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IATF 16949 internal audit checklist
An IATF 16949 internal audit checklist is the list of questions an internal auditor uses to check an automotive plant against IATF 16949, the quality standard of the International Automotive Task Force. It covers the quality system, the manufacturing processes and the products, against the standard, the plant's own procedures and each customer's specific requirements. The standard names three kinds of internal audit in clause 9.2.2: the quality management system audit, the manufacturing process audit and the product audit, and this checklist has one part for each. There are 20 system questions, 15 process questions to ask at the station on every shift the process runs, and 5 product audit questions for parts ready to ship, 40 in all. Each one names the IATF 16949:2016 clause it tests and the evidence to look for, is tagged with the core tool it draws on (APQP, PPAP, PFMEA, control plan, MSA or SPC) where one fits, and has a column for the customer-specific requirement that applies. The PDF has the audit plan, the three parts, a finding report, a findings log and a worked example; the Excel version grades each answer, works out conformance by part and by group, and keeps the findings log. The questions are our own words, not the standard's text. The checklist supports internal audits run beside your quality system; it does not make a plant compliant or certified.
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The audit plan with header fields, the three audit types with their clauses, a shift coverage grid and the five grades.40 questions in 3 partsSystem, process and product auditsIATF 16949:2016 clause for eachWhat to look forCore tool tagCustomer requirement columnFive grades definedEvery shift and the handoverFinding report and logWorked example
When to use it
When to use an IATF 16949 internal audit checklist
- Running the plant's internal audit program: a system process, one manufacturing process or a product audit, on the dates the program sets.
- Before a surveillance or recertification audit, to find gaps on the floor and in the records while there is time to close them.
- After a customer complaint, a new launch or a big process change, as a targeted audit of that process on every shift.
- To train new internal auditors on what the three audit types look for, and what evidence counts.
- Not in place of your layered process audits: those are short, frequent checks by every layer of leadership, and this is the planned, graded audit.
How to fill it in
- 1
Plan the program from risk
List every quality system process, every manufacturing process with the shifts it runs on, and every product family. Schedule them so each system and manufacturing process is covered within each three-year calendar period, more often where risk, complaints or changes call for it, and set product audits at the frequency your customers ask for.
- 2
Read your customers' requirements first
Before the audit, fill the customer-specific requirement column for the questions it touches: a required LPA frequency, a labeling standard, a problem-solving format, a process audit method such as VDA 6.3. Audit to those as well as to the standard.
- 3
Pick auditors who meet your criteria
The plant sets and records what each type of auditor must know: the process approach, the core tools and the customers' requirements for system auditors; the process's PFMEA and control plan for process auditors; the product's requirements and gauges for product auditors. Keep people off their own work.
- 4
Run the process audit at the station, on every shift
Take the PFMEA and control plan for the process with you. Watch the work, then check the records, on each shift the process runs, and read the handover sheets between them. A problem on night shift will not show on day shift.
- 5
Pick the product audit sample yourself
Take parts that have passed every check, from the dock or the last operation, and measure or test them with the audit's own gauges, not the line's results.
- 6
Grade, write findings, follow up
Grade each question conforming, opportunity, minor, major or N/A from the evidence you wrote down. Write each finding as condition, requirement, evidence and impact, give it an owner, and close it only after someone checks that the action worked, in the problem-solving format your customer asks for.
The three audits
System, process and product audits: what each one checks
IATF 16949 names three internal audits in clause 9.2.2 and asks for an audit program that covers all of them (9.2.2.1). The frequencies below are our summary of the standard; your copy of the standard and your customers' requirements set the details, and a customer's own method comes first where it prescribes one. A layered process audit is not one of the three, but many customers ask for it too.
