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Risk register template
A risk register is the living list of what could go wrong for a plant, a project or a change, with each risk scored, owned, treated and reviewed. Each row holds what could happen and why, a likelihood from 1 to 5, an impact from 1 to 5, the score (the two multiplied) and a rating, what you will do about it (avoid, reduce, transfer or accept), the action, the owner, the due date, and the score left once the action is done. This template has three landscape pages: the register, the scales with four rating bands, a heat map and a review log, and a worked example of a made-up plant adding a second shift, with 15 risks. The Excel version works out the score and rating, flags overdue actions and high risks with no owner, draws a heat map of open risks as raised and after the action, and tracks when the next review is due. It sits beside the risk assessment matrix, which is the grid, while the register is the list you keep.
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, owner, start date and review interval above a register table with columns for the risk, cause, likelihood, impact, score, rating, treatment, action, owner and due date.Register with scores and ratingsLikelihood and impact scalesRating bandsTreatment optionsHeat mapReview logWorked example with 15 risks
When to use it
When to use a risk register
- When a plant or project has risks in people's heads, in emails and in meeting notes, but not in one place.
- Before a change such as a new shift, a new line, a new supplier or a move, to list what could go wrong and who owns each risk.
- For a regular review with the plant manager, where the question is which risks changed since last time.
- To show an auditor, an insurer or a customer that risks are identified, scored, owned and reviewed.
- Not for scoring one hazard on one task (use a job safety analysis or the risk assessment matrix) or for failure modes of a process (use a process FMEA).
How to fill it in
- 1
Set the scales and bands once
Agree what a 1 and a 5 mean for likelihood and for impact, and the score at which a risk is low, medium, high or critical. Keep them the same for every risk so scores can be compared. The key page gives an example to edit.
- 2
List the risks
One row for each risk: what could happen, the category and the cause. Write the event, not a fear: single-source supplier fails to ship, not supply chain.
- 3
Score likelihood and impact
Score each from 1 to 5. The score is likelihood times impact, and the rating comes from the bands. Score the risk as it stands today, with the controls you already have.
- 4
Choose a treatment, an action and an owner
Decide whether to avoid, reduce, transfer or accept the risk. Write the action, one named owner and a due date. A risk with no owner is not being managed.
- 5
Score again after the action
Write the likelihood and impact you expect once the action is done. The gap between the two scores is what the action buys. Keep accepted risks on the list with a review date.
- 6
Review on a schedule
Review the register at a set interval, record it in the review log, close what is done, add what is new and re-score what changed. The heat map shows where to start.
A filled-in example
Illustrative, not a benchmarkAn example: a made-up plant adding a second shift, with 15 risks, scored as raised and after the action.
- The risks include a single-source casting supplier, untrained relief operators, a compressor at the end of its life, lone working at night, no fire warden for the new shift and overtime that could break working-time limits.
- As raised, 8 risks are High and 7 are Medium. The worst are the single-source supplier (likelihood 3, impact 5, score 15) and several scored 12.
- Most are reduced: a second source and four weeks of stock, cross-training before the shift starts, a standby for the compressor, a buddy system at night. One is avoided, one transferred through insurance and two accepted.
- After the actions, 10 are Medium and 5 are Low, and nothing is left in High or Critical. The two accepted risks keep their scores and stay on the register with an owner.
The heat map moves from a cluster in the orange cells to the lower left, which is the picture a review wants to see. The risks and scores are invented to show how the register is used.
Common mistakes
Risks written as vague topics
A row that says supply chain or morale cannot be scored or owned. Write the event that could happen and its cause.
No owner or no date
A risk with an owner and no date, or a date and no owner, drifts. Every open risk needs both.
Scoring everything high
If most risks are rated High, the register stops showing what to do first. Use the scales to separate them, and check the bands.
Never closing a risk
A register that only grows becomes noise. Close a risk when the action is done and it no longer matters, and record it in the review.
Filing it after the first review
A risk register is only worth having if it is reviewed on a schedule. Put the next review date in the diary at the end of each one.
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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 safety procedures start from marketplace templates, including risk assessments; anyone reports a hazard as a tag from a QR code, and a serious hazard can become a CAPA project with root cause analysis.
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FAQ
Risk register template: common questions
A risk register is a list of the risks to a plant, project or change, each with a description, a likelihood and impact score, a rating, a treatment, an action, an owner, a due date and a status. It is reviewed on a schedule.
An ID, the date raised, a category, what could happen, the cause, likelihood, impact, the score and rating, the treatment (avoid, reduce, transfer or accept), the action, the owner, the due date, the score after the action and the status.
Score likelihood and impact on the same scale, here from 1 to 5, and multiply them. Compare the score with agreed bands to get a rating such as low, medium, high or critical. The scales and bands need to be the same for every risk.
At a fixed interval that fits the pace of your changes, often monthly or quarterly, and whenever something major changes. High risks usually need more frequent review than low ones. The Excel review log works out the next review date from the interval you set.
The matrix is the grid used to score a risk. The register is the list of all the risks you have scored, with owners, actions and dates. You use the matrix to fill in the register.
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- 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.
- 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.
- 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.
- 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.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- 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.
- 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.
- 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.
- 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.