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ISO 22716 GMP audit checklist for cosmetics
ISO 22716 is the international guideline for good manufacturing practice (GMP) in cosmetics. It sets how a plant controls people, premises, equipment, materials, production, testing and records, so each batch is made the way it should be. An ISO 22716 GMP audit checklist turns those sections into questions an internal auditor can answer. This one has 25 checks in five groups. Two are a floor walk, done while a batch is made or filled: people, premises and equipment (sections 3 to 5), and materials, production and finished products (sections 6 to 8). Three are system checks with the quality team: the lab and out-of-specification product (9 and 10), waste, subcontracting, deviations, complaints and recalls (11 to 14), and change control, internal audit and documentation (15 to 17). Each check is graded OK, Minor, Major, Critical or N/A, with a findings log and a worked audit of a filling line. In the US, MoCRA gave FDA authority to set GMP rules for cosmetic facilities; this checklist is built on ISO 22716, not on an FDA rule. It supports internal audits beside your quality system and does not make a plant compliant or certified.
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Audit details, the five grades, and floor walk checks on people, premises and equipment, each with its section, a grade and a finding column.25 checks by ISO 22716 sectionFloor walk and system checksFive grades with days to fixFindings logScore by groupWorked filling line auditPDF, Excel and Word
When to use it
When to use an ISO 22716 audit checklist
- For the internal audits ISO 22716 section 16 asks for, one area or group of sections at a time.
- Before a certification audit, a retailer or brand-owner audit, or an FDA visit, to find gaps while there is time.
- After an out-of-specification batch, a complaint trend or a mix-up on a filling line, to check the system behind it.
- When a contract manufacturer onboards a new customer, to show where its GMP stands.
How to fill it in
- 1
Plan the audit
Pick the area and sections from your internal audit program, and an auditor who does not work there. Mark sections that do not apply N/A, with the reason.
- 2
Walk while a batch runs
The floor walk only works with production on: hygiene at the line, status labels on bulk, the start-up check for the run, in-process checks being done.
- 3
Then the system checks
With the quality team, sample the lab records, the last out-of-specification investigation, deviations, complaints, change records and documents.
- 4
Grade with evidence
Grade each check OK, Minor, Major, Critical or N/A and write the evidence: batch numbers, tank numbers, record pages.
- 5
Act on product questions first
Bulk past its hold time, unlabeled tanks or released product with a doubt go to quality the same day, before the audit moves on.
- 6
Log and follow up
Log each finding with an owner and a due date, and check the fix before closing it. Trend the Minors by line: they show where the routine is slipping.
ISO 22716 sections and where to check them
Floor walk or system check: sections 3 to 17
Where this checklist checks each section of ISO 22716, named, not quoted.
| Sections | Where | What you look at |
|---|---|---|
| 3 Personnel, 4 Premises, 5 Equipment | Floor walk | Hygiene and clothing, flow and separation, cleaning status labels, calibrated instruments |
| 6 Raw and packaging materials, 7 Production, 8 Finished products | Floor walk | Release status, water monitoring, start-up checks, bulk labels and hold times, in-process checks, storage |
| 9 QC laboratory, 10 Out-of-specification product | System | Test records, retained samples, release decisions, the last out-of-specification investigation |
| 11 Wastes, 12 Subcontracting, 13 Deviations, 14 Complaints and recalls | System | Waste handling, contracts, the deviation log, complaint files, the last mock recall |
| 15 Change control, 16 Internal audit, 17 Documentation | System | Change records, the audit plan and its actions, document versions and how records are corrected |
3 Personnel, 4 Premises, 5 Equipment
- Where
- Floor walk
- What you look at
- Hygiene and clothing, flow and separation, cleaning status labels, calibrated instruments
6 Raw and packaging materials, 7 Production, 8 Finished products
- Where
- Floor walk
- What you look at
- Release status, water monitoring, start-up checks, bulk labels and hold times, in-process checks, storage
9 QC laboratory, 10 Out-of-specification product
- Where
- System
- What you look at
- Test records, retained samples, release decisions, the last out-of-specification investigation
11 Wastes, 12 Subcontracting, 13 Deviations, 14 Complaints and recalls
- Where
- System
- What you look at
- Waste handling, contracts, the deviation log, complaint files, the last mock recall
15 Change control, 16 Internal audit, 17 Documentation
- Where
- System
- What you look at
- Change records, the audit plan and its actions, document versions and how records are corrected
The 25 checks
What to check, by section of ISO 22716
The first two groups are a floor walk, done while a batch runs; the last three are system checks with the quality team. Each check names its section, asks one question in plain words and says what to look at, and is graded OK, Minor, Major, Critical or N/A.