| Audit | Clause | What it checks | How often |
|---|---|---|---|
| System audit | 9.2.2.2 | Every quality system process, checked with the process approach, sampling each customer's specific requirements. | All processes within each three-year calendar period, on an annual program set by risk. |
| Manufacturing process audit | 9.2.2.3 | One manufacturing process at the station: is the PFMEA and control plan in use, and does the process run as planned? | Every manufacturing process within each three-year calendar period, on every shift it runs, sampling the shift handover. A customer's prescribed method, such as layered process audits, comes first. |
| Product audit | 9.2.2.4 | Finished parts checked against every requirement by the audit, not the line, at the stages that make sense. | At the stages and frequency the customer sets, or the plant sets where the customer does not. |
| Layered process audit | Customer-specific | A few high-risk checks at the station, by every layer of leadership. | Every shift for team leaders, less often for each layer above. See the LPA checklist. |
System audit
- Clause
- 9.2.2.2
- What it checks
- Every quality system process, checked with the process approach, sampling each customer's specific requirements.
- How often
- All processes within each three-year calendar period, on an annual program set by risk.
Manufacturing process audit
- Clause
- 9.2.2.3
- What it checks
- One manufacturing process at the station: is the PFMEA and control plan in use, and does the process run as planned?
- How often
- Every manufacturing process within each three-year calendar period, on every shift it runs, sampling the shift handover. A customer's prescribed method, such as layered process audits, comes first.
Product audit
- Clause
- 9.2.2.4
- What it checks
- Finished parts checked against every requirement by the audit, not the line, at the stages that make sense.
- How often
- At the stages and frequency the customer sets, or the plant sets where the customer does not.
Layered process audit
- Clause
- Customer-specific
- What it checks
- A few high-risk checks at the station, by every layer of leadership.
- How often
- Every shift for team leaders, less often for each layer above. See the LPA checklist.
What's on the checklist
The 40 audit questions: system, process and product
Groups 1 to 4 are the system audit, 5 to 7 the manufacturing process audit (asked at the station on every shift) and 8 the product audit. Every question ends with the IATF 16949:2016 clause number and short title it tests; the questions are our own words. On the sheet each one has room for the evidence you saw, the customer-specific requirement that applies, a grade and a finding number.
System audit: customer requirements and leadership
Sample: the customer-specific requirements of your 2 largest customers, the last management review and 2 contingency plans.
- 1Is there a current list of each customer's specific requirements, showing where each one is met in your own procedures? Look for: the CSR list or matrix with its revision dates, one requirement traced into a procedure. (4.3.2 Customer-specific requirements)
- 2Pick one requirement from a customer's CSR and follow it to the floor: is it done the way your procedure says? Look for: the requirement, the procedure, the record at the station. (4.3.2 Customer-specific requirements)
- 3Who can stop shipment or production to fix a quality problem, and do the leads on every shift know it? Look for: the named roles, a shift lead who can say what they would do and who they would call. (5.3.2 Responsibility and authority for product requirements and corrective actions)
- 4Are there contingency plans for the key equipment, supplier, utility and labor risks, and have they been tested? Look for: the plans, the date of the last test or exercise, what changed after it. (6.1.2.3 Contingency plans)
- 5Did the last management review cover the inputs the automotive standard adds, such as cost of poor quality, customer scorecards and field failures, and set actions? Look for: the minutes, the input data, actions with owners and dates. (9.3.2.1 Management review inputs)
System audit: people and measurement
Sample: 3 operators on stations with special characteristics, 2 internal auditors and 5 gauges named in control plans.
- 6Are operators on stations with special characteristics trained on the job, including what a mistake there means for the customer? Look for: training records, the skills matrix, a short talk with one operator. (7.2.2 Competence: on-the-job training)
- 7Do the internal auditors meet the competence the plant has set for each audit type, including the core tools and the customers' requirements? Look for: auditor records against the criteria, training on CSRs and core tools. (7.2.3 Internal auditor competency)
- 8Is there a measurement system study for each type of gauge named in the control plans, and was action taken where one failed? Look for: gage R&R or attribute studies, their dates, one failed study and what was done. (7.1.5.1.1 Measurement system analysis)
- 9Are calibration records complete, and when a gauge was found out of tolerance, was the product it accepted reviewed? Look for: the gauge register, one out-of-tolerance record and its product review. (7.1.5.2.1 Calibration/verification records)
- 10When a customer sends a new or changed engineering standard, is it reviewed and brought into production in the time the standard and the customer set? Look for: the log of standards received, review dates, the change in the work instruction. (7.5.3.2.2 Engineering specifications)
System audit: launch, suppliers and change
Sample: the last part launched, 3 suppliers and 2 recent process changes.
