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Safety audit checklist
A safety audit is a planned check of how well a workplace controls its hazards: an auditor walks the site, looks at the conditions, asks people how the work is done and checks the records behind it, then scores what was found and turns every gap into an action with an owner. A safety inspection checks the condition of equipment and areas on a short cycle; a safety audit also asks whether the program behind them works. A safety audit checklist makes that walk the same every time, so it covers the controls that prevent injuries in every area: exits, fire extinguishers, machine guards, electrical, lockout/tagout, chemicals, PPE, first aid and training records. Scoring it the same way each time shows which areas slip. In the US many of the checks relate to OSHA 29 CFR 1910 rules, such as 1910.22 (walking-working surfaces), 1910.37 (exit routes), 1910.157 (portable fire extinguishers), 1910.212 (machine guarding), 1910.147 (lockout/tagout), 1910.1200 (hazard communication) and 1910.132 (PPE); the checklist does not replace a compliance review. Page 1 of this template has 34 checks in ten areas, each answered Yes, No or N/A with space for the finding. Page 2 has the score by area (Yes ÷ (Yes + No), with N/A left out), a high, medium and low risk rating with example timescales, an action table for every No and sign-off. The Excel version works out the score by area and overall, counts the No answers by risk, and lists every No on an actions sheet with its status and days late.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for site, date, auditor and area manager, and 34 checks in ten areas from walking-working surfaces to training and records, each with Yes, No or N/A to circle and a column for the finding.Walking-working surfacesExits and fire protectionMachine guardingElectricalLockout/tagoutChemicals and labelsPPEErgonomicsFirst aidTraining recordsRisk-rated actions
When to use it
When to use a safety audit checklist
- Monthly or quarterly, as a full walk of the plant by a supervisor, the safety team or the safety committee.
- Before an internal or external safety audit, or an insurer's visit.
- After a change to the layout, new equipment or a new process.
- After an incident, to check the same conditions in the rest of the plant.
How to fill it in
- 1
Plan the route
Cover every area, including maintenance shops, chemical stores, plant rooms and the corners nobody visits. Bring the actions from the last audit. - 2
Answer every check on the floor
Yes when it meets the standard, No when it does not, N/A only when it truly does not apply. A blank is a check that was not done. - 3
Talk to people
Ask how to raise the alarm, where the safety data sheets are, what PPE the job needs. Some checks can only be answered by asking. - 4
Make it safe now
A missing guard or a blocked exit is dealt with before you leave the area, and still written down. - 5
Rate and assign every No
High, medium or low risk, an action, an owner and a due date. Set your own timescale for each rating. - 6
Score and compare
Score each area as Yes ÷ (Yes + No) and compare it with the last audit. A falling area or a repeat finding needs a look at the cause.
Types of safety audit
Safety inspection vs safety audit vs compliance audit vs ISO 45001 audit
The words get used loosely. These are the four checks most plants run, from the most frequent to the least.
| Check | What it looks at | Who, and how often | On this site |
|---|---|---|---|
| Safety inspection | The condition of one area or piece of equipment today: guards, exits, extinguishers, racking, forklifts | The area's own people or a supervisor, daily to monthly | Warehouse, forklift, crane and machine guarding inspection checklists |
| Safety audit (this checklist) | Every area of the plant, the conditions and the records behind them, scored so areas can be compared | A supervisor, the safety team or the safety committee, monthly or quarterly | This checklist, then the job hazard analysis for the tasks it flags |
| Compliance audit | Whether the site meets the regulations that apply to it, rule by rule, such as the OSHA standards for general industry | A safety professional or an outside auditor, often yearly | A legal review; this checklist does not replace one |
| ISO 45001 internal audit | Whether the safety management system works as planned: policy, risk assessment, objectives, incident follow-up | Trained internal auditors on an audit programme | ISO 45001 internal audit checklist |
Safety inspection
- What it looks at
- The condition of one area or piece of equipment today: guards, exits, extinguishers, racking, forklifts
- Who, and how often
- The area's own people or a supervisor, daily to monthly
- On this site
- Warehouse, forklift, crane and machine guarding inspection checklists
Safety audit (this checklist)
- What it looks at
- Every area of the plant, the conditions and the records behind them, scored so areas can be compared
- Who, and how often
- A supervisor, the safety team or the safety committee, monthly or quarterly
- On this site
- This checklist, then the job hazard analysis for the tasks it flags
Compliance audit
- What it looks at
- Whether the site meets the regulations that apply to it, rule by rule, such as the OSHA standards for general industry
- Who, and how often
- A safety professional or an outside auditor, often yearly
- On this site
- A legal review; this checklist does not replace one
ISO 45001 internal audit
- What it looks at
- Whether the safety management system works as planned: policy, risk assessment, objectives, incident follow-up
- Who, and how often
- Trained internal auditors on an audit programme
- On this site
- ISO 45001 internal audit checklist
What's on the checklist
The 34 checks on the safety audit checklist
Ten areas of a general manufacturing plant. On the sheet each check is answered Yes, No or N/A, with space for the finding; every No gets a risk rating and an action on page 2.