Floor walk: people, premises and equipment
ISO 22716 sections 3, 4 and 5
- 1Sec. 3: Are people trained for their tasks and in GMP, with records, and do they follow hygiene and clothing rules in production areas? Look at: two operators' training records; hair covers, gloves and hand washing at the line.
- 2Sec. 3: Do visitors and contractors follow the same hygiene rules and stay with an escort in production areas? Look at: the visitor log; anyone on the floor without the right clothing.
- 3Sec. 4: Are premises laid out so materials and people flow without mix-ups, with separate or defined areas for storage, production, QC and washing? Look at: floor markings; a pallet of raw material standing in a filling area.
- 4Sec. 4: Are floors, walls, ceilings and drains clean and in good repair, with cleaning and pest control done to plan? Look at: corners, overhead pipes above open tanks, drains, pest device records.
- 5Sec. 5: Is equipment suited to its use, cleaned and sanitized to written procedures, and labeled with its clean or dirty status? Look at: status labels on tanks and fillers; the cleaning record for the last change.
- 6Sec. 5: Are measuring instruments (balances, thermometers, fill weight scales) calibrated and labeled? Look at: calibration labels; the balance check log.
Floor walk: materials, production and finished products
ISO 22716 sections 6, 7 and 8
- 7Sec. 6: Are raw and packaging materials received against written specifications, sampled, and held until released? Look at: status labels in the warehouse; one lot's release record.
- 8Sec. 6: Is water (purified or treated) produced and monitored to its specification, and are results reviewed? Look at: water test results and the trend.
- 9Sec. 7: Before each manufacturing or packaging run, are start-up checks done, the line cleared of the last product and its components, and recorded? Look at: the start-up check or line clearance record for the run on now.
- 10Sec. 7: Is each bulk batch made to the formula and written instructions, with weighings checked and recorded at the time? Look at: the batch record and one weighing in progress.
- 11Sec. 7: Are bulk tanks and containers labeled with product, batch and status, and used within their set hold time? Look at: labels on bulk; the date made against the hold time.
- 12Sec. 7: Are in-process checks (fill weight, torque, label position, coding) done at the set frequency and recorded? Look at: the in-process check sheet at the filler.
- 13Sec. 8: Is finished product held until released, stored to protect it, and shipped so that oldest released stock goes first? Look at: warehouse status labels; storage conditions.
System: quality control and out-of-specification product
ISO 22716 sections 9 and 10
- 14Sec. 9: Does the QC lab test against written specifications and methods, keep reagents and reference samples identified, and keep retained samples of each finished batch? Look at: one test record; the retained sample store.
- 15Sec. 9: Are results reviewed and signed before release, with a clear release decision for each batch? Look at: the release record of two batches.
- 16Sec. 10: Is out-of-specification product investigated, with the decision (release, rework or reject) taken by authorized people and recorded? Look at: the last out-of-specification investigation.
System: waste, subcontracting, deviations, complaints and recalls
ISO 22716 sections 11 to 14
- 17Sec. 11: Is waste collected, stored and removed so it cannot reach product, with destroyed printed packaging recorded? Look at: waste containers in production; the destruction record.
- 18Sec. 12: Is there a written contract with each subcontractor for manufacturing, packing or testing, setting who does what in GMP? Look at: one contract and the last check of that subcontractor.
- 19Sec. 13: Are deviations from written instructions recorded, justified and assessed for their effect on quality? Look at: the deviation log; two recent entries.
- 20Sec. 14: Are complaints recorded, investigated and followed up, with trends reviewed? Look at: the complaint file; two recent complaints.
- 21Sec. 14: Is there a recall procedure that can trace a batch to its customers, and has it been tested? Look at: the procedure and the last mock recall.
