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OSHA compliance calendar (general industry)
An OSHA compliance calendar lists the duties federal OSHA says an employer must repeat, such as the yearly injury summary, the monthly extinguisher check and the three-year forklift evaluation, with the date each was last done and the date it is next due, so nothing slips unseen. This template pre-fills 37 general-industry duties from 29 CFR Parts 1904 and 1910, each with its paragraph, its interval and the record the rule names. You mark which apply to your site, add an owner and a last-done date, and the Excel file works out the next due date, flags what is overdue or due soon, shows the next 12 months and counts by owner. It is a planning aid, not legal advice: the standard and your State Plan govern.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for plant and date, then a table of injury record and fire duties with the CFR paragraph, how often, a box for whether it applies here, owner, last done and next due.37 recurring OSHA dutiesCFR paragraph for eachInterval or fixed dateApplies here: Yes, No or CheckOwnerLast done and next dueOverdue and due-soon flags12-month year viewCounts by ownerDaily and triggered dutiesWorked example
When to use it
When to use an OSHA compliance calendar
- At the start of the year, to see which duties fall in which month and spread the work.
- When a new EHS or plant manager takes over and needs to know what is due and who owns it.
- Before an OSHA inspection, an insurer visit or a customer audit, to show that every recurring duty has an owner and a date.
- At a monthly safety meeting: what is overdue, and what is due in the next 30 days.
How to fill it in
- 1
Decide what applies
Set Applies here? on every row to Yes, No or Check. Only Yes rows get dates. Whether process safety, hearing conservation, confined space entry or the online filing to OSHA applies depends on your size, industry and work.
- 2
Enter the last done date
For each Yes row type the date it was last done. Where one row covers many items, such as every extinguisher or every forklift operator, enter the oldest date and keep the item list elsewhere.
- 3
Read next due and status
Next due is the last done date plus the months between. For the Feb 1 posting and the Mar 2 filing it is the deadline in the year after the one you last did it. Red is overdue, amber is due in the next 30 days.
- 4
Give every row an owner
Pick a name from the list. The By owner sheet counts each person's overdue and due-soon rows.
- 5
Look at the year
The year view puts a dot in each month a duty falls due, so you can see a crowded March and move what you can.
- 6
Add your own and review monthly
Use the blank rows for State Plan items, permits and customer requirements. Review the sheet at a regular meeting, not only before an inspection.
The register
37 recurring duties and how often each comes round
Read from 29 CFR Parts 1904 and 1910 on 14 October 2026. Whether a row applies depends on your site: the Excel file marks the ones that apply to nearly every plant as Yes and the rest as Check.
| Duty | Rule (29 CFR) | How often |
|---|---|---|
| Review the 300 Log, total it and certify the 300A summary | 1904.32(a), (b)(2) to (b)(4) | By Feb 1 |
| Post the 300A summary where employee notices go | 1904.32(b)(5), (b)(6) | By Feb 1 |
| Send 300A data to OSHA online | 1904.41(a)(1), (c) | By Mar 2 |
| Send 300 Log and 301 data to OSHA online | 1904.41(a)(2), (c) | By Mar 2 |
| Visually check every portable fire extinguisher | 1910.157(e)(2) | Every month |
| Annual maintenance check on every extinguisher | 1910.157(e)(3) | Every year |
| Hydrostatic test of the 5-year extinguisher types | 1910.157(f)(2), Table L-1 | Every 5 years |
| Hydrostatic test of the 12-year extinguisher types | 1910.157(f)(2), Table L-1 | Every 12 years |
| Empty and service stored pressure dry chemical extinguishers that need a 12-year test | 1910.157(e)(4) | Every 6 years |
| Teach employees how to use extinguishers; train designated fire fighters | 1910.157(g)(2), (g)(4) | Every year |
| Test non-supervised employee alarm systems | 1910.165(d)(2) | Every 2 months |
| Test supervised employee alarm systems | 1910.165(d)(4) | Every year |
| Main drain flow test on each sprinkler system | 1910.159(c)(2) | Every year |
| Open the inspector's test valve on each sprinkler system | 1910.159(c)(2) | Every 2 years |
| Inspect fixed extinguishing systems | 1910.160(b)(6) | Every year |
| Weigh or pressure-check fixed system containers | 1910.160(b)(7) to (b)(9) | Every 6 months |
| Review the training of people who inspect or operate fixed systems | 1910.160(b)(10) | Every year |
| Periodic inspection of each lockout/tagout procedure | 1910.147(c)(6)(i), (ii) | Every year |
| Evaluate each powered industrial truck operator | 1910.178(l)(4)(iii) | Every 3 years |
