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Layered process audit (LPA) checklist
A layered process audit (LPA) is a short check at the station that the key steps and controls of a process are being followed, done by several layers of leadership, each on its own schedule. The team leader might audit every shift, the supervisor every week and the plant manager every month, all with the same short list. This checklist has 20 checks in four groups: work instructions and training, quality checks, process settings and material, and safety and workplace. Each is answered yes, no or N/A, with a box for a no that was fixed on the spot, a score by group, a table for the findings that need an owner and a note of who audits the area. In automotive supply LPAs are often a customer-specific requirement, and AIAG publishes a guideline for running them, CQI-8 Layered Process Audits. Page 3 adds a matrix of the four layers, how often each audits and what it adds, plus question banks of six checks each for stamping, welding, molding and assembly. A rotation rule keeps the bank questions moving, so the list does not turn into a ritual.
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Header fields for area, station, date, shift, auditor and time, a layer to circle from team leader to plant leadership, and the first 15 checks with yes, no or N/A to circle and a fixed on the spot box.20 checks in 4 groupsYes / No / N/AFixed on the spot boxScore by groupFindings with owner and due dateLayer and frequency matrixQuestion banks: stamping, welding, molding, assemblyRotation ruleSign-off
When to use it
When to use a layered process audit checklist
- On high-risk steps where a skipped check or a wrong setting reaches the customer, such as crimping, welding, torque or final inspection.
- When a customer asks for layered process audits, which is common in automotive supply.
- After a corrective action, to check at every layer that the new method is still being followed weeks later.
- To get leaders onto the floor on a fixed routine, as part of their leader standard work.
- Not in place of a full process audit or a 5S audit: an LPA is short on purpose and looks at a few things often.
How to fill it in
- 1
Set the layers and the schedule
Decide who audits at each layer and how often, and write it on page 2. The matrix on page 3 is a common starting point. Spread the audits across shifts so night shift is audited too. - 2
Make the checks fit the station
Start from the 20 checks. Replace the ones that do not apply with the bank for your process on page 3 and with checks for the station's own risks, taken from the process FMEA, the control plan and recent defects. Keep error-proofing verification and any open containment on every audit. - 3
Audit at the station
Fill in the header and circle your layer. Ask the operator to show you, look at the records, and answer each check yes, no or N/A from what you see. - 4
Fix what you can on the spot
For every no, write what you saw. If it can be put right during the audit, such as a missing record or a gauge out of place, do it and tick fixed on the spot. - 5
Log the rest with an owner
Anything not fixed goes in the findings table with an action, an owner and a due date. The Excel version counts them and marks overdue ones. - 6
Work out the score and pass it on
Score is yes ÷ (yes + no) for each group and for the whole audit. Note anything the next layer should look at again.
Question banks by process
What an automotive LPA asks at stamping, welding, molding and assembly
Page 3 of the checklist has six bank questions for each of four processes. Keep error-proofing verification and any open containment on every audit, and swap bank questions in and out in a fixed order so the list does not turn into a ritual.
