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Management of change form
A management of change (MOC) form is the record a plant uses to propose, review, approve and close out a change to a process, machine, material or method before it goes live. It finds the hazards and knock-on effects while the change is still on paper. This form is for manufacturing changes, not IT (information technology) change management: a new valve, a different raw material, a higher line speed, a revised cleaning method or a temporary bypass. It runs in eight parts: the request, the technical reason, a hazard review with 25 checks, the documents to update, approvals, a pre-startup review, training, and close-out. For processes covered by OSHA's Process Safety Management standard, 29 CFR 1910.119, paragraph (l) is the management of change element and paragraph (i) the pre-startup safety review. The form follows their order and names them, but it is not a PSM program and does not decide what PSM requires of your plant. LeanSuite does not run PSM or MOC. The Excel file is an MOC register that counts days open and flags temporary changes past their end date.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for the MOC number, area and requester, tick boxes for the type of change and permanent or temporary, and boxes for what will change and the technical reason.Change requestReplacement in kind screenTechnical basis25-check hazard reviewDocuments to updateApprovalsPre-startup reviewTrainingClose-outMOC register in Excel
When to use it
When to use a management of change form
- Before any change to raw materials or process chemicals, equipment, technology, operating conditions, procedures or the building that is not a replacement in kind.
- For a temporary change, such as a bypass, a hired-in pump or a trial material, with an end date.
- For an emergency change, written up and reviewed straight after it is made.
- When a change on one line touches safety, the environment, product quality and the customer at once, and no one person can see all of it.
- Not for shift to shift changes of people, machines, material or method at a station: the 4M change management sheet is for those.
How to fill it in
- 1
Raise the request
Say exactly what will change, where, why, whether it is permanent or temporary, and the end date of a temporary change. Screen out replacements in kind: the same specification needs no MOC.
- 2
Write the technical basis
Give the reason for the change and the data behind it: drawings, ratings, supplier data or trial results.
- 3
Run the hazard review
Bring operations, maintenance, EHS and quality together and go through the 25 checks. Mark each Yes, No or N/A, and give every effect found an action, an owner and a date.
- 4
List the documents and get approval
Tick every document the change touches. The approvers named on the form sign before any work starts.
- 5
Pre-startup review and training
Before start-up, confirm it was built as approved, procedures are in place, hazard review actions are closed and everyone who runs or maintains it is trained.
- 6
Close out
After start-up, check the change works, update and issue every document on the list, and remove or approve as permanent a temporary change by its end date.
Which change record
Management of change vs the other change records in a plant
Four records get called change management. They cover different changes, and a plant usually needs more than one.
| Record | What changes | Who reviews it | Use it when |
|---|---|---|---|
| Management of change (MOC) form | A planned change to a process, machine, material, method or the building | Operations, maintenance, EHS and quality, then named approvers | Before the change is made, so hazards and knock-on effects are found on paper |
| 4M change management sheet | A change of man, machine, material or method at one station during the shift | The team leader and quality at the line | When a change point happens, to add extra checks on the first parts after it |
| Engineering change request (ECR) | A product design, drawing or specification | Design engineering, quality and often the customer | When the part or its specification changes, not only how it is made |
| IT change management | Software, servers, networks and IT services | An IT change advisory board | When a system or service changes; most change management plan templates online are this kind |
Management of change (MOC) form
- What changes
- A planned change to a process, machine, material, method or the building
- Who reviews it
- Operations, maintenance, EHS and quality, then named approvers
- Use it when
- Before the change is made, so hazards and knock-on effects are found on paper
4M change management sheet
- What changes
- A change of man, machine, material or method at one station during the shift
- Who reviews it
- The team leader and quality at the line
- Use it when
- When a change point happens, to add extra checks on the first parts after it
Engineering change request (ECR)
- What changes
- A product design, drawing or specification
- Who reviews it
- Design engineering, quality and often the customer
- Use it when
- When the part or its specification changes, not only how it is made
IT change management
- What changes
- Software, servers, networks and IT services
- Who reviews it
- An IT change advisory board
- Use it when
- When a system or service changes; most change management plan templates online are this kind
The review
The 25 checks in the management of change review
Five groups, in the order the change moves through them. On the form each check is Yes, No or N/A, and every effect found gets an action, an owner and a date before approval.
Is it a change?
