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Audit template in the LeanSuite app

Last reviewed

Energy walk

An energy walk is a monthly tour of one area to find energy that is paid for and wasted: air leaks, machines left running, lights on in empty areas, doors left open, steam leaks and missing insulation. The 12 questions end with logging what you found, because a walk only saves energy once its findings become actions with an owner.

An energy champion, a maintenance technician or a small cross-functional team can run it, ideally at a weekend or a shift change, when idle equipment and empty areas stand out. Typical findings: a hiss from an air drop nobody uses, a compressor feeding a plant that is not running, high bay lights on over an empty bay, a dock door left open with the heating on. Tag leaks on the spot and log them on the leak survey.

What it is for, as built: Walk an area to find energy waste: leaks, idle equipment, lighting and settings.

Use this template in LeanSuite

The full question list

The 12 questions in the audit

Every question is answered Yes, No or N/A. Each No is flagged and asks for a photo and a comment, so the finding arrives with its evidence.

Compressed air

  1. 1No audible compressed air leaks
  2. 2Air is shut off to idle machines
  3. 3Air is not used where a fan or blower would do

Equipment

  1. 4Motors, conveyors and machines are not running when not needed
  2. 5Standby settings are used where available
  3. 6Large loads are switched off at the end of the shift

Lighting and heating

  1. 7Lights are off in unused areas
  2. 8Heating and cooling set points are sensible
  3. 9Doors and openings are kept shut where they should be

Utilities and metering

  1. 10There are no steam or hot water leaks and insulation is intact
  2. 11Meters are read and recorded
  3. 12Opportunities found on this walk are logged

Worked example, illustrative

A filled-in example

One section as it might be filled in on the floor, with every other section of the audit answered Yes. The place and finding are made up to show how the audit reads and scores.

Result: pass, 83.3% against a pass mark of 80

  • 12 questions, all of them count.
  • 2 answered No, so 10 of 12 are Yes: 10 ÷ 12 = 83.3%.
  • 83.3% is at or above 80, so the audit passes. The Nos still need their fix.

What happened next: Maintenance capped the dead drop the same day. Team lead issued brushes for swarf clean-down by the end of the week.

Scored here as one point per question with N/A left out. In the app each answer carries the points set on the template, so change them after you clone it if your plant weighs some checks more.

Energy Walk

Audit, monthly

Area
Press shop

Compressed air

  1. No audible compressed air leaksNo
  2. Air is shut off to idle machinesYes
  3. Air is not used where a fan or blower would doNo

    Comment: Loud hiss from the air drop behind press 4, nobody uses it. Bench 2 uses an open air line to blow swarf off parts.

    Photo attached to each No

Drawn from this template's own questions, not a screenshot of the app. Illustrative answers.

When to use it

  • Once a month.
  • An auditor or leader answers each question from what they see, hear and read in the area.
  • Each record starts with: Area.

How it is scored

The template is built with points per answer and a pass mark of 80. In this library every audit is set to pass at 80 and every inspection at 90. Each submitted audit shows its score and pass or fail, and every No is flagged with its photo and comment.

Change the points or the pass mark after you clone it. How rules and scoring work.

Read and print

More in environment and energy

All environment and energy templates

FAQ

Energy walk: common questions

  1. Monthly, one area per walk, as built. Add a walk after a compressor, boiler or lighting change, when a new line or shift pattern starts, and when the utility bill jumps without a production reason. A walk at a weekend or during a shutdown is worth an extra one too, because idle machines and empty bays stand out then.

  2. An energy champion, a maintenance technician or a small team from maintenance, production and facilities. They need to know which machines should be running at that hour, what the set points are and where the air drops and steam lines go. Findings go to the maintenance lead for work orders, and the plant manager reviews the open list each month.

  3. A failed walk means the area is paying for air, power or heat that does nothing. Nothing is tagged out of service. Tag each leak and idle machine on the spot, log it with a location, and give every item a work order owner and a date before you leave the area. In this template every No is flagged and asks for a photo and a comment, and an audit that scores under its pass mark of 80 is a fail.

  4. Keep the area, date, each finding with its location and a photo, the meter readings taken on the walk, and the work order that closed each item. Over months the list shows whether leaks come back at the same drops and whether readings fall after the fixes, which is the only proof the walk saves anything. In LeanSuite each submitted audit is stored with its score, its pass or fail, and the photo and comment on every No.

  5. 12 questions in 4 sections: compressed air, equipment, lighting and heating, and utilities and metering. Every question is answered Yes, No or N/A.

Use this template in LeanSuite

It is ready in the Template Marketplace inside Lean Creator as “Energy Walk”. Clone it into your plant, change any question, then schedule it to a person, role or asset with reminders. Auditors complete it on a phone or tablet, with photo evidence where required.

Not on LeanSuite yet? On a 90-day pilot our team sets up your account and digitizes the forms and checklists you use today, this one included.

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