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Pre-trip inspection checklist
A pre-trip inspection checklist is the list a driver works through before moving a truck or tractor-trailer, in an order that covers the vehicle once and leaves nothing out. This one has 42 checks in ten groups, from the last report to the load, each graded OK, Defect, Do not drive or N/A. Page 3 is a driver vehicle inspection report (DVIR), because the federal rules split the job in two: before driving the driver must be satisfied the vehicle is in safe operating condition and review the last report (49 CFR 396.13), and at the end of each day's work the driver writes up any defects (396.11). The checks and stop conditions come from 49 CFR Parts 392, 393 and 396. It is a working aid, not legal advice, and using it does not make a vehicle DOT compliant. Those rules apply to commercial motor vehicles as defined in 390.5, and differ for other vehicles.
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A table of checks in walk-round order for the last report, engine compartment and cab, each with the rule it comes from and OK, Defect, Do not drive and N/A circles.42 checks in walk-round orderStop conditions with rule citationsDriver vehicle inspection report (DVIR)Repair certification and driver reviewRetention dateRule scope noteWorked example
When to use it
When to use a pre-trip inspection checklist
- At the start of every shift, before the driver moves a truck, tractor or trailer.
- When a driver picks up a vehicle or trailer someone else drove, including a drop trailer.
- To train new drivers on the walk-round route, so everyone checks the same things in the same order.
- To keep the driver vehicle inspection report, with the repair certification and the driver's review, in one place.
- Not for the fleet lead's full inspection or the annual inspection. The vehicle inspection checklist has 53 checks, including the periodic items.
How to fill it in
- 1
Review the last report
If the last driver vehicle inspection report listed defects, read it and check the repairs were certified. Sign it to say you reviewed it (396.13). If it listed nothing, there is nothing to sign. - 2
Lift the hood and check fluids
With the engine off, check for leaks and the levels the maker's manual gives. The rules set no oil or coolant levels, so the manual decides. - 3
Start the engine and check the cab
Steering, horn, wipers, glass, mirrors, parking brake, seat belt, and the warning lamps. Let the air system build pressure and watch the low pressure warning. - 4
Walk round in the same order every time
Lights on, then tires and wheels from the front left all the way round, brake lines, couplings, a quick look underneath, emergency equipment and the load. A fixed route stops you missing a corner. - 5
Grade, then decide
OK, Defect, Do not drive or N/A. A Do not drive item means the vehicle stays put until it is repaired and the repair is certified (396.11(a)(3)). - 6
Write the DVIR at the end of the day
On page 3, identify the vehicle, list each defect, and sign. Keep it for three months. The next driver reviews it and signs that repairs were certified.
Before and after the trip
What the driver does before driving and what is written at the end of the day
The sections split the work into a check before driving and a report afterwards. Section numbers and wording checked in the eCFR on 2026-11-05.
| When | What the driver does | Section |
|---|---|---|
| Before driving | Be satisfied the vehicle is in safe operating condition. Be satisfied that the listed parts, including service brakes, parking brake, steering, lights and reflectors, tires, horn, wipers, mirrors, coupling devices, wheels and rims and emergency equipment, are in good working order. | 396.13(a); 392.7(a) |
| Before driving | Review the last driver vehicle inspection report if it listed defects, and sign that you reviewed it and that repairs were certified. | 396.13(b), (c) |
| During the trip | For trucks and truck tractors, inspect the cargo and its securement within the first 50 miles, then at each change of duty status, after 3 hours of driving or 150 miles, whichever comes first. | 392.9(b) |
| End of each day's work | Write a report on each vehicle operated: identify it, list any defect found or reported that would affect safe operation or cause a breakdown, and sign. No report is needed if nothing was found. | 396.11(a)(1), (a)(2) |
| After a defect is listed | The carrier repairs defects likely to affect safe operation before the vehicle is operated again, and certifies the repair or that none was needed. The report is kept three months. | 396.11(a)(3), (a)(4) |
Before driving
- What the driver does
- Be satisfied the vehicle is in safe operating condition. Be satisfied that the listed parts, including service brakes, parking brake, steering, lights and reflectors, tires, horn, wipers, mirrors, coupling devices, wheels and rims and emergency equipment, are in good working order.
- Section
- 396.13(a); 392.7(a)
Before driving
- What the driver does
- Review the last driver vehicle inspection report if it listed defects, and sign that you reviewed it and that repairs were certified.