Screen every request first
- 1The request says exactly what will be different, and on which line, machine or process
- 2It is not a replacement in kind, meaning a part or material that meets the same design specification
- 3It is marked permanent or temporary, and a temporary change has an end date
- 4If it had to be made in an emergency, it is reviewed straight afterwards
Technical basis and hazards
Answered before any work starts
- 5The technical reason for the change is written down with the data behind it
- 6A hazard review was done with operations, maintenance, EHS and quality in the room
- 7Effects on safety and health are assessed: exposure, stored energy, ergonomics and fire
- 8Effects on the environment, permits and emissions are assessed
- 9Effects on product quality, the customer and any approved process are assessed
- 10Lockout points, guards, interlocks and alarms affected by the change are listed
- 11Materials, ratings and limits were checked for the new operating conditions
Documents to update
Every document the change touches
- 12Drawings, piping and instrument diagrams or layouts
- 13Operating procedures, work instructions and setup sheets
- 14Maintenance procedures, PM tasks and spare parts
- 15PFMEA, control plan or process sheet
- 16Safety data sheets, labels and the chemical inventory
- 17Training material and the skills matrix
Before start-up
The pre-startup review
- 18The change was built or installed as approved
- 19Safety, operating, maintenance and emergency procedures for it are in place
- 20Actions from the hazard review are closed, or have an approved plan and date
- 21Everyone who runs or maintains the changed process was trained before start-up
- 22The approvers signed before the work started
After start-up and close-out
Closing the loop
- 23The change was checked in use and works as intended
- 24A temporary change was removed, or approved as permanent, by its end date
- 25Every document on the list was updated and issued
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a made-up adhesives blending plant that is not covered by PSM and uses the same steps by choice. The change: replace the manual valve on the resin transfer line to mix tank 2 with an automatic valve that closes on the tank's high level switch. The same example is page 4 of the PDF and the Example sheet of the Excel file.
The example change, request to close-out
- Day 0, 1 SeptRequestAutomatic valve on the resin line to mix tank 2.
- Day 6Hazard review25 checks; a new lockout point and a PM task found.
- Day 9ApprovedBy 4 managers.
- Day 20 to 21Pre-startup review, start-up14 of 16 trained first.
- Day 35Close-out5 documents issued, after two weeks of running.
- No effect: 18 review checks
- Effect, with an action: 6 review checks
- N/A: 1 review check
Requested 1 Sept, hazard review day 6, approved day 9, pre-startup review day 20, start-up day 21, closed day 35. Review checks: 18 no effect, 6 with an effect and an action, 1 not applicable.
- Requested on 1 September, hazard review on 7 September, approved by 4 managers on 10 September: 9 days.
- The 25 review checks: 18 no effect, 6 with an effect and an action, 1 N/A. The effects included a new lockout point on the valve's air supply and a level switch that now needs a PM task.
- 5 documents updated: the piping and instrument diagram, the transfer procedure, the lockout procedure, the PM task and the training record.
- Pre-startup review on 21 September. 14 of 16 operators (87.5%) were trained before start-up; the 2 on leave were trained before their first shift back and kept off the task until then.
- Start-up on 22 September, 21 days after the request. Close-out on 6 October, 35 days after the request, once the valve had run for two weeks and every document was issued.
Nothing in the example needed PSM. The review was worth it because the new lockout point and the PM task were found before start-up rather than after it.
Common mistakes
Calling every change a replacement in kind
A replacement in kind meets the same design specification. A different valve type, a new supplier's resin or a higher setpoint is a change, even if it does the same job.
Approving before the hazard review
Signatures on a request nobody has reviewed only record who agreed to the risk. Review first, approve second.
Temporary changes that stay
A bypass or a trial without an end date becomes permanent without a review. Give it a date and check the register every week.
Forgetting the documents
The change is not finished when it runs. If the procedure, the drawing or the PM task still shows the old way, the next person works from the wrong information.
Training after start-up
People who run or maintain the changed process need to know before it starts, including contractors and the shifts that were not there on the day.
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Run this template in LeanSuite
LeanSuite runs the daily routines of a chemical manufacturing plant in one place. It covers operator rounds, batch and filling-line losses, off-spec batches, near misses, lockout and controlled procedures. It works beside your process safety management program and control systems, and it does not run PSM, management of change or permits.
See it in a 45-minute demoIn the lean glossary
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FAQ
Management of change form: common questions
It is the way a plant reviews and approves a change to a process, machine, material or method before making it, so hazards and knock-on effects on safety, quality and the environment are found first. Each change gets a request, a technical reason, a hazard review, approvals, a check before start-up, training and a close-out.
For processes covered by the Process Safety Management standard, 29 CFR 1910.119(l) calls for written procedures to manage changes, other than replacements in kind, to process chemicals, technology, equipment, procedures and facilities. Before a change they must address its technical basis, its effect on safety and health, changes to operating procedures, the time needed and who authorizes it. Affected employees are informed and trained before start-up, and process safety information and procedures are updated. Read the standard for your own process.
IT change management controls changes to software, servers and IT services. A management of change form in a plant controls changes to the physical process, such as equipment, materials, chemistry, operating conditions and procedures, where the risk is an injury, a release or bad product.
It is the check made before a new or changed process starts: built as designed, procedures in place, hazard review actions resolved and people trained. Under PSM, 29 CFR 1910.119(i) requires one for new facilities and for modified facilities when the change is big enough to change the process safety information.
No. LeanSuite does not run PSM or MOC, and this is a free form for paper or Excel. LeanSuite runs the daily routines around them: operator rounds and equipment checks, near-miss reports, audits with photo evidence, lockout steps and corrective actions tracked to closure.