| Monthly inspection of crane hooks, hoist chains and running ropes | 1910.179(j)(2)(iii), (iv), (m)(1) | Every month |
| Periodic (complete) inspection of each overhead crane | 1910.179(j)(1)(ii)(b), (j)(3) | Every year |
| Thorough inspection of alloy steel chain slings | 1910.184(e)(3)(i), (ii) | Every year |
| Fit test every wearer of a tight-fitting respirator | 1910.134(f)(2) | Every year |
| Retrain respirator users | 1910.134(k)(5) | Every year |
| Inspect respirators kept for emergency use and SCBA | 1910.134(h)(3)(i)(B), (h)(3)(iii) | Every month |
| Audiogram for each employee at or above 85 dB (8-hour average) | 1910.95(g)(6) | Every year |
| Repeat the hearing conservation training | 1910.95(k)(2) | Every year |
| Acoustic calibration check of each audiometer | 1910.95(h)(5)(ii) | Every year |
| Exhaustive calibration of each audiometer | 1910.95(h)(5)(iii) | Every 2 years |
| Review the permit-required confined space program | 1910.146(d)(14) | Every year |
| Review and update the bloodborne pathogens exposure control plan | 1910.1030(c)(1)(iv) | Every year |
| Bloodborne pathogens training | 1910.1030(g)(2)(ii) | Every year |
| Test eyewash and drench equipment | 1910.151(c) | Every month |
| Certify that operating procedures are current and accurate | 1910.119(f)(3) | Every year |
| Refresher training for people who operate a covered process | 1910.119(g)(2) | Every 3 years |
| Certify the process safety compliance audit | 1910.119(o)(1) | Every 3 years |
| Update and revalidate the process hazard analysis | 1910.119(e)(6) | Every 5 years |
Review the 300 Log, total it and certify the 300A summary
- Rule (29 CFR)
- 1904.32(a), (b)(2) to (b)(4)
- How often
- By Feb 1
Post the 300A summary where employee notices go
- Rule (29 CFR)
- 1904.32(b)(5), (b)(6)
- How often
- By Feb 1
Send 300A data to OSHA online
- Rule (29 CFR)
- 1904.41(a)(1), (c)
- How often
- By Mar 2
Send 300 Log and 301 data to OSHA online
- Rule (29 CFR)
- 1904.41(a)(2), (c)
- How often
- By Mar 2
Visually check every portable fire extinguisher
- Rule (29 CFR)
- 1910.157(e)(2)
- How often
- Every month
Annual maintenance check on every extinguisher
- Rule (29 CFR)
- 1910.157(e)(3)
- How often
- Every year
Hydrostatic test of the 5-year extinguisher types
- Rule (29 CFR)
- 1910.157(f)(2), Table L-1
- How often
- Every 5 years
Hydrostatic test of the 12-year extinguisher types
- Rule (29 CFR)
- 1910.157(f)(2), Table L-1
- How often
- Every 12 years
Empty and service stored pressure dry chemical extinguishers that need a 12-year test
- Rule (29 CFR)
- 1910.157(e)(4)
- How often
- Every 6 years
Teach employees how to use extinguishers; train designated fire fighters
- Rule (29 CFR)
- 1910.157(g)(2), (g)(4)
- How often
- Every year
Test non-supervised employee alarm systems
- Rule (29 CFR)
- 1910.165(d)(2)
- How often
- Every 2 months
Test supervised employee alarm systems
- Rule (29 CFR)
- 1910.165(d)(4)
- How often
- Every year
Main drain flow test on each sprinkler system
- Rule (29 CFR)
- 1910.159(c)(2)
- How often
- Every year
Open the inspector's test valve on each sprinkler system
- Rule (29 CFR)
- 1910.159(c)(2)
- How often
- Every 2 years
Inspect fixed extinguishing systems
- Rule (29 CFR)
- 1910.160(b)(6)
- How often
- Every year
Weigh or pressure-check fixed system containers
- Rule (29 CFR)
- 1910.160(b)(7) to (b)(9)
- How often
- Every 6 months
Review the training of people who inspect or operate fixed systems
- Rule (29 CFR)
- 1910.160(b)(10)
- How often
- Every year
Periodic inspection of each lockout/tagout procedure
- Rule (29 CFR)
- 1910.147(c)(6)(i), (ii)
- How often
- Every year
Evaluate each powered industrial truck operator
- Rule (29 CFR)
- 1910.178(l)(4)(iii)
- How often
- Every 3 years
Monthly inspection of crane hooks, hoist chains and running ropes
- Rule (29 CFR)
- 1910.179(j)(2)(iii), (iv), (m)(1)
- How often
- Every month
Periodic (complete) inspection of each overhead crane
- Rule (29 CFR)
- 1910.179(j)(1)(ii)(b), (j)(3)
- How often
- Every year
Thorough inspection of alloy steel chain slings
- Rule (29 CFR)
- 1910.184(e)(3)(i), (ii)
- How often
- Every year
Fit test every wearer of a tight-fitting respirator
- Rule (29 CFR)
- 1910.134(f)(2)
- How often
- Every year
Retrain respirator users
- Rule (29 CFR)
- 1910.134(k)(5)
- How often
- Every year
Inspect respirators kept for emergency use and SCBA
- Rule (29 CFR)
- 1910.134(h)(3)(i)(B), (h)(3)(iii)
- How often
- Every month
Audiogram for each employee at or above 85 dB (8-hour average)
- Rule (29 CFR)
- 1910.95(g)(6)
- How often
- Every year
Repeat the hearing conservation training
- Rule (29 CFR)
- 1910.95(k)(2)
- How often
- Every year
Acoustic calibration check of each audiometer
- Rule (29 CFR)
- 1910.95(h)(5)(ii)
- How often
- Every year
Exhaustive calibration of each audiometer
- Rule (29 CFR)
- 1910.95(h)(5)(iii)
- How often
- Every 2 years
Review the permit-required confined space program
- Rule (29 CFR)
- 1910.146(d)(14)
- How often