- Section
- 396.13(b), (c)
During the trip
- What the driver does
- For trucks and truck tractors, inspect the cargo and its securement within the first 50 miles, then at each change of duty status, after 3 hours of driving or 150 miles, whichever comes first.
- Section
- 392.9(b)
End of each day's work
- What the driver does
- Write a report on each vehicle operated: identify it, list any defect found or reported that would affect safe operation or cause a breakdown, and sign. No report is needed if nothing was found.
- Section
- 396.11(a)(1), (a)(2)
After a defect is listed
- What the driver does
- The carrier repairs defects likely to affect safe operation before the vehicle is operated again, and certifies the repair or that none was needed. The report is kept three months.
- Section
- 396.11(a)(3), (a)(4)
What's on the checklist
The 42 checks on the pre-trip inspection checklist, in walk-round order
Ten groups in the order a driver walks the vehicle: the last report, the engine compartment, the cab, lights, tires and wheels, brakes, couplings and trailer, under the vehicle, emergency equipment and the load. On the sheet each check is graded OK, Defect, Do not drive or N/A, and page 3 is the driver vehicle inspection report.
Last report
Before you touch the vehicle
- 1Last driver vehicle inspection report: if it listed defects, read it, check repairs were certified, and sign it
Engine compartment and fluids
Hood up, engine off
- 2Hydraulic brakes only: the master cylinder is at least 1/4 full and there is no leaking brake fluid
- 3No fuel, brake fluid or other fluid is dripping under the vehicle
- 4Engine oil, coolant, power steering fluid, washer fluid and any exhaust fluid are within the maker's marks
In the cab
Controls, glass, mirrors and warning lights
- 5Steering wheel is secure and has no more free play than Appendix A allows for its diameter (engine running on power steering)
- 6Horn works
- 7Windshield wipers sweep the glass and the washer sprays
- 8Windshield has no cracks, discoloration or anything else that reduces vision in the swept area
- 9Both outside rear-vision mirrors are firmly attached, clean and show the road behind along each side
- 10Parking brake holds the vehicle when applied
- 11Driver's seat belt is fitted and worn; belts at other seats are fitted and work
- 12Low pressure (or low fluid) warning device works
- 13On vehicles with ABS: the malfunction lamp lights at power-up and goes out, and the trailer lamp works
Lights and reflectors
Switch on, walk round
- 14Headlamps (low and high beam), tail lamps, stop lamps, turn signals and hazard flashers work on the vehicle and on every trailer
- 15Lamps and reflectors are clean and not covered by the load, a tailboard or added equipment
- 16Trailer 80 in or wider with a GVWR over 10,000 lb built on or after 1 December 1993: reflective sheeting or reflectors (conspicuity treatment) are in place
Tires and wheels
Start at the front left and go round
- 17Tires on the steering axle have at least 4/32 in of tread in a major groove (measure away from tie bars and humps)
- 18All other tires have at least 2/32 in of tread in a major groove
- 19No tire shows body ply or belt material, has tread or sidewall separation, or has a cut that exposes ply or belt
- 20No tire is flat or leaking air (you can hear or feel it) or overloaded because of low pressure
- 21No tire rubs the frame, the body, a brake part or its dual mate
- 22Wheels and rims have no cracks or broken sections and no elongated bolt holes; lock rings are seated
- 23Wheel fasteners (nuts, studs) are all present, tight and not cracked or stripped
Brakes you can check without tools
Service brake on the move, lines and hoses by eye and ear
- 24Service brakes work: the pedal is firm, the vehicle slows in a straight line and every axle that should brake does
- 25Air brakes: no audible air leak at the chambers, hoses, tubing or fittings with the system charged
- 26Brake hoses and tubing are not cut, chafed through the outer reinforcement, bulging, cracked, crimped or spliced over a piece of tubing
- 27Trailer brake connections: air lines are coupled and not leaking, the tractor protection valve is present, and electrical lines are plugged in
Coupling devices and trailer
Tug the connection, look for light between the halves
- 28Fifth wheel: jaws are locked on the kingpin, the release handle is closed and locked, and no light shows between the upper and lower halves
- 29Fifth wheel mounting: fasteners are all there, there are no cracks in the plate or brackets, and slider locks and stops are in place
- 30Pintle hook or drawbar: latch is secure, mounting fasteners are all there, and there are no cracks or welded repairs
- 31Safety chains or cables are fitted, attached, not worn or repaired with wire, rope or tape, and cables are not kinked
- 32Rear impact guard (underride guard) on a trailer is present, firmly attached and not cracked or bent out of position
Under the vehicle