- 11For the last part launched, do the APQP outputs agree with each other: process flow, PFMEA, control plan and work instructions? Look for: the four documents with matching operation numbers and characteristics. (8.3.5.2 Manufacturing process design output)
- 12Are special characteristics marked with the customer's symbols in the drawing, the PFMEA, the control plan and the work instruction? Look for: one special characteristic traced through all four documents. (8.3.3.3 Special characteristics)
- 13Was the part approved by the customer before it shipped, and is the approval kept current after changes? Look for: the PPAP submission, the customer's approval, a resubmission after a change. (8.3.4.4 Product approval process)
- 14Are suppliers measured on delivered quality, delivery and disruptions to your plant, and do poor performers have a plan? Look for: supplier scorecards, one supplier below target and its actions. (8.4.2.4 Supplier monitoring)
- 15Is every process change assessed for risk, verified and, where the customer asks, approved by the customer before it is used? Look for: the change log, the risk review, the customer's approval where needed. (8.5.6.1 Control of changes)
System audit: monitoring, audits and improvement
Sample: the audit program, 3 months of customer scorecards, 2 closed problems and 1 warranty return if there is one.
- 16Is the internal audit program set by risk, performance and complaints, and does it cover all processes, activities and shifts? Look for: the program, a frequency changed after a complaint, the shifts covered. (9.2.2.1 Internal audit programme)
- 17Are all quality system processes audited within each three-year calendar period, with the customers' requirements sampled in those audits? Look for: the three-year plan, the audits done, CSRs sampled in them. (9.2.2.2 Quality management system audit)
- 18Are customer scorecards, delivered part quality, delivery performance and field returns tracked, with action on poor results? Look for: the last 3 months of scorecards, one action from a poor result. (9.1.2.1 Customer satisfaction)
- 19Does problem solving cover containment, root cause, corrective action and a check that it worked, in the format the customer asks for, such as an 8D? Look for: 2 closed problems, the containment record, the effectiveness check, the PFMEA and control plan updated. (10.2.3 Problem solving)
- 20If you supply warranty parts, are returns analysed, including parts where no fault is found? Look for: the warranty process, one return analysed and its result. N/A if the plant has no warranty parts. (10.2.5 Warranty management systems)
Process audit: set-up, instructions and people
Audit one manufacturing process on every shift it runs and sample the handover between shifts. Bring its PFMEA and control plan.
- 21Do the PFMEA and the control plan match how the process runs today, and is the control plan at the station the current revision? Look for: both revisions, recent changes and complaints reflected, one check watched against the plan. (8.5.1.1 Control plan)
- 22Are the operator instructions at the station current, readable from the work position and followed in the order shown? Look for: the revision level, the instruction compared with the job you watch. (8.5.1.2 Standardised work: operator instructions and visual standards)
- 23Was the set-up verified before the run, with a first-off part checked, and a last-off part kept where the plant uses one? Look for: the set-up sign-off, the first-off record with measured values, the last-off part tagged. (8.5.1.3 Verification of job set-ups)
- 24After the last planned or unplanned stop, was the process checked before production restarted? Look for: the restart record after the most recent stop. (8.5.1.4 Verification after shutdown)
- 25Is every operator on this process on this shift trained and signed off for it, cover and temporary staff included? Look for: the skills matrix against the names on the shift, the cover person. (7.2.2 Competence: on-the-job training)
Process audit: controls, error-proofing and equipment
Watch the checks being done, then look at the records for the last week on each shift.
