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Safety pillar 90-day model area plan
A safety pillar model area plan is a 90-day plan for proving the safety routine on one area of the plant, the model area, before it spreads to every other area. The team moves from reactive work (learning from what already happened) to preventive work (finding hazards before they hurt anyone) and then to proactive work (standards and safe habits): the incident pyramid for the area, a safety cross, near-miss reporting, a hazard hunt, a risk assessment of every task, high risks removed by the hierarchy of controls, investigations, safety standards, safety observations and an audit. This template has the 13-week plan as a Gantt chart in three phases with the owner, deliverable and done-when of each activity, a scoring table to choose the model area from loss data, the team, a KPI board, the day-90 gate, and the expansion plan for months 4 to 12 in three waves, with a worked example.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use a safety pillar 90-day plan
- When a plant wants to move from reacting to injuries to finding hazards first, and wants to prove it in one area before asking every team.
- When near-miss reporting, risk assessments or safety walks exist on paper but nobody is sure they work on the floor.
- When an area has had a run of first-aid cases or a serious near miss and needs a structured 90 days, not a poster campaign.
- When leaders want a safety plan they can review every week: who does what, by when, and what done looks like.
How to fill it in
- 1
Choose the model area from loss data
Score up to three candidate areas (five in Excel) on loss data, visibility, team willingness and repeatability, from 1 to 3. Loss data here means injuries, first-aid cases, near misses and high-rated risks. Pick the highest total; on a tie, the higher loss data score wins.
- 2
Name the team and write day 1
Sponsor, pillar lead, the safety coordinator, the area supervisor and operators, and a maintenance technician for guards and lockout points. In Excel, day 1 and the status date set the dates and status of every activity.
- 3
Set the baseline and the day-90 targets
Near misses reported, actions closed on time, high risks open, tasks with a current risk assessment and first-aid and recordable cases. More near-miss reports is the aim at first: it shows people trust the route.
- 4
Run the 13 weeks and update the plan every week
Move a bar if your area needs it, write the week each activity really finished, and add one actual per KPI each week. Late activities turn red in the Excel version.
- 5
Pass the day-90 gate
The sponsor and pillar lead check the six gate items with evidence. If one is not met, fix it before any other area starts.
- 6
Plan the expansion waves
Wave 1 goes to the areas with the same hazards and tasks, with a model area team member coaching the first hazard hunt in each. Each new area runs its own 13 weeks against its own baseline.
The 90-day plan
Week by week: from the incident pyramid to safety standards
The standard plan printed on page 1 and in the Excel version, tagged reactive, preventive or proactive. Days 1 to 30 are weeks 1 to 4, days 31 to 60 weeks 5 to 9 and days 61 to 90 weeks 10 to 13. Move the weeks to fit your area.
| Weeks | Activity | Owner | Deliverable | Done when |
|---|---|---|---|---|
| 1 | Choose the model area and form the team (Setup) | Pillar lead | Team list and area map; area chosen with the selection table | Team named, sponsor agreed, first meeting held |
| 1 to 2 | Draw the incident pyramid for the area (Reactive) | Safety coordinator | 12 months of injuries, first-aid cases, near misses and unsafe conditions by level | Every recorded event in the period is on the pyramid |
| 2 to 3 | Start the safety cross (Reactive) | Area supervisor | Safety cross posted at the team board, one box per day | Filled in every day and reviewed at the team meeting |
| 2 to 4 | Launch near-miss reporting (Preventive) | Safety coordinator | A simple card or QR route, a log, and a reply to every reporter | Every report gets an owner and a due date |
| 3 to 5 | Hazard hunt: walk the whole area (Preventive) | Model area team | Unsafe condition and unsafe act log with photos | Area fully walked and every finding logged |
| 4 to 7 | Risk assessment of every task in the area (Preventive) | Pillar lead | Risk register: task, hazard, rating before and after controls | Every routine and non-routine task has a current rating |
| 5 to 9 | Remove high risks by the hierarchy of controls (Preventive) | Maintenance technician | Action list: eliminate, substitute, engineer, admin, PPE | High risks closed or reduced, interim controls on the rest |
| 6 to 9 | Investigate incidents and serious near misses (Reactive) | Safety coordinator | Investigation report with root cause and actions | Each one has a root cause and similar risks were checked |
| 8 to 11 | Write the safety standards for the area (Proactive) | Pillar lead | Lockout points, PPE by zone, safe work steps for the top tasks, one point lessons | Standards posted where the work is done and the team trained |
| 9 to 12 | Start safety observations (Proactive) | Area supervisor | Observation schedule and log, feedback given on the spot | Observations done to plan for three weeks |
| 11 to 13 | Safety audit of the area and close the gaps (Proactive) | Pillar lead | Safety audit checklist result and gap list | Audit done and every gap has an owner and a date |
| 13 | Day-90 review and decision to expand (Gate) | Sponsor | Day-90 gate sheet, KPIs against baseline, lessons | Gate signed by the sponsor and the pillar lead |
1
- Activity
- Choose the model area and form the team (Setup)
- Owner
- Pillar lead
- Deliverable
- Team list and area map; area chosen with the selection table
- Done when
- Team named, sponsor agreed, first meeting held
1 to 2
- Activity
- Draw the incident pyramid for the area (Reactive)
- Owner
- Safety coordinator
- Deliverable
- 12 months of injuries, first-aid cases, near misses and unsafe conditions by level
- Done when
- Every recorded event in the period is on the pyramid
2 to 3
- Activity
- Start the safety cross (Reactive)
- Owner
- Area supervisor
- Deliverable
