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Project savings validation checklist
A project savings validation checklist is the gate a continuous improvement saving passes through before it is reported: finance and the project agree the baseline, the boundaries, the size and the type of the saving, and that it will last. Without a gate, savings are counted twice, claimed for changes that were volume, or reported in full when no budget fell. This template has a claim form that works from the baseline and result to an annual value, 20 checks in five groups answered Yes, No or N/A with evidence, a decision of accept, return or reject with a reason code, a claims register that stops the same loss being claimed twice, and a six-month sustainment check. The Excel version also tracks accepted hard cash against a target month by month. The numbers and thresholds are conventions to agree with your own finance team.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for project ID, date, owner, title, sponsor and finance reviewer above boxes for the loss attacked, the baseline, the result and the calculation from change to annual value.
When to use it
When to use a savings validation checklist
- Before a project's savings go into a report, a bonus, a business case or a number given to the board.
- When projects overlap, such as several attacking the same line, and a loss could be claimed twice.
- When finance and the improvement team disagree about what counts, and you need one standard they can both sign.
- To separate hard cash from time freed and cost avoided, so the three are never added together.
- Not as a business case for a new project. For that, use the cost-benefit analysis or the CapEx request; this is the check on the result afterwards.
How to fill it in
- 1
Write the claim
Describe the loss attacked and the perimeter. Enter the baseline and the result with their periods and sources, and the agreed cost per unit. The form works out the annual saving and the payback.
- 2
Classify the saving
Hard cash falls from a named budget line. Soft savings free time or capacity but remove no cost until it is used or taken out. Cost avoidance is a cost that would have happened and did not. Agree the class with finance.
- 3
Answer the 20 checks
Go through the baseline, the perimeter, the result, the type and size, and the sustain-and-decide groups. Each is Yes, No or N/A, with a line of evidence. Any No means the claim goes back.
- 4
Decide and give a reason code
Finance and the sponsor accept, return or reject the claim and sign it. Use a reason code for a return, a reject or an adjustment, such as no baseline evidence or a double count.
- 5
Log it in the register
Every claim goes in the register with its outcome and validated value. Check the register before accepting a new claim, so the same loss, line or period is not claimed twice.
- 6
Check it holds for six months
Enter the KPI's saving each month for six months and compare it with the expected monthly figure. A slip triggers an action; a saving that has not held is reported as at risk.
What finance checks
The 20 checks on the project savings validation checklist
Five groups, from the baseline to the decision. On page 2 each check is answered Yes, No or N/A with a line for the evidence; a No sends the claim back, and the decision carries a reason code.
Baseline
What the loss was before the project
- 1The baseline period is written down and long enough to cover normal variation, such as twelve months or a full seasonal cycle
- 2The baseline value comes from a named source, such as a ledger, a system report or a log, that someone outside the project can open
- 3The baseline is adjusted for changes in volume, product mix and price, so the project is not credited with them
- 4The unit and the cost per unit are agreed with finance and are the standard rate, not a best case
Perimeter
What the saving covers, and what it does not
- 5The area, line, product and period the saving applies to are written down
- 6No other project, price change or budget cut claims the same loss, checked against the register of claims
- 7Costs that rise because of the project, such as extra labour, spares, energy or maintenance, are netted off
- 8The saving does not depend on a change in another department that has not agreed to it
Result
What changed, and why
- 9The result period is long enough to show the change is stable, and its value and source are recorded
- 10The difference between baseline and result is explained by the project's actions, not by volume, mix or a one-off event
- 11The annual value is calculated by a method finance accepts, shown line by line
- 12The one-off costs, such as equipment, trials, training and outside help, are recorded against the project
Type and size
What kind of saving it is, and whether it is big enough to report
- 13The saving is classed as hard cash, soft (time or capacity freed) or cost avoidance, and finance agrees the class
- 14A hard saving names the budget line or cost centre that falls, and by how much
- 15The annual value meets the minimum set for a reported saving
- 16A KPI with an owner shows the saving every month
Sustain and decide
Whether the gain will hold, and who decides
- 17The standard, setting or control that holds the gain is in place and the people affected are trained
- 18The KPI is reviewed every month for six months, with an action when it slips
- 19A reviewer outside the project has checked the evidence
- 20The decision (accept, return or reject), with its reason code, is signed by finance and the project sponsor
A filled-in example
Illustrative, not a benchmarkAn invented changeover project on press 7 claims a saving, and the claim goes through the gate.
- The baseline is 1,100 hours of changeover in six months and the result is 780 hours: 320 hours saved, at a standard $100 an hour, or $64,000 a year.
- In round 1 the claim is returned at the check for double counting: $13,000 of the labour saving was already claimed by another project.
- With that removed the claim is $51,000, hard cash from the overtime budget, above the minimum for a reported saving and with a KPI on the shift board.
- Six months later the KPI held in five of six months. In month 5 it fell to 85% when the night shift stopped using the staged tool cart, and an action brought it back.
The project is accepted at $51,000 hard cash, not $64,000. The register also shows a rejected claim with no baseline evidence and a soft saving kept out of the hard cash total.
Common mistakes
Counting the same loss twice
Two projects on one line can both claim the same labour or scrap. A register checked before acceptance is the cheapest protection.
Crediting the project with volume or mix
If output rose and cost per unit fell, check how much was the project and how much was the volume. Adjust the baseline before you claim.
Adding soft savings to hard cash
Time freed is not money saved until it is used for output or taken out of the cost base. Report hard, soft and avoidance as separate lines.
Ignoring what the project costs
A saving net of extra labour, spares or energy is smaller than the gross figure. Net them off, and record the one-off costs against the project.
Reporting once and never checking
Many gains fade within months. A six-month check on the KPI turns a claim into a saving that is still there.
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 the Loss and Cost Management System ranks each loss by what it costs, KPI Builder tracks your cost KPIs against targets, and the Glidepath report shows closed, projected and carried-over savings against target month by month.
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FAQ
Project savings validation checklist: common questions
Savings validation is the step where finance and the project team check a savings claim before it is reported: that the baseline is evidenced, the boundary is clear, nothing is counted twice, the saving is the right type and size, and it can be measured and held.
A hard saving is a cost that really falls, such as overtime or scrap, and appears in a budget line. A soft saving frees time or capacity, but no cost falls until that time is used or removed. Cost avoidance is a cost that would have occurred and did not. Keep the three apart.
Many improvements fade when attention moves on. Checking the KPI each month for six months shows whether the standard holds. Six months is a common choice rather than a rule, so agree the period with finance.
Short codes for the common failures help: no baseline evidence, perimeter not agreed, double count, below the minimum value, no monthly KPI, not sustained, costs not netted off and wrong saving type. The template has a starter set to adapt.
Finance, usually the plant controller or an analyst, and the project sponsor, who is accountable for the improvement. A second person outside the project checking the evidence is better still. Decide the rule once and apply it to every claim.
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- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- 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.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- 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.
- 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.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- 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.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Chemical inventory and SDS register templateA register of every chemical on site with its hazard class, safety data sheet and label, and a check that incompatible products are kept apart.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- 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.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
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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.