- 26Are the special characteristics checked at the control plan frequency, with SPC charts or results kept, and the reaction plan followed when a result is out? Look for: the chart or check sheet, one out-of-control point and what was done. (9.1.1.1 Monitoring and measurement of manufacturing processes)
- 27Were the error-proofing devices tested for failure at the frequency in the control plan, on every shift, with a reaction plan for a failed test? Look for: the test record by shift, challenge parts marked and in good condition, the reaction plan. (10.2.4 Error-proofing)
- 28Are the gauges at the station the ones the control plan names, identified, in calibration and covered by a measurement study? Look for: gauge IDs at the station against the register. (7.1.5.1.1 Measurement system analysis)
- 29Is preventive maintenance on this equipment done on time, with critical spare parts available? Look for: the PM schedule and its status, the spare parts list for this machine. (8.5.1.5 Total productive maintenance)
- 30Is the production tooling identified and tracked, with its life and its last repair recorded? Look for: tool ID, tool life or shot count, the last tool repair record. (8.5.1.6 Management of production tooling)
Process audit: product flow, change and the shift handover
Follow the parts from the station to the next operation, and read the last 3 handover sheets.
- 31Is nonconforming and suspect product identified and kept apart, with its disposition recorded? Look for: the hold area, tags, the disposition record. (8.7.1.7 Nonconforming product disposition)
- 32Where product is reworked, is there an approved instruction, a re-check of the reworked part and a record? Look for: the rework instruction, the rework record, the re-inspection result. (8.7.1.4 Control of reworked product)
- 33Is any temporary change to a process control, such as a backup method or a bypassed device, on the approved list, with its time limit and the extra checks it needs? Look for: the list of approved alternative controls, the daily check while it runs. N/A if none was used. (8.5.6.1.1 Temporary change of process controls)
- 34Can the parts made here be traced to their material lot, shift and machine, as far as the customer and the risk require? Look for: the label or traveler, the lot record, a trace done in front of you. (8.5.2.1 Identification and traceability)
- 35Does the shift handover pass on open problems, containment, changes and equipment status, and does the next shift act on it? Look for: the last 3 handover sheets, one item followed up by the next shift. (9.2.2.3 Manufacturing process audit)
Product audit: parts ready to ship
Sample: 5 parts or boxes picked by the auditor from stock that has passed every check. Use the customer's method where it sets one.
- 36Do the sample parts meet every characteristic on the drawing and control plan when the audit measures or tests them, not the line? Look for: measured results against the drawing, the gauges used. (9.2.2.4 Product audit)
- 37Is the layout inspection and functional check done at the frequency the control plan sets, with the results on file? Look for: the last layout and functional test report, its date against the plan. (8.6.2 Layout inspection and functional testing)
- 38For appearance items, are the evaluation area, lighting, master samples and trained evaluators in place? Look for: the area, the masters and their date, the evaluator's record. N/A if the part has no appearance requirement. (8.6.3 Appearance items)
- 39Do the packaging and labels meet the customer's requirements, with the right part number, quantity and traceability on each? Look for: 5 boxes against the packaging specification and the label standard. (8.5.2.1 Identification and traceability)
- 40Is stock at the dock rotated first in, first out, kept in its packaging and free from damage? Look for: dates on stock, damaged or open boxes, obsolete stock marked. (8.5.4.1 Preservation)
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a manufacturing process audit of weld cell 3, which MIG welds a seat bracket, on day, afternoon and night shift, plus a product audit of 5 brackets from the dock. These are questions 21 to 40, the same as the Excel example sheet and pages 7 and 8 of the PDF.
The example audit in one picture
- Conforming: 13 questions
- Opportunity: 1 question
- Minor: 3 questions
- Major: 1 question
- N/A: 2 questions
Conformance = (conforming + opportunity) ÷ graded
20 questions, 2 N/A
- (13 + 1) ÷ 18= 77.8%
- Process audit, questions 21 to 35= 78.6%
- Product audit, questions 36 to 40= 75%
Conformance77.8%
20 questions on weld cell 3: 13 conforming, 1 opportunity, 3 minor, 1 major and 2 not applicable. Conformance is 13 plus 1, divided by 18, which is 77.8 percent.
- 20 questions, 2 N/A: no temporary change of a process control in the last 3 months, and the bracket has no appearance requirement. So 18 graded.