Stamping
- A1The die in the press matches the part number on the job and the die set-up sheet
- A2The first-off part was checked against the check fixture or checklist and signed before the run
- A3Shut height, tonnage monitor limits and feed length match the set-up sheet
- A4The misfeed and part-out sensors were tested at the start of the shift and the test was recorded
- A5The coil or blank lot on the line matches the traveler and can be traced to the parts made
- A6Parts made since the last stop or die hit are tagged and held until checked, never mixed with good parts
Welding
- B1The weld schedule on the controller matches the approved settings for this part
- B2Tip dressing, or the contact tip and nozzle change, was done at the set interval and recorded
- B3The destructive or chisel test was done at the control plan frequency, with results in limits
- B4Part presence and weld count sensors were challenged at the start of the shift and recorded
- B5Fixture clamps and locating pins are in place, tight and not worn
- B6Parts made since the last good test can be identified, so they can be held if the next test fails
Molding
- C1Press settings match the approved process sheet, inside the set windows
- C2Regrind percentage and dryer temperature and time match the process sheet
- C3The resin lot and colorant at the hopper match the traveler
- C4Start-up parts were checked and released before production parts were packed
- C5Short-shot detection (cavity pressure, vision or weigh scale) was checked this shift
- C6The mold and the cavities running match the job; any blocked cavity is approved and recorded
Assembly, crimp and torque
- D1The torque tool, its program and its calibration date match the work instruction
- D2The fastening sequence follows the instruction, and the controller rejects a missed or out-of-range fastener
- D3Crimp height and pull test were done at the set times, such as start of shift and reel change, and are in limits
- D4Error-proofing (pick-to-light, presence sensors, fixtures) was challenged with the master or reject parts and recorded
- D5Rejected and suspect parts are in the red bin, tagged, and the count matches the scrap log
- D6Any open containment (a sort, a 100% check, a hold) is tagged at the station, and the operator can explain it
The rotation rule
- Keep about half the questions as a core set on every audit: the highest-risk controls from the PFMEA and control plan, error-proofing verification and any open containment.
- Fill the rest from the bank for that process in a fixed order, so every bank question is asked at least once a month on each shift.
- When a question has been yes at every layer for about three months, move it to the bank and bring in a newer risk.
- After a complaint or a corrective action, add a question that checks the fix to every layer's list for the next few months.
To run the banks on a schedule for every layer, see layered process audit software for automotive plants.
Layers and frequency
Who audits, how often, and what each layer adds
A common way to set up the four layers, in the spirit of AIAG's CQI-8 guideline (named here, not quoted). Your customers' specific requirements set the minimum where they name a frequency, and risk sets the rest: a safety-critical weld cell may get a layer 2 audit every day.
| Layer | Who | How often | Minutes | What this layer adds |
|---|---|---|---|---|
| 1 | Team leader or group leader | Every shift | 5 to 10 | The core checks at their own stations, on their own shift. |
| 2 | Production supervisor | Every week, each area at least once | 10 to 15 | Whether the layer 1 sheets are filled in honestly and their findings closed. |
| 3 | Area manager: production, quality, maintenance or engineering | Every month, rotating across areas | 15 to 20 | Fresh eyes from outside the area; at least one audit in four on an off shift. |
| 4 | Plant manager or leadership team | Every month | 15 to 20 | Whether the system works: every layer done, repeat findings taken to a root cause. |
1
- Who
- Team leader or group leader
- How often
- Every shift
- Minutes
- 5 to 10
- What this layer adds
- The core checks at their own stations, on their own shift.
2
- Who
- Production supervisor
- How often
- Every week, each area at least once
- Minutes
- 10 to 15
- What this layer adds
- Whether the layer 1 sheets are filled in honestly and their findings closed.
3
- Who
- Area manager: production, quality, maintenance or engineering
- How often
- Every month, rotating across areas
- Minutes
- 15 to 20
- What this layer adds
- Fresh eyes from outside the area; at least one audit in four on an off shift.
4
- Who
- Plant manager or leadership team
- How often
- Every month
- Minutes
- 15 to 20
- What this layer adds
- Whether the system works: every layer done, repeat findings taken to a root cause.
What's on the checklist
The 20 checks on the layered process audit checklist
Five checks in each of four groups. On the sheet each one is answered yes, no or N/A at the station, with a box for a no that was fixed on the spot and space for what you saw; replace the checks that do not fit with the station's own risks.