System: change control, internal audit and documentation
ISO 22716 sections 15, 16 and 17
- 22Sec. 15: Are changes that could affect product quality approved before they are made, with the reasons and checks recorded? Look at: change records from the last 6 months.
- 23Sec. 16: Are internal audits planned and done by competent people, with findings followed up to closure? Look at: the audit plan and the last audit's actions.
- 24Sec. 17: Are documents (specifications, formulas, instructions, procedures, records) approved, at the current version where they are used, and are old versions withdrawn? Look at: two documents at the line against the master list.
- 25Sec. 17: Are records filled in at the time, legible, corrected so the original stays readable, and kept for the set period? Look at: two pages of a batch record.
A filled-in example
Illustrative, not a benchmarkAn example: an internal audit of filling line 3 at a made-up lotion and shampoo plant, running a body lotion, plus the system checks with the quality team (illustrative, the same as the Excel example sheet and page 6 of the PDF). The plant uses no subcontractors.
The example audit, graded
- OK: 20 checks
- Minor: 3 checks
- Major: 1 check
- N/A: 1 check
Score = OK ÷ (OK + Minor + Major + Critical)
25 checks, 1 N/A left out
- 20 ÷ 24= 83.3%
Score83.3%
25 checks: 20 OK, 3 minor, 1 major, 0 critical and 1 not applicable. Score 20 of 24 graded, 83.3 percent.
- 25 checks: 1 N/A (section 12, no subcontractors), so 24 graded.
- 1 Major (section 7): bulk tank T3 labeled with the product but not the batch or status, holding lotion made 9 days earlier against a 7-day hold time. Tank put on hold until quality tested the bulk.
- 3 Minor: filler 3's last cleaning record with no verifier signature (section 5); two cases of released caps with torn status labels (section 6); a batch record entry overwritten so the first value cannot be read (section 17).
- 20 OK, no Critical.
Score = 20 ÷ 24 = 83.3%. The tank is the finding to chase: bulk with no batch or status, past its hold time. The three Minors are all labels and signatures, the everyday paperwork that makes a batch traceable.
Common mistakes
Auditing with the line stopped
A floor walk on a quiet day sees clean equipment and tidy labels. Walk while a batch is being made or filled.
Skipping the system sections
Deviations, complaints, change control and documentation are where repeat problems show up. A floor walk alone misses them.
No hold time on bulk
Bulk waiting to be filled needs a batch, a status and a use-by date on its label. Without them, nobody can say whether it is still fit to fill.
Correcting records by overwriting
A correction must leave the first value readable, with who changed it, when and why. An overwrite looks like a hidden error even when it is not.
Assuming ISO 22716 covers OTC products
In the US, products such as sunscreen or anti-dandruff shampoo are also OTC drugs and fall under drug GMP. Check which rules apply to each product.
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FAQ
ISO 22716 GMP audit checklist for cosmetics: common questions
The international guideline for good manufacturing practice in cosmetics. It covers personnel, premises, equipment, raw and packaging materials, production, finished products, the QC lab, out-of-specification product, waste, subcontracting, deviations, complaints and recalls, change control, internal audit and documentation.
Whether the plant does what each section asks, in practice. On the floor: hygiene, clean equipment, released materials, start-up checks, labeled bulk and in-process checks. In the system: lab records, out-of-specification decisions, deviations, complaints, recalls, change control, audits and documents.
Not by name. MoCRA, the Modernization of Cosmetics Regulation Act of 2022, gave FDA authority to set GMP rules for cosmetic facilities; check FDA's cosmetics pages for where that rule stands. Many plants use ISO 22716 because customers ask for it and EU rules expect GMP.
Drug GMP (21 CFR 210 and 211 in the US) is a binding rule with a quality unit, validated processes, label reconciliation and lab controls for every batch. ISO 22716 covers similar ground with lighter, more general requirements. Cosmetics that are also OTC drugs, such as sunscreen, follow drug GMP.
As often as your internal audit program sets, by risk. A common pattern is to cover every section at least once a year, and the filling and packing lines, where mix-ups and labeling errors can happen, more often.
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- 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.