour. Pick one thing to understand each time.
Talking more than watching
Watch several cycles of the work before you ask questions or suggest anything.
Solving problems for people
Fixing it yourself teaches less than questions that help the team see the problem. Safety hazards are the exception: deal with them at once.
No follow-up
If nothing happens after a walk, people stop telling you things. Every concern needs an owner, a date and an answer.
In LeanSuite
Use this as a Lean Studio board
The same method is one of the 30 ready-made board templates in Lean Studio, LeanSuite's whiteboard: Gemba Walk Board, plan a gemba walk, capture observations at the workplace, and turn them into follow-ups.
- Start from the Gemba Walk Board template: plan, observations and follow-ups as three columns.
- Add an observation sticky per finding during or straight after the walk, colour-coded by safety, quality, flow or 5S.
- Turn each observation that needs action into a follow-up sticky with an owner, and review them at the next walk.
Worked example · sample data
The sample walk went from receiving through weld cell 3 to packing, with flow and waiting as the theme and the plant manager and the CI lead walking. Three observations went up: pallets waiting two days at receiving, the welder walking to the tool room twice per shift, and a pallet blocking the fire door, the last in pink as a safety item. Each became a follow-up with an owner: a daily release rule at receiving for J. Lind, a tool kit kept at weld cell 3 for R. Patel, and a marked pallet bay, to be done today, for M. Osei. The fire door was cleared before the walkers left the area. The next walk, two weeks later, started at weld cell 3 to see whether the tool kit had stopped the walking.
Open this board in LeanSuite
Gemba Walk Board is one of the 30 ready-made boards in Lean Studio, LeanSuite's whiteboard. Try LeanSuite in your browser, or run it on your own lines for 90 days.
What Lean Studio isHow to run a Gemba Walk Board session
- 1Plan the walk: a route, a theme (flow, safety, 5S, standard work) and who walks. Two or three walkers, typically 30 to 45 minutes.
- 2Walk the route and watch the work for several minutes at each stop before asking anything. Ask what makes the job hard today; do not offer fixes.
- 3Record each observation on its own sticky, colour-coded by theme, during or straight after the walk.
- 4Back at the board, turn the observations that need action into follow-ups with an owner and a date. Leave the rest as observations.
- 5Start the next walk by reviewing the last walk's follow-ups with the people who raised the issues.
Common mistakes
- Walking to inspect people rather than to see the process.
- Solving on the spot. Observe, ask, record; fix later with the team.
- Observations that never become follow-ups, so the floor stops telling walkers anything.
- Walking the same route with the same theme every time.
- No review of the last walk's actions at the start of this one.
Where it goes next in LeanSuite
- A gemba walk checklist is built in Lean Creator, scheduled to a person or role in Daily Standard Work and completed on a phone or tablet with photos and comments; findings become tags, actions or Kaizens. Audit Management
- A safety observation becomes a tag with an owner and a due date in Daily Issue Management, shown on the live floor plan. Daily Issue Management
- A follow-up that needs a project becomes a Kaizen with owners, due dates and tracked savings. Kaizen & Projects
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite you build a gemba walk checklist in Lean Creator, complete it on a phone or tablet with photos and comments, and turn anything you find into an issue tag, a corrective action or a Kaizen project.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- How to Perform an Effective Gemba Walk on the Shop Floor
- What is Gemba in Lean Manufacturing?
- Gemba Walks vs Audits: Key Differences Every Manufacturer Should Know
- Waste Walk: Step-by-Step Shop Floor Waste Identification
- Gemba walk examples: what to look for and what to ask
- Lean in 7 days, day 2: gemba walks for first-timers
- Best gemba walk software: 7 tools compared
- Gemba walk questions: 60 to ask, and why you ask each one
Train the team
Put it on the wall
FAQ
Gemba walk checklist: common questions
To see how the work is really done, understand the problems the people doing it face, and support them in solving those problems. It is a leader's planned visit to the place where the work happens, not an inspection of people.
An audit checks an area or process against a standard and usually scores it. A gemba walk is for watching and learning: the leader observes the process, asks questions and follows up what they find. The prompts on this checklist guide attention; they are not a score.
A common approach is to build gemba walks into leader standard work, so team leaders are on the floor every day and managers walk on a fixed schedule, for example weekly. A regular, predictable rhythm matters more than a long walk.
Open questions about the work: what are you working on, how do you know it is good, what gets in your way, what happens when something goes wrong, and can you show me. Then listen, and write down what you hear.
Yes. Skip the prompts that do not apply to the area, or use one group for a walk with a single focus, such as safety. Add prompts for your process, but keep the ones you use the same from walk to walk so you can see what changes.
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- 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.
- Is / is not analysis templateWhat, where, when and extent with is, is not, distinctions and changes, then each possible cause tested against every pair and ranked.
- 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.
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- 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.
- Histogram templateReadings, bins set by the square root rule, a tally and counts, the spec limits drawn and the share out of spec, with the common shapes explained.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Gauge calibration logA gauge register with next due dates and status, a calibration record with as-found and as-left readings, and the steps when a gauge fails.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- 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.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- 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.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- 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.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- 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.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- 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.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- 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.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- 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.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Line clearance checklist28 line clearance checks in six sections (area, equipment, materials, printed materials, documents, coder and vision settings), cleared by the operator and verified by a second person, with a printed-materials reconciliation and a worked example that does not balance.
- SSOP template: sanitation standard operating procedureOne sanitation SOP sheet per area or machine (steps, chemical, contact time, PPE, lockout, owner), a 23-check pre-op inspection and a verification log for visual, ATP and micro checks.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- 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.
- Goods received note templateA one-page goods received note and an Excel register with accepted to date, still to come and an invoice check for each PO line.
- 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.
- Part submission warrant (PSW) templateA PSW working form plus twelve checks before anyone signs, and an Excel that works out whether the warrant is ready.
- Ballooned drawing and dimensional results templateA ballooning guide and a results sheet for six parts per characteristic, with OK, NEAR LIMIT or NOT OK worked out for each row.
- Attribute agreement analysis templateA 30-part, three-appraiser study sheet for pass or fail decisions, with kappa, effectiveness, miss rate and false alarm rate in Excel.
- DVP&R template (design verification plan and report)A design verification plan and report on one sheet: tests, criteria, owners and dates, with status worked out as of a date.
- Special characteristics matrix templateOne row per special characteristic, followed from drawing to PFMEA, control plan, gauge study and capability, with the first gap named.
- 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.