- 13 conforming and 1 opportunity: a weld gauge in calibration but kept loose in a drawer with old gauges.
- 1 major, on night shift only: the part presence sensor on fixture B was taped over, with no challenge test recorded for 3 nights. The cell was stopped, the sensor tested, and the parts from those nights held and checked.
- 3 minor: night first-off parts signed with no measured values, a day to afternoon handover that left out the parts on hold, and 1 of 5 boxes with no shift code on the label.
Conformance = (13 + 1) ÷ 18 = 77.8%: the process audit 11 ÷ 14 = 78.6%, the product audit 3 ÷ 4 = 75%. Four findings, each with an owner; the major goes to an 8D. An audit of day shift alone would have missed it. Time on the floor: 45 + 45 + 50 minutes on the three shifts and 30 for the product audit, 170 minutes.
Common mistakes
Auditing day shift only
The process audit has to see the process on every shift it runs. Most of what drifts, drifts where leaders and auditors are not: nights, weekends and the handover in between.
Reading the PFMEA in the office
The process audit tests whether the PFMEA and control plan are in use at the station: the checks at their frequency, the error-proofing tested, the reaction plan followed. Start at the machine and work back to the documents.
Leaving the customers out
A plant can meet the standard and still miss what a customer asked for. Fill the customer-specific requirement column before the audit, not after.
Using the line's own results for the product audit
The product audit is a second, independent look. Pick the parts yourself and measure them with the audit's gauges.
Treating layered audits as the process audit
Unless a customer prescribes them as the method, the layered audits do not replace the manufacturing process audit. They are shorter and test a few controls; the process audit tests the whole process against its PFMEA and control plan.
Closing a finding when the action is done
Close it when someone has checked that the action worked. A finding closed early comes back at the next audit, or at the customer.
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FAQ
IATF 16949 internal audit checklist: common questions
The quality management system audit (9.2.2.2), which covers every quality system process with the process approach; the manufacturing process audit (9.2.2.3), which checks each manufacturing process at the station on every shift; and the product audit (9.2.2.4), which checks finished parts against their requirements. The audit program (9.2.2.1) has to cover all three.
In our reading of IATF 16949, every manufacturing process within each three-year calendar period, on every shift it runs, with the shift handover sampled, and more often where risk, complaints or changes call for it. A customer can ask for more, or for its own method. Check your copy of the standard and your customers' requirements.
A manufacturing process audit is a planned, graded audit of one whole process against its PFMEA, control plan and requirements, done by a trained auditor. A layered process audit is a short check of a few high-risk controls, repeated every shift by team leaders and less often by each layer of management. Most automotive plants need both.
A process audit standard from the German automotive industry association, with its own question catalogue and scoring. Some customers ask for it as the method for the manufacturing process audit. This checklist does not reproduce it; if a customer asks for VDA 6.3, use their version.
No. It is a set of questions to run internal audits beside your quality system. Compliance comes from the system itself and is judged by your certification body. The clause numbers follow IATF 16949:2016; the questions are our own words, not the standard's text.
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- 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.
- 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.
- 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.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- 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.
- 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.
- 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.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- 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.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
- Cleanroom audit checklist33 cleanroom checks split by how often they run (each shift, weekly, per plan, system), a gowning order to watch against, a differential pressure log and a findings log, with a worked week of readings.
- GMP audit checklist for drug manufacturing42 self-inspection checks ordered by the subparts of 21 CFR 211, each with its section, the matching EU GMP chapter and whether it is seen on the floor or in records, graded critical, major or minor, with a worked audit of a packaging line.
- 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.
- ISO 13485 internal audit checklist38 questions on ISO 13485 clauses 4 to 8, each with the FDA QMSR section that brings it in or adds to it, a production floor tab (records, current instructions, training, nonconforming product, CAPA) and a worked audit of a catheter line.
- ISO 22716 GMP audit checklist for cosmetics25 cosmetic GMP checks following the sections of ISO 22716, split into a floor walk (people, premises, equipment, materials, production) and system checks (lab, out of specification, deviations, complaints, change control, audits, documents), with a worked audit of a filling line.
