Free template
Updated
Mock recall template: traceability exercise worksheet
A mock recall is a practice run of your recall procedure. Someone names a finished lot, and the team traces it one step back to every ingredient and packaging lot and its supplier, and one step forward to every first customer, against the clock. SQF requires the test at least once a year (Food Manufacturing Code, Edition 9, element 2.6.3.2), and BRCGS asks for an annual traceability test with a quantity check. This worksheet has an exercise sheet (header, six timed milestones, where every unit of the finished lot went, the recall contacts tested and a scorecard), a trace-back table with a mass balance for each input lot, a trace-forward table and a gap log with owners, due dates and re-tests. The Excel version works out the elapsed time against your target and the unaccounted quantity and percent accounted for each lot, flags anything outside the tolerance your site sets, and gives an overall result. The PDF has the paper sheets, a worked example, and the rules paraphrased with their section numbers. It is an example to adapt, not legal advice.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Header fields for site, product, lot, scenario, time target and tolerance, a clock of six milestones, a finished lot reconciliation table, a scorecard and a recall contacts table.When to use it
When to run a mock recall
- For the yearly test your certification scheme or your customers require, on a different product, line and shift each time.
- After a change to how lots are tracked: a new ERP or receiving process, a new warehouse, a new line or a new supplier of a bulk ingredient.
- When a customer audit or questionnaire asks for your last mock recall and how long it took.
- To train a new recall team or a new QA manager before they face a real recall.
- If you make or use foods on the FDA Food Traceability List, to practise pulling the records that rule asks for.
How to fill it in
- 1
Choose the lot and the scenario
Pick a finished lot that has already shipped, so the forward trace is real. Change product, line, shift and supplier from one test to the next, and favour lots with many inputs, rework or a bulk material used across many products. Write the scenario in one line: a customer complaint, a supplier's notice, a positive test.
- 2
Decide planned or no-notice
A planned exercise trains people; a no-notice one shows what really happens on a night shift. In both, someone outside the team names the lot and starts the clock. Set the time target and the mass balance tolerance before you start, not after.
- 3
Trace one step back
From the batch and production records, list every lot used: ingredients, packaging that touches the food, processing aids and rework. For each one find the receiving record (supplier, supplier lot, date received, quantity, document number) and write down the time it was found.
- 4
Trace one step forward
From the shipping records, list every shipment of the lot to its first customer, the first place it went after it left your control, with the bill of lading or invoice number and the quantity. Check that each customer is on the recall contact list with current details.
- 5
Reconcile the quantities
For each input lot, received minus used in this lot, used in other lots, on hand and waste should come close to zero; the Excel flags anything outside your tolerance. For the finished lot, shipped plus on hand, samples and destroyed should equal what was produced.
- 6
Test the people, not the customers
Call the recall team at the hours a real recall could start and count who answers. Do not contact customers unless your procedure says so, and never in a way that could start publicity.
- 7
Close out the same day
Stop the clock and review with the team. Log every gap with a cause, an owner and a due date, re-test each fix on a later lot, and keep the records: auditors ask for the last test and what changed after it.
What auditors and the rules ask
What the codes and regulations ask for, in plain words
Paraphrased with section numbers so you can check the documents themselves. No US regulation sets a time limit for a mock recall: the time target is your site's or your customer's.
| Source | What it asks | Where the worksheet records it |
|---|---|---|
| SQF Food Manufacturing Code, Edition 9, elements 2.6.2 and 2.6.3 | Trace at least one step back to the supplier and one step forward to the customer. Test the withdrawal and recall system at least once a year, on different products and shifts, and keep records of the tests and the corrective actions. | Trace back and trace forward tables, gap log, next test due |
| BRCGS Food Safety, Issue 9, clauses 3.9.3 and 3.11.3 | A traceability test across product groups at least once a year, with a quantity check or mass balance, and a yearly test of the incident and recall procedure. In earlier wording, as quoted by BRCGS, full traceability should take no more than 4 hours and the test records the timings of key steps. | Mass balance for each lot, the clock, the time target |
| 21 CFR 117.139 (FDA) | A written recall plan for food with a hazard requiring a preventive control: who notifies direct consignees and, when needed, the public, how effectiveness is checked and how the food is disposed of. | Recall contacts tested, trace forward |
| 21 CFR 1.337 and 1.345 (FDA, Subpart J) | Records of the immediate previous source and the immediate subsequent recipient of food, and for manufacturers the source of each ingredient in each finished lot. FDA can ask for them within 24 hours (1.361). | Supplier, lot, date, quantity and document columns |
| 21 CFR Part 1 Subpart S, the Food Traceability Rule (FSMA 204) | For foods on the FDA Food Traceability List: a traceability plan, traceability lot codes and key data elements for receiving, transformation and shipping, and the records to FDA within 24 hours, as a sortable spreadsheet during an outbreak or recall. | Location and reference document columns, the Food Traceability List column, the Excel sheets |
SQF Food Manufacturing Code, Edition 9, elements 2.6.2 and 2.6.3
- What it asks
- Trace at least one step back to the supplier and one step forward to the customer. Test the withdrawal and recall system at least once a year, on different products and shifts, and keep records of the tests and the corrective actions.