- Safety cross posted at the team board, one box per day
- Done when
- Filled in every day and reviewed at the team meeting
2 to 4
- Activity
- Launch near-miss reporting (Preventive)
- Owner
- Safety coordinator
- Deliverable
- A simple card or QR route, a log, and a reply to every reporter
- Done when
- Every report gets an owner and a due date
3 to 5
- Activity
- Hazard hunt: walk the whole area (Preventive)
- Owner
- Model area team
- Deliverable
- Unsafe condition and unsafe act log with photos
- Done when
- Area fully walked and every finding logged
4 to 7
- Activity
- Risk assessment of every task in the area (Preventive)
- Owner
- Pillar lead
- Deliverable
- Risk register: task, hazard, rating before and after controls
- Done when
- Every routine and non-routine task has a current rating
5 to 9
- Activity
- Remove high risks by the hierarchy of controls (Preventive)
- Owner
- Maintenance technician
- Deliverable
- Action list: eliminate, substitute, engineer, admin, PPE
- Done when
- High risks closed or reduced, interim controls on the rest
6 to 9
- Activity
- Investigate incidents and serious near misses (Reactive)
- Owner
- Safety coordinator
- Deliverable
- Investigation report with root cause and actions
- Done when
- Each one has a root cause and similar risks were checked
8 to 11
- Activity
- Write the safety standards for the area (Proactive)
- Owner
- Pillar lead
- Deliverable
- Lockout points, PPE by zone, safe work steps for the top tasks, one point lessons
- Done when
- Standards posted where the work is done and the team trained
9 to 12
- Activity
- Start safety observations (Proactive)
- Owner
- Area supervisor
- Deliverable
- Observation schedule and log, feedback given on the spot
- Done when
- Observations done to plan for three weeks
11 to 13
- Activity
- Safety audit of the area and close the gaps (Proactive)
- Owner
- Pillar lead
- Deliverable
- Safety audit checklist result and gap list
- Done when
- Audit done and every gap has an owner and a date
13
- Activity
- Day-90 review and decision to expand (Gate)
- Owner
- Sponsor
- Deliverable
- Day-90 gate sheet, KPIs against baseline, lessons
- Done when
- Gate signed by the sponsor and the pillar lead
What's on the gates
The day-90 gate and the wave gate for the safety pillar
The day-90 gate decides whether the model area is ready to be copied; the wave gate is checked for each new area before the next wave starts. Both are on page 3 of the PDF and on the Excel version's Day-90 gate and Expansion sheets.
Day-90 gate
All met before the first expansion wave starts
- 1Every task in the area has a current risk assessment
- 2High risks are closed or reduced, with interim controls on the rest
- 3Near misses are reported and every report gets an owner and a reply
- 4The safety cross and the observation routine run without the pillar lead
- 5The KPI board has 13 weeks of data against the baseline
- 6The standards and lessons are written up so another team can copy them
Wave gate
For each new area, before the next wave starts
- 7The area passed the same day-90 gate as the model area
- 8Its KPIs are measured against its own baseline, not the model area's
- 9The risk register, standards and lessons were copied and adapted, and the copy is recorded
- 10Coaches for the next wave are named and have run a session with the pillar lead watching
- 11The model area was audited again and still holds its standard
A filled-in example
Illustrative, not a benchmarkAn example: a metal stamping plant (illustrative, with made-up numbers; the same as page 4 of the PDF and the Excel example sheets). Not a benchmark.
- Model area choice, loss data, visibility, team willingness and repeatability scored 1 to 3: Press line 2 scored 11, Weld cell A scored 9 and Shipping dock scored 7. Press line 2 had the most first-aid cases and the highest-rated risks (pinch points at die change), sits on the main aisle, and its tasks repeat on two other press lines.
- Near misses and unsafe conditions reported: baseline 2 a week, day-90 target 8 a week, week 13 actual 7 a week, 83% of the gap closed.
- Safety actions closed on time: baseline 45%, day-90 target 90%, week 13 actual 85%, 89% of the gap closed.
- High risks still open: baseline 6, day-90 target 0, week 13 actual 1, 83% of the gap closed.
- Tasks with a current risk assessment: baseline 20%, day-90 target 100%, week 13 actual 100%, 100% of the gap closed.
- First-aid and recordable cases: baseline 3, day-90 target 0, week 13 actual 1, 67% of the gap closed.
The team passed the day-90 gate in week 13. Wave 1 (months 4 to 6) went to Press lines 1 and 3, wave 2 (months 7 to 9) to Weld cells A and B, and wave 3 (months 10 to 12) to Shipping dock, stores, tool room, with a model area team member coaching each wave 1 area.
Common mistakes
Judging the area by injuries alone
Injuries are rare and lag behind the hazards. Track near misses, unsafe conditions and actions closed as well, or the board will look fine until someone is hurt.
Asking for near misses and never replying
People stop reporting when reports disappear. Give every report an owner and a due date, and tell the reporter what was done.
Fixing every risk with PPE and signs
Work down the hierarchy of controls: remove the hazard, substitute, engineer it out, then procedures, and PPE last.
Writing standards nobody was trained on
A standard in a binder protects nobody. Post it where the work is done and train the team before the observation routine starts.
Spreading before the gate
Copying an unproven routine to every area spreads its gaps too. Hold the gate, then expand in waves.
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 near misses, unsafe acts and unsafe conditions are routed to an owner with a due date, every corrective action is tracked to completion, and safety metrics such as near misses show on an SQDC tier board with a safety heat map.
In the lean glossary
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FAQ
Safety pillar 90-day model area plan: common questions
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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.
- 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.
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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.