Walking-working surfaces and housekeeping
Floors, aisles, stairs, platforms
- 1Floors clean and as dry as possible, with no spills or leaks
- 2Aisles and walkways marked and kept clear of stored material
- 3No trip hazards: cords, hoses, loose mats or damaged flooring
- 4Stairs, platforms and guardrails in good repair, handrails fitted
Exits and fire protection
Getting out and putting a fire out
- 5Exit routes and exit doors free and unobstructed
- 6Exits marked with a visible Exit sign, exit routes lit
- 7Extinguishers mounted, unobstructed, charged, monthly check recorded
- 8Flammable liquids in safety cabinets, sprinkler heads kept clear
Machine guarding
Points of operation, nip points, rotating parts
- 9Guards in place at points of operation, nip points and rotating parts
- 10Guards secured, not removed, bypassed or propped open
- 11Emergency stops marked, within reach and tested
- 12Interlocks on doors and covers stop the machine when opened
Electrical
Panels, disconnects, cords
- 13Clear working space in front of panels, nothing stored there
- 14Panel covers closed, breakers and disconnects labeled
- 15Cords and plugs undamaged, extension cords not used as fixed wiring
Lockout/tagout
Control of hazardous energy
- 16Written energy control procedures for the machines that need them
- 17Locks and tags applied by authorized employees during servicing
- 18Periodic inspection of each procedure done within the last year
Hazardous chemicals and labels
Hazard communication
- 19All containers labeled, including secondary containers
- 20Safety data sheets readily accessible on every shift
- 21Chemicals stored by compatibility, lids closed, spill kit nearby
PPE
Assessed, provided, worn
- 22Written PPE hazard assessment for the area, certified and current
- 23Required PPE posted at the area entrance and worn there
- 24PPE in good condition, damaged PPE taken out of use
Ergonomics and manual handling
Lifting, reaching, repetition
- 25Lifting aids, carts or hoists used for heavy or awkward loads
- 26Work heights and reaches suit the people doing the job
- 27Reports of strain or discomfort followed up, not left open
First aid and emergency
First response
- 28First aid kits stocked and checked, trained first aiders on each shift
- 29Eyewash or shower where corrosives are used, clear and tested
- 30Emergency numbers, evacuation map and assembly point posted
- 31People asked can say how to raise the alarm and where to go
Training and records
The records behind the checks
- 32Training current for LOTO, hazard communication, PPE and equipment
- 33Actions from the last audit closed or on schedule
- 34Near misses and incidents in the area reported and followed up
A filled-in example
Illustrative, not a benchmarkAn example: a monthly audit of a machining and assembly plant (illustrative).
The example audit in one picture
- Yes: 26 checks
- No: 5 checks
- N/A: 3 checks
Score = Yes ÷ (Yes + No)
- 26 ÷ (26 + 5)= 84%
Audit score84%
34 checks: 26 yes, 5 no, 3 not applicable. Score 26 divided by 31 is 84 percent. Of the 5 no answers, 1 is high risk, 3 medium and 1 low.
- 34 checks: 26 Yes, 5 No, 3 N/A (no flammable liquids stored, no interlocked covers, no corrosives in the area). Score = 26 ÷ (26 + 5) = 84%.
- No, high risk: a fixed guard taken off a conveyor tail pulley and left on the floor. The conveyor was locked out until maintenance refitted the guard that shift.
- No, medium risk: pallets stored in front of an electrical panel (cleared during the audit), an unlabeled spray bottle of degreaser, and two new starters not yet trained in hazard communication.
- No, low risk: the monthly extinguisher check not recorded for two months.
The guard finding was the second in three months, so the team asked why the guard kept coming off: operators removed it to clear jams. Maintenance fitted a hinged, interlocked cover so jams can be cleared safely, and the next audit checked it.
Common mistakes
Auditing from the office
A checklist ticked at a desk finds nothing. Walk every area, every time.
Using N/A to avoid a No
N/A raises the score. Use it only when the hazard really is not there.
Findings with no owner
A No without an action, an owner and a date is still a hazard next month.
Fixing the condition, not the cause
If the same No comes back, ask why it keeps happening before fixing it again.