- Where the worksheet records it
- Trace back and trace forward tables, gap log, next test due
BRCGS Food Safety, Issue 9, clauses 3.9.3 and 3.11.3
- What it asks
- A traceability test across product groups at least once a year, with a quantity check or mass balance, and a yearly test of the incident and recall procedure. In earlier wording, as quoted by BRCGS, full traceability should take no more than 4 hours and the test records the timings of key steps.
- Where the worksheet records it
- Mass balance for each lot, the clock, the time target
21 CFR 117.139 (FDA)
- What it asks
- A written recall plan for food with a hazard requiring a preventive control: who notifies direct consignees and, when needed, the public, how effectiveness is checked and how the food is disposed of.
- Where the worksheet records it
- Recall contacts tested, trace forward
21 CFR 1.337 and 1.345 (FDA, Subpart J)
- What it asks
- Records of the immediate previous source and the immediate subsequent recipient of food, and for manufacturers the source of each ingredient in each finished lot. FDA can ask for them within 24 hours (1.361).
- Where the worksheet records it
- Supplier, lot, date, quantity and document columns
21 CFR Part 1 Subpart S, the Food Traceability Rule (FSMA 204)
- What it asks
- For foods on the FDA Food Traceability List: a traceability plan, traceability lot codes and key data elements for receiving, transformation and shipping, and the records to FDA within 24 hours, as a sortable spreadsheet during an outbreak or recall.
- Where the worksheet records it
- Location and reference document columns, the Food Traceability List column, the Excel sheets
A filled-in example
Illustrative, not a benchmarkAn example: a no-notice mock recall of lot TB-5281 of tomato basil pasta sauce, 2,000 cases of 680 g jars, with a 4-hour target and a 2% tolerance set by the site (illustrative numbers, not a real plant).
The example mock recall, by the clock
- 08:40Lot named
- 10:25 · 105 minTrace back
- 10:55 · 30 minTrace forward
- 11:40 · 45 minReconciled
- 12:00 · 20 minClosed
- Lot named to close-out3 h 20 minpass
Lot named at 08:40, records pulled at 09:05, trace back complete at 10:25, trace forward complete at 10:55, quantities reconciled at 11:40, exercise closed at 12:00: 3 hours 20 minutes against a 4-hour target.
- 08:40: the plant manager names the lot. The production records are pulled by 09:05, and by 10:25 the trace back has found all 14 input lots; the last, a label roll, was only on the paper receiving log.
- 10:55: the trace forward finds 5 first customers and 1,826 cases. With 150 cases on hand, 2 retained samples and 22 destroyed after a QA hold, all 2,000 cases are accounted for.
- 11:40: the mass balance shows olive oil lot O1-5531 at 1,000 - 420 - 380 - 160 - 10 = 30 kg unaccounted, 3.0%, over the 2% tolerance: the tote heel went into the day tank with no record. Salt (0.5%) and dried basil (0.4%) are inside the tolerance.
- 6 of the 7 people on the recall contact list are reached; one number is out of date.
Closed at 12:00: 3 h 20 min against the 4-hour target, with every lot and shipment found, so the result is Pass with gaps. Three corrective actions follow: a day-tank transfer record, packaging lots entered at receipt and an updated contact list, each with an owner, a due date and a re-test.
Common mistakes
Choosing an easy lot
A lot with five inputs and one customer always passes. Pick lots with rework, bulk materials used across many products and many customers, and change product, line and shift each time.
Stopping once the records are found
Finding every lot is half the test. Without the quantities you cannot tell whether product went somewhere you have no record of, which is exactly what a real recall needs to know.
Leaving out packaging and rework
Packaging that touches the food, processing aids and rework are inputs too, and they are the ones most often kept on paper logs.
Running it from the office
Use the records the shifts really keep. If the answer depends on one person who knows where things are, the test should show that; run the next one on the night shift.
Calling customers during a test
A customer who thinks the recall is real can pull product or raise an alarm. Check the contact details instead; call only if your procedure says so, and say clearly that it is a test.