- Every year
Review and update the bloodborne pathogens exposure control plan
- Rule (29 CFR)
- 1910.1030(c)(1)(iv)
- How often
- Every year
Bloodborne pathogens training
- Rule (29 CFR)
- 1910.1030(g)(2)(ii)
- How often
- Every year
Test eyewash and drench equipment
- Rule (29 CFR)
- 1910.151(c)
- How often
- Every month
Certify that operating procedures are current and accurate
- Rule (29 CFR)
- 1910.119(f)(3)
- How often
- Every year
Refresher training for people who operate a covered process
- Rule (29 CFR)
- 1910.119(g)(2)
- How often
- Every 3 years
Certify the process safety compliance audit
- Rule (29 CFR)
- 1910.119(o)(1)
- How often
- Every 3 years
Update and revalidate the process hazard analysis
- Rule (29 CFR)
- 1910.119(e)(6)
- How often
- Every 5 years
A filled-in example
Illustrative, not a benchmarkAn example: a 120-person plant opens the calendar and finds four duties overdue (illustrative, a made-up plant).
- 37 rows: 24 marked Yes for this plant, 12 marked No (for example the four process safety rows, because no process is covered by 1910.119, the fixed extinguishing system rows and the bloodborne pathogens rows) and 1 still marked Check.
- Overdue: the monthly extinguisher check (last done 45 days ago), the lockout/tagout inspection (400 days ago, against a 12-month interval), the audiograms (380 days) and the hearing training (410 days).
- Due in the next 30 days: the annual extinguisher check, the monthly crane hook, chain and rope inspection, the respirator fit tests and the monthly eyewash test.
- One alarm test has no date entered yet, and one fixed-system training row is still marked Check. The other 15 rows are OK.
On track means OK or due soon: (15 + 4) ÷ 24 = 79.2% of the duties that apply. The By owner sheet shows the four overdue rows sit with three people: two with the EHS manager, one with Facilities and one with HR or training.
Common mistakes
Marking every row Yes to be safe
Rows that do not apply clutter the calendar and teach people to ignore overdue flags. Decide, and write why in the notes.
Treating the calendar as the inspection
It tracks when a duty is due. The extinguisher walk, the audiogram or the lockout inspection still has to be done and, where the rule asks for one, recorded.
Dating one row for many items
A row for every extinguisher is only as good as its oldest unit. Enter the oldest date, or the next due will look fine while one unit slips.
Forgetting the state
State Plan states run their own programs and can set other dates or intervals. Read your state's rule and add those duties as your own rows.
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 run safety inspections, Gemba walks and LOTO checks from ready-made templates, a failed item raises a safety tag automatically, and every corrective action has an owner and a due date, with delays flagged.
See it in a 45-minute demoIn the lean glossary
FAQ
OSHA compliance calendar (general industry): common questions
Many. The 300A summary is posted by February 1 (29 CFR 1904.32), portable extinguishers get a monthly visual check and an annual maintenance check (1910.157(e)), lockout/tagout procedures are inspected at least yearly (1910.147(c)(6)), and forklift operators are evaluated at least every three years (1910.178(l)(4)(iii)). Respirator fit tests and hearing tests are yearly. The register lists 37.
Post the 300A summary no later than February 1 of the year after the year it covers and keep it up until April 30 (1904.32(b)(6)). Establishments that must submit online do so by March 2 (1904.41(c)). Who must submit depends on employee count and industry, so check 1904.41 and its appendices for your NAICS code.
Visually every month, and with an annual maintenance check whose date is recorded (29 CFR 1910.157(e)(2) and (e)(3)). Hydrostatic tests follow Table L-1: every 5 years for some types and every 12 for others. Employees are taught how to use extinguishers at hire and at least yearly (1910.157(g)).
No. It tracks when each duty comes round. The inspection, test or training still has to be done and, where the rule asks for it, recorded. It covers federal OSHA general industry as read on 14 October 2026. State Plan states can differ, and construction and other industry standards are not included.
The safety audit checklist checks conditions on a walk, and the training matrix tracks expiry dates per person. This calendar tracks when the site's own recurring duties are next due: inspections, tests, filings and reviews, with the rule behind each. The forklift operator, lockout/tagout and crane templates hold the detail of single duties; the calendar shows their dates next to everything else.
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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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
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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.