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
Guides
- Top Five Common Manufacturing Hazards
- Five Ways to Improve Safety on the Shop Floor
- OSHA Audit Preparation: Reducing 40 Hours to 4 Hours
- 7 Preventable Shop Floor Incidents Most Plants Miss
- ISO 45001 internal audit checklist
- ISO 9001 internal audit checklist (production area)
- Job hazard analysis guide: audit the task, not only the area
- Toolbox talk topics for the gaps an audit finds
- Risk assessment guide: rate a finding with a 5x5 matrix
- Lockout tagout guide: the periodic inspection the audit checks for
- Incident report template: when a finding was found too late
- Risk assessment matrix: score each No on a 5x5 grid
- Near miss report form, for what people see between audits
- Safety cross calendar, to show each day's result on the wall
- Workplace safety ideas: 54 changes to pick from when the audit finds a hazard
Train the team
Put it on the wall
- Free pPE by zone poster
- Free 5 shop floor safety rules poster
- Free slips, trips and falls housekeeping poster
- Free emergency response poster
- Free spill response poster
- Free working at height and ladder safety poster
- Free machine guarding poster
- Free electrical safety basics poster
- Free workstation ergonomics poster
- Free hearing protection poster
- Free heat stress poster
- Free gHS hazard pictograms poster
- Free eyewash station poster
- Free fire extinguisher classes poster
- Free safety observation conversation poster
FAQ
Safety audit checklist: common questions
A planned check of how well a workplace controls its hazards. The auditor walks the site, looks at conditions, asks people how the work is done and checks the records behind it, such as training, inspections and procedures. Every gap gets a risk rating, an action, an owner and a due date, and the score shows which areas are slipping.
An inspection checks the condition of an area or a piece of equipment, often daily to monthly, by the people who work there. An audit is wider and less frequent: it covers every area, checks the records and asks whether the safety program behind the inspections works. Plants need both.
Walking and working surfaces, exits and fire protection, machine guarding, electrical, lockout/tagout, hazardous chemicals, PPE, manual handling, first aid and emergency response, and the training records behind them. Add checks for the hazards specific to your site.
Many plants do a full audit monthly or quarterly and shorter area walks weekly. Some items have their own frequency, such as the monthly visual inspection of portable extinguishers in OSHA 29 CFR 1910.157(e)(2).
Among others, 29 CFR 1910.22 (walking-working surfaces), 1910.37 (exit routes), 1910.157 (portable fire extinguishers), 1910.212 (machine guarding), 1910.303 (working space about electric equipment), 1910.147 (lockout/tagout), 1910.1200 (hazard communication), 1910.132 (PPE) and 1910.151 (first aid). The checklist does not replace a compliance review.
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- 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.
- Rolling action item list (RAIL) templateA single running list of actions kept from meeting to meeting, with a weekly review sheet and age counts.
- Goods received note templateA one-page goods received note and an Excel register with accepted to date, still to come and an invoice check for each PO line.
- Lessons learned templateA one-page lessons log, a 45 minute session guide and an Excel register that shows which actions are done, open or overdue.
- Packing list templateA one-page packing list with a pack checklist, and an Excel file that works out volume, shipped to date and back order.
- Meeting minutes templateA one-page minutes form and an Excel log of decisions and actions with owners, due dates and status.
- Purchase order templateA one-page purchase order and an Excel version that adds up the lines, checks the approval limit and tracks what is still to come.
- Action plan templateA one-page action plan and an Excel tracker with percent done, status and a weekly timeline.
- Part submission warrant (PSW) templateA PSW working form plus twelve checks before anyone signs, and an Excel that works out whether the warrant is ready.
- Ballooned drawing and dimensional results templateA ballooning guide and a results sheet for six parts per characteristic, with OK, NEAR LIMIT or NOT OK worked out for each row.
- Attribute agreement analysis templateA 30-part, three-appraiser study sheet for pass or fail decisions, with kappa, effectiveness, miss rate and false alarm rate in Excel.
- DVP&R template (design verification plan and report)A design verification plan and report on one sheet: tests, criteria, owners and dates, with status worked out as of a date.
- Special characteristics matrix templateOne row per special characteristic, followed from drawing to PFMEA, control plan, gauge study and capability, with the first gap named.
- Maintenance request form templateA one-page request form and an Excel log that times each answer against a priority target.
- Maintenance log templateA maintenance log page and an Excel log that totals cost, downtime and planned work and flags repeat breakdowns.
- Preventive maintenance schedule templateA PM schedule with next due dates and status, and an Excel calendar of the jobs and hours in each month.
- Machine setup sheet templateA setup sheet with limits, a first piece check and setup minutes, and an Excel log of setups against a standard.
- Work instruction templateA one-page work instruction with key points and step times, and an Excel training record that flags re-checks.
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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.