No re-test
A corrective action is done when a later trace shows it worked, not when the form is signed. Log the re-test date and run it.
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
LeanSuite lets food and beverage plants build their own GMP inspections and HACCP verification checks, complete them on a phone or tablet with photos, and turn failed items into corrective actions tracked to verified closure.
See it in a 45-minute demoIn the lean glossary
Free tools
FAQ
Mock recall template: traceability exercise worksheet: common questions
More free templates
All templates- 8D report templateD0 to D8 with targets, containment counts, occurrence, escape and systemic causes, verified actions and a worked example.
- Poka-yoke worksheetEach step's errors and what they cost, the device (approach, function, method), payback, and a log that proves each device works.
- Layered process audit (LPA) checklist20 yes, no or N/A checks at the station, a fixed-on-the-spot box, scores by group and a findings table.
- PFMEA template (process FMEA)Failure modes, effects and causes rated for severity, occurrence and detection, with RPN before and after action.
- Pareto chart templateA tally sheet, the Pareto by count and by cost with the cumulative line and the 80% cut, and a before and after comparison. Excel sorts and draws it.
- Control plan templateWhat is checked at each step, against which limits, how, how often, and what to do when a result is out.
- Corrective action request (CAPA) formOne problem from containment to proof the fix worked, with occurrence and escape causes and a closure check that tells you when it can close.
- Non-conformance report (NCR) formA two-page NCR from the requirement against what was found to disposition and closure, and an Excel NCR log.
- CAPA log templateAn Excel CAPA tracker with status, days open, late flags and counts by source, plus a printable log and monthly review.
- Supplier corrective action request (SCAR) formA SCAR from the problem and containment asked for to the supplier's 8D-style response, verification and closure.
- First article inspection (FAI) report templatePart information, a ballooned characteristic table with tolerances and results, material and process certificates, and sign-off.
- Design FMEA (DFMEA) templateA design FMEA worksheet with S, O, D and RPN before and after action, a class column and a design rating guide.
- PPAP checklistThe 18 PPAP elements with owner, due date and status, the five submission levels and a readiness count.
- Process capability (Cpk) study sheet25 subgroups of readings with Cp, Cpk, Pp and Ppk worked out, control limits to check stability, and a histogram.
- Inventory cycle count sheetA blind count sheet with variance and tolerance, an ABC count schedule and record accuracy, worked out in Excel.
- Incoming inspection checklistReceiving inspection checks from paperwork to sample, the sampling plan, the decision, and an Excel log by supplier.
- Supplier audit checklistA supplier process audit of 32 questions scored 0 to 3, with section scores, a rating and the findings.
- 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.
- 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.
- 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.
- Defect check sheetTally defects by type and day, with units inspected, defect rates, a location sheet and the week's Pareto.
- 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.
- 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.
- 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.
- 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.
- Gauge calibration logA gauge register with next due dates and status, a calibration record with as-found and as-left readings, and the steps when a gauge fails.
- 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.
- 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.
- 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.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- 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.
- 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.
- 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.
- 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.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- 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.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- 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.
- 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.
- 5S audit checklist template25 checks, five per S, scored 1 to 5, with a score summary and a chart of the five S's.
- 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.
- Gemba walk checklistA walk plan and route, 30 prompts in six groups and a findings table with owners and due dates.
- 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.
- 5S red tag log and red tagsA log of every red-tagged item with its decision, and six printable red tags to cut out.
- Shift handover templateSafety, production against plan, holds, downtime events, materials and people, and the open actions the next shift takes over.
- 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.
- 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.
- Forklift inspection checklist23 pre-shift checks for a week on one page, a do-not-operate rule, and a defect and repair log.
- 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.
- 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.
- Office 5S audit checklist25 checks written for offices and shared areas, five per S, scored 1 to 5, with a score summary and actions.
- Floor marking color guideA floor marking color standard with swatches, marks and line widths to fill in, and a floor marking check with a layout sketch.
- Shadow board plannerTool inventory with fetch time, a layout planned from each tool's outline size, a month of daily checks with 5S audit evidence, and a missing tool log.
- 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.
- 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.
- 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.
- Safety audit checklistThirty-four plant-wide safety checks answered Yes, No or N/A, scored by area, with a risk rating and an action for every No.
- 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.
- Maintenance work order formOne form per maintenance job from request to handback, and a log that tracks 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.
- 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 matrixCost 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.
- 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.
- 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.
- Visual management audit checklist29 checks of whether anyone can tell normal from abnormal at a glance, scored by group, with a trend and actions.
- 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.
- 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.
- 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.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- 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.
Can't find the template you need?
Tell us what you're looking for. We'll make it and send it to your inbox, free.
A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.