Work instructions and training
The job is done the way the instruction says
- 1The current work instruction is at the station and matches the part being run
- 2The operator follows the steps in the order the instruction shows
- 3The operator can explain the key quality points of the job
- 4The operator is trained and signed off for this job
- 5Gauges and tools at the station are the right ones, labeled and in calibration
Quality checks
The checks that catch defects are done and recorded
- 6The first-piece or start-up check was done and recorded this shift
- 7In-process checks are done at the frequency the control plan sets, and recorded
- 8Recorded results are within limits, or the reaction plan was followed
- 9Nonconforming and suspect parts are tagged and held in the marked area
- 10Mistake-proofing devices work, and were checked at the start of the shift
Process settings and material
The process runs as approved
- 11Machine settings match the setup sheet or process parameter card
- 12The last changeover was signed off before production restarted
- 13The right material or component lot is loaded and can be traced
- 14Maintenance and CILR checks for the machine are up to date
- 15Fixes from earlier audits at this station are still in place
Safety and workplace
The area is safe and organized
- 16Required PPE is worn
- 17Guards, interlocks and emergency stops are in place and work
- 18The area meets its 5S standard, with nothing that does not belong
- 19Material is at its marked location, between the minimum and maximum
- 20Open findings from the last audit at this station are closed or have an owner and a date
A filled-in example
Illustrative, not a benchmarkAn example: a team leader's layer 1 audit at a hose crimping station on day shift.
The example audit, filled in
Work instructions and training5 of 5 yes
- 1Yes
- 2Yes
- 3Yes
- 4Yes
- 5Yes
Quality checks3 of 4 yes
- 6Yes
- 7No
- 8Yes
- 9N/A
- 10Yes
Process settings and material4 of 5 yes
- 11Yes
- 12Yes
- 13No
- 14Yes
- 15Yes
Safety and workplace4 of 5 yes
- 16Yes
- 17Yes
- 18Yes
- 19No
- 20Yes
- Check 7: noFixed on the spot: the record was written in during the audit
- Check 13: noRack held; lot checked and the traveler corrected. Owner: materials lead, due same shift
- Check 19: noExtra boxes back to stores; delivery quantity reviewed. Owner: line lead, due next day
A layer 1 audit at a hose crimping station: 20 checks in four groups. Work instructions and training 5 of 5 yes. Quality checks 3 of 4 yes, check 7 no and fixed on the spot, check 9 N/A. Process settings and material 4 of 5, check 13 no. Safety and workplace 4 of 5, check 19 no.
Scoring the example audit
Score = yes ÷ (yes + no)
20 checks: 16 yes, 3 no, 1 N/A
- 16 ÷ (16 + 3) = 16 ÷ 19= 84%
Audit score84%
20 checks: 16 yes, 3 no and 1 not applicable. 16 divided by 19 is 84 percent.
- Work instructions and training: all five checks yes.
- Quality checks: check 7 no, the 10:00 crimp diameter check was not recorded. The operator had done it and wrote it in during the audit, so it was fixed on the spot.
- Process settings and material: check 13 no, the hose lot on the rack did not match the lot on the traveler. The rack was held and the finding went in the table with an owner.
- Safety and workplace: check 19 no, eight boxes of fittings stacked above the marked maximum.
- Check 9, suspect parts held in the marked area, was N/A: there were none that shift.
16 yes, 3 no and 1 N/A, a score of 84%. Two findings go in the table with owners and dates, and the supervisor's layer 2 audit that week starts with checks 13 and 19.
Common mistakes
Auditing from the office
An LPA done from the records alone misses what the operator is really doing. Go to the station every time.
Only the first layer shows up
If managers skip their audits, the team hears that the checks do not matter. Track audits done against planned for every layer.
Writing no and walking away
Every no needs what you saw and either a fix on the spot or an owner and a date. A score with no actions changes nothing.
Treating it as an audit of the operator
A no usually means the process makes the right way hard: no gauge at hand, an unclear instruction, a record nobody reads. Fix the process.
Never changing the checks
A check that has been yes at every layer for months tells you little. Swap it for a newer risk, but keep most of the list stable so the scores can be compared.
From this worksheet to a running system
LeanSuite runs this checklist for every layer on its own schedule and turns each finding into a tracked action.
- Schedule the same LPA checklist for each layer, with reminders; missed audits show in red.
- Auditors complete their checks on a phone or tablet, with photo evidence where required.
- Each report shows its score and pass or fail; a live dashboard shows completion across the plant.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite you schedule the same LPA checklist for each layer. Auditors see checks on a calendar or Kanban board and complete them on a phone or tablet, with photo evidence where required. Missed audits show in red.