Quick look for leaks
- 33Fuel system: no visible fuel leak, the filler cap is on, and the tank is firmly mounted
- 34Exhaust: no leak forward of or below the cab or sleeper, and no part touches wiring, fuel lines or anything that can burn
Emergency equipment
Extinguisher, triangles and your kit
- 35Fire extinguisher is in a bracket within reach, its gauge or indicator shows charged, its rating is marked, and the rating is high enough (5 B:C or two of 4 B:C; 10 B:C if you carry placarded hazardous materials)
- 36Warning devices for a stopped vehicle: three bidirectional reflective triangles, or at least six fusees (no fusees on some loads and fuels: see 393.95(g))
- 37Your own kit is complete: first aid kit, flashlight, reflective vest, wheel chocks and spare fuses as company policy requires
Load
Before you roll
- 38Cargo is properly distributed and secured, and the securement meets 393.100 through 393.136
- 39Tailgate, tailboard, doors, tarps, spare tire and other equipment used in operating the vehicle are secured
- 40The load does not block the view ahead or to the sides, limit arm or leg movement, block emergency equipment, or block the exit from the cab
- 41Tiedowns, chains, straps, binders, anchor points and dunnage have no cracks, cuts or damage that reduce their working load limit
- 42Plan the re-check: look at the cargo and its securement within the first 50 miles, then at each change of duty status, after 3 hours of driving or after 150 miles, whichever comes first
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): a made-up route. A driver does the pre-trip on a straight truck on 5 November 2026. The truck has no trailer.
- The sheet has 42 checks. Seven are N/A because there is no fifth wheel (two checks), pintle hook, safety chain, rear impact guard, trailer conspicuity tape or trailer brake connection. 42 - 7 = 35 applicable checks.
- Of the 35, 32 are OK, 2 are Defect and 1 is Do not drive. 32 ÷ 35 = 91.4% OK.
- Do not drive, 1: the driver's side wiper blade is torn and leaves a band of glass unwiped. Appendix A item 13 lists an ineffective wiper as a failure. The shop replaces the blade at 07:40 and certifies the repair on the report.
- Defect, 2: washer fluid is low (topped up) and one strap is frayed at the edge (replaced from stock before loading). Both closed.
- The DVIR lists the wiper. Three months from 5 November 2026 is 5 February 2027, so the report is kept until then.
The torn wiper was found before the truck left, repaired and certified in under an hour, and written down for the next driver to review.
Common mistakes
Checking in a different order each day
A fixed route is the whole method. If the walk-round changes every time, the corner you skip is different every time.
Looking without pressure
Air leaks and the low pressure warning only show with the system charged. Start the engine, build air, then check the brakes and lines.
Writing the DVIR from memory
Write the report at the end of the day's work, from the sheet, not from memory three days later. A defect you did not write down was not reported.
Signing the last report without reading it
Your signature says you reviewed it and that repairs were certified (396.13(c)). Read what was listed and look at the part.
Forgetting the load
Cargo securement is part of the inspection (392.9). Check the tiedowns and doors before you leave, and plan the first re-check within 50 miles.
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In LeanSuite each machine's clean, inspect, lubricate and retighten routine is a checklist on the operator's Daily Standard Work, assigned to a person, a role or the machine with a repeat rule, and missed checks show in red.
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FAQ
Pre-trip inspection checklist: common questions
It is the walk-round a driver does before driving. Under 49 CFR 396.13 the driver must be satisfied the vehicle is in safe operating condition, review the last driver vehicle inspection report if it listed defects, and sign it to acknowledge the review. 392.7(a) names the parts that must be in good working order.
For drivers of commercial motor vehicles, 396.13 and 392.7 require the driver to be satisfied about the vehicle before driving. The written report (DVIR) is required at the end of each day's work under 396.11, with exceptions in 396.11(a)(5) such as a carrier operating only one commercial motor vehicle. Check which apply to you.
At least service brakes including trailer brake connections, parking brake, steering mechanism, lighting devices and reflectors, tires, horn, windshield wipers, rear vision mirrors, coupling devices, wheels and rims, and emergency equipment (396.11(a)(1)). It identifies the vehicle, lists any defect found or reported, and is signed by the driver.
The carrier keeps the report, the certification of repairs and the certification of the driver's review for three months from the date the written report was prepared (396.11(a)(4)).