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- Supplier scorecardMonthly PPM, on-time delivery and SCAR measures turned into points, a weighted score and a rating per supplier.
- Receiving logA dock receiving log with quantities, damage, QC holds and putaway, plus a discrepancy report and dock-to-stock time.
- Pre-shipment inspection checklistThe last check before shipping: part, quantity, labels, packaging, paperwork and photos, then release.
- Material shortage logEvery part short with its need date, line impact, ETA and escalation, and counts by reason and supplier.
- 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.
- Standard work audit checklist24 checks of a job against its written standard, ten timed cycles, and each gap sorted by cause before anyone acts.
- Defect check sheetTally defects by type and day, with units inspected, defect rates, a location sheet and the week's Pareto.
- 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.
- Waste walk checklist (TIMWOODS)32 things to look for across the eight wastes, with where and how much, and a findings log with dot votes, owners and dates.
- 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.
- QA matrix templateDefect modes against stations in flow order: where each is made and first caught, a weight × occurrence × detection score, an AA to C class and the escapes flagged.
- Fault tree analysis templateA drawing area with the FTA symbols, an event table with probabilities and minimal cut sets, and the gates worked out bottom-up in Excel.
- Is / is not analysis templateWhat, where, when and extent with is, is not, distinctions and changes, then each possible cause tested against every pair and ranked.
- 5G investigation sheetConfirm the facts before naming a cause: 5W1H, the five G's with 20 prompts, the gap against the principle and the standard, and the countermeasures.
- Yokoten tracker (horizontal deployment)Copy a proven improvement line by line: the source result, each candidate's own before and after, its share of the source's improvement and the standard updated.
- Coaching kata template (improvement kata storyboard)The learner's storyboard (target condition, current condition, obstacles, PDCA cycles) and a fold-over card with the coach's five questions.
- SMART goals templateWrite a goal, test it against the five SMART letters, then track progress toward the target against the time used.
- Lean readiness assessment templateTwenty statements in four factors, scored 1 to 5 by several people on their own, with averages, the spread between them and the actions.
- Nemawashi template (stakeholder plan)Plan the one-to-one conversations before a decision: who to talk to in what order, their concerns, what changed and where they stand.
- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- Future state value stream map worksheetThe eight future-state questions worked through in order: takt, pitch, flow, supermarkets, the pacemaker and the mix, with an EPEI check and current against future lead time.
- Value stream plan (VSM action plan)The future-state map cut into loops, each with an objective and a measurable goal, and its kaizen bursts turned into owned, dated projects on a 12-month timeline.
- Kaizen project plan (Gantt chart)One improvement project as a Gantt chart: tasks by phase with owners, predecessors and working days, a 16-week grid, milestones and a status from planned against actual % done.
- Histogram templateReadings, bins set by the square root rule, a tally and counts, the spec limits drawn and the share out of spec, with the common shapes explained.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- TQM self-assessment templateThe eight TQM principles in 24 statements you can check on the floor, scored 0 to 4 by several people, with the spread, the top 3 gaps and an action plan.
- 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.
- 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.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- 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.
- 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.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- 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.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- 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.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- 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.
- 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.
- 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.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- 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.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
- Cleanroom audit checklist33 cleanroom checks split by how often they run (each shift, weekly, per plan, system), a gowning order to watch against, a differential pressure log and a findings log, with a worked week of readings.
- GMP audit checklist for drug manufacturing42 self-inspection checks ordered by the subparts of 21 CFR 211, each with its section, the matching EU GMP chapter and whether it is seen on the floor or in records, graded critical, major or minor, with a worked audit of a packaging line.
- Line clearance checklist28 line clearance checks in six sections (area, equipment, materials, printed materials, documents, coder and vision settings), cleared by the operator and verified by a second person, with a printed-materials reconciliation and a worked example that does not balance.
- ISO 13485 internal audit checklist38 questions on ISO 13485 clauses 4 to 8, each with the FDA QMSR section that brings it in or adds to it, a production floor tab (records, current instructions, training, nonconforming product, CAPA) and a worked audit of a catheter line.
- ISO 22716 GMP audit checklist for cosmetics25 cosmetic GMP checks following the sections of ISO 22716, split into a floor walk (people, premises, equipment, materials, production) and system checks (lab, out of specification, deviations, complaints, change control, audits, documents), with a worked audit of a filling line.
- SSOP template: sanitation standard operating procedureOne sanitation SOP sheet per area or machine (steps, chemical, contact time, PPE, lockout, owner), a 23-check pre-op inspection and a verification log for visual, ATP and micro checks.
- SQF internal audit checklist for food manufacturing54 questions in the two parts of the SQF manufacturing code (system elements and GMP), each group mapped to BRCGS and FSSC 22000, graded Conforms to Critical, with findings, a score and a yearly plan.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- ESD audit checklist29 checks for an ESD protected area, with daily tests split from periodic verification, a measurement log and a worked audit.
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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.