- 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.
- SQF internal audit checklist for food manufacturing54 questions in the two parts of the SQF manufacturing code (system elements and GMP), each group mapped to BRCGS and FSSC 22000, graded Conforms to Critical, with findings, a score and a yearly plan.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- ESD audit checklist29 checks for an ESD protected area, with daily tests split from periodic verification, a measurement log and a worked audit.
- 1-1-90 method worksheetOne page: score areas 1 to 5, write the pain point with a before and target number, check days 30, 60 and 90, and plan the next three areas.
- Leader standard work templateA team leader's daily, weekly and monthly routine with a box per day, follow-ups and a weekly review.
- Supervisor leader standard work templateA supervisor's daily, weekly and monthly routine with a box per day, an escalation log and a weekly review.
- Production manager leader standard work templateA production or value stream manager's routine by day, week and month, with an escalation log and a weekly review.
- Plant manager leader standard work templateA plant manager's short routine by day, week and month, with an escalation log and a weekly review.
- Autonomous maintenance (CILR) checklist20 clean, inspect, lubricate and retighten checks with a box per day, an abnormality log and sign-off.
- A3 problem solving templateThe standard seven-box A3 from background to follow-up, with a filled-in worked example. PDF and Excel.
- PDCA templateOne improvement cycle on one page: plan, do, check against the goal, then standardize or adjust. PDF and Excel.
- 5 Whys templateA problem statement, a why chain that can branch, evidence for every answer, root causes and countermeasures that are checked.
- 5W1H templateWho, what, when, where, why and how: a problem statement built from checked facts, and an action plan with nothing left open.
- Skills matrix templatePeople by tasks on a 0 to 4 scale, coverage and gaps per task and shift, and a training plan that closes them.
- Standard work sheet templateTakt time, each element's manual, machine and walk time on a time chart, key points and standard WIP.
- One point lesson (OPL) templateOne topic on one page: wrong way and right way pictures, checkable key points, the standard it belongs to and a sign-off record.
- SMED changeover worksheetChangeover steps with times, internal or external, what can move, ideas and before/after totals.
- Kaizen event charter templateProblem, goal, scope in and out, boundaries, metrics from baseline to target, team and roles, and sign-off before day one.
- RACI matrix template17 kaizen project tasks by 10 roles, with R, A, C, I drop-downs and a check for one accountable per task.
- Shift handover templateSafety, production against plan, holds, downtime events, materials and people, and the open actions the next shift takes over.
- Shift schedule packTen shift patterns defined exactly, each with a 28-day calendar, hours worked out from the cycle and a US 40-hour check, plus an Excel roster.
- Kanban card templateSix production and six withdrawal kanban cards to print and cut out, with loop sizing and a card register.
- Idea suggestion formA one-page idea form with the supervisor's answer and points, and an idea log that tracks days to answer.
- Just Do It (JDI) card templateSix Just Do It cards per sheet for quick fixes, with the rules for what counts and a log of every card.
- Quick kaizen templateOne page for a small improvement: before and after, the cause, the countermeasure, the results and whether the standard changed.
- Time study sheetTime each element over 10 cycles and work out the average, lowest repeatable and standard time. Excel does the sums.
- Spaghetti diagram templateSquared paper to trace every trip, a trip log that turns grid squares into feet, meters and walking time, and a before and after comparison.
- OEE tracking sheetOne row per shift for a week. The Excel version works out availability, performance, quality and OEE and charts the week.
- Near miss report formA two-page near miss report from the first report to closure, and an Excel log with status and days open.
- Safety observation card templateFour behavior-based safety cards per sheet, with safe and at-risk checks, the conversation and a tally sheet.
- Job safety analysis (JSA) templateJob steps, hazards, risk scored before and after the controls, the hierarchy of controls, PPE and sign-off.
- Risk assessment matrix template (5×5)A color-coded 5 × 5 severity and likelihood matrix, a scoring guide and a risk register.
- 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.