See it in a 45-minute demoIn the lean glossary
Free tools
Guides
- What is a layered process audit: the layers, the questions and a worked schedule
- Gemba Walks vs Audits: Key Differences Every Manufacturer Should Know
- Why Defects Reach Customers Despite Quality Control
- Layered process audit software for automotive plants: what to check by process and a worked month
- IATF 16949 internal audit checklist: system, process and product audits
- Best layered process audit software: 7 tools compared
- ISO 9001 internal audit checklist (production area)
- Process audit checklist: the full audit of one process, less often
- Quality assurance vs quality control: audits are assurance, not inspection
- Layered process audit questions: 56 in eight groups, and why each one is on an audit
FAQ
Layered process audit (LPA) checklist: common questions
A short, frequent check at the station that key process steps and controls are being followed, done by several layers of the organization on their own schedules. For example, team leaders audit every shift, supervisors weekly and managers monthly, all with the same short checklist.
A regular audit is usually long, done by a quality auditor and months apart. An LPA takes a few minutes, is done by leaders from the team leader up, and happens often enough that a process that drifts is caught within days. Findings are fixed on the spot where possible.
Few enough to answer at the station in a few minutes. This template has 20 in four groups. Many plants keep a core set and add a few checks for the station's own high-risk steps, taken from the process FMEA and past defects.
Yes, slowly. Keep about half the list as a core set on every audit, the highest-risk controls, error-proofing verification and any open containment, and fill the rest from a bank in a fixed order so every bank question is asked at least monthly on each shift. When a check has been yes at every layer for about three months, move it to the bank and bring in a newer risk.
CQI-8 Layered Process Audits is a guideline from AIAG, the North American automotive industry group, on how to set up and run an LPA program: the layers, the frequency, the questions and what to do with findings. The second edition came out in 2014. Many automotive customers point to it in their own requirements, so check what yours ask for.
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- 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.
- OKR template for manufacturingObjectives with three or four key results each, scored 0 to 1.0 from baseline and target every month, cascaded to facility, department and person with an Other bucket for work that serves no objective.
- Goal cascade and alignment templateA one-page cascade tree from company to person with the catchball reply on every card, and an initiatives list that shows how much work serves a goal and how much sits in Other.
- Monthly business review template (operations review agenda)A 90-minute operations review in nine timed blocks: who speaks when, the KPIs each block reviews with red or green, a prep checklist for every presenter and a log of decisions and actions.
- Rolling action item list (RAIL) templateA single running list of actions kept from meeting to meeting, with a weekly review sheet and age counts.
- Lessons learned templateA one-page lessons log, a 45 minute session guide and an Excel register that shows which actions are done, open or overdue.
- Packing list templateA one-page packing list with a pack checklist, and an Excel file that works out volume, shipped to date and back order.
- Meeting minutes templateA one-page minutes form and an Excel log of decisions and actions with owners, due dates and status.
- Sign-in sheet templateA training and meeting sign-in sheet, a visitor sign-in and out sheet, and an Excel register of attendance and visitors on site.
- Purchase order templateA one-page purchase order and an Excel version that adds up the lines, checks the approval limit and tracks what is still to come.
- Action plan templateA one-page action plan and an Excel tracker with percent done, status and a weekly timeline.
- Maintenance request form templateA one-page request form and an Excel log that times each answer against a priority target.
- Maintenance log templateA maintenance log page and an Excel log that totals cost, downtime and planned work and flags repeat breakdowns.
- Preventive maintenance schedule templateA PM schedule with next due dates and status, and an Excel calendar of the jobs and hours in each month.
- Machine setup sheet templateA setup sheet with limits, a first piece check and setup minutes, and an Excel log of setups against a standard.
- Work instruction templateA one-page work instruction with key points and step times, and an Excel training record that flags re-checks.
- Fire drill report templateA report for each fire or mock drill: a timeline from the alarm, the head count, an observer checklist, actions and a yearly log.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.