Grade it. If it is likely to affect safe operation, or is on the Appendix A list of failing conditions, do not drive. Under 396.11(a)(3) the carrier or its agent repairs a defect likely to affect safety before the vehicle is operated and certifies the repair, or that none was needed. This checklist does not replace the carrier's own rules.
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- Welder continuity log templateA continuity log for welder qualifications with the next lapse date worked out for each process, 20 checks on the records and the log, and a worked example with three welders and one lapse.
- Weld inspection checklist (visual welding inspection)30 checks before, during and after welding, a guide to the discontinuities visual inspection looks for, a weld map report and a worked example on a 12-weld frame.
- Preventive maintenance checklist templateA PM checklist per machine with readings and sign-off, and a PM schedule that works out the next due date.
- Equipment downtime log (MTTR and MTBF)A breakdown and downtime log, with MTTR, MTBF and downtime by machine and cause worked out in Excel.
- Environmental aspects and impacts registerAn ISO 14001-style register of aspects and impacts, with significance scoring, legal requirements, controls and owners.
- Manufacturing process instruction (MPI) templateOperation steps with parameters, tools, quality checks, safety and a photo each, plus revision history and approval.
- Engineering process instruction (EPI) templateScope, parameters and limits, equipment and materials, validation steps, acceptance criteria, change history and approvals.
- Training sign-off sheetAn attendance and sign-off record where each person signs they understood, with a competence check and an Excel log.
- Learning curve and ramp-up workbookBoth learning curve models side by side, a fit from your own observed hours, batch hours, the unit that reaches standard and a weekly ramp plan.
- Operator staffing calculatorTakt, work content, the operators a line needs, a check of your station plan and the roster with absence cover, from your own demand and element times.
- On-the-job training (OJT) checklistThe training record for one trainee on one job: the four TWI steps signed, every try judged, qualified when your rule is met, then tapering follow-up checks.
- New hire onboarding checklist (manufacturing)29 onboarding items from before day 1 to the 90-day review, with owners, dates and review notes.
- Competency assessment formThe one-person assessment behind a skills matrix rating: each task rated 0 to 4 from evidence, checked, with a training plan for every gap.
- Cross-training plan templateWho is learning which task, from and to which level, by when, and how many are qualified on each task.
- Absenteeism tracker templateA monthly attendance grid with codes, absence rate by person and team, and an optional Bradford factor.
- Engineering change request (ECR) formAn ECR form with the change, what it touches, risk and approvals, and an Excel log that tracks each change to done.
- 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.
- 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.
- 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.
- Lubrication schedule templateEvery lube point with lubricant, method, amount, frequency and who, with next due dates and a monthly sign-off record.
- TPM tag logEvery abnormality tag with type, who fixes it, priority and dates, with days open and counts by type and week.
- Autonomous maintenance step auditCriteria for each of the seven autonomous maintenance steps, scored 0 to 2, with the step result and the decision to move on.
- Inventory cycle count sheetA blind count sheet with variance and tolerance, an ABC count schedule and record accuracy, worked out in Excel.
- Hour-by-hour production boardHourly plan against actual with running totals and the reason for each miss, plus a shift summary by reason.
- Cost savings trackerA savings log with hard and soft savings, payback and Finance's sign-off, plus a glide path against the year's target.
- CapEx request formA capital request with options, costs, benefits, payback and NPV, and the approval levels the amount needs.
- Standard cost variance workbookEight standard cost variances from your standards and actuals, favorable or unfavorable, proved against actual cost, with the questions to ask on the floor.
- Cost-benefit analysis templateUp to three options side by side with costs, hard and soft benefits, payback, NPV and the benefit-cost ratio.
- Cost of poor quality (COPQ) worksheetCost of quality by prevention, appraisal, internal and external failure, with COPQ as a share of sales.
- 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.
- 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.
- 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.
- 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.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- 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.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- 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.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- 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.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- 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.
- 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.
- Injection molding defects chart16 molding defects with causes by machine, material, mold and method, first checks, and an Excel defect log with a Pareto.
- OKR template for manufacturingObjectives with three or four key results each, scored 0 to 1.0 from baseline and target every month, cascaded to facility, department and person with an Other bucket for work that serves no objective.
- Goal cascade and alignment templateA one-page cascade tree from company to person with the catchball reply on every card, and an initiatives list that shows how much work serves a goal and how much sits in Other.
- Monthly business review template (operations review agenda)A 90-minute operations review in nine timed blocks: who speaks when, the KPIs each block reviews with red or green, a prep checklist for every presenter and a log of decisions